1000+ Design Engineer Interview Questions and Answers

Using petrol in diesel engine and diesel in petrol engine can cause serious damage to the engine.

• Petrol in diesel engine can cause knocking, damage to fuel pump and injectors, and clog the fuel filter.

• Diesel in petrol engine can cause incomplete combustion, damage to spark plugs and catalytic converter, and clog the fuel system.

• It is important to always use the correct fuel for the engine to avoid costly repairs and potential safety hazards.

Lathe is used for cylindrical workpieces while milling machine is used for flat or irregularly shaped workpieces.

• Lathe rotates the workpiece while the cutting tool remains stationary, while milling machine rotates the cutting tool while the workpiece remains stationary.

• Lathe is used for turning, drilling, and boring operations, while milling machine is used for cutting, drilling, and shaping operations.

• Lathe is ideal for creating cylindrical shapes such as shafts, while milli...read more

Design considerations for a part

• Functionality and purpose of the part

• Material selection based on properties and manufacturing process

• Cost-effectiveness and feasibility of production

• Ease of assembly and maintenance

• Environmental impact and sustainability

• Compliance with regulations and standards

• Aesthetics and user experience

Operations like bending, folding, and crimping can increase the strength of sheet metal without changing its thickness.

• Bending: This process involves bending the sheet metal along a straight line to increase its strength.

• Folding: Folding the sheet metal creates multiple layers, increasing its strength.

• Crimping: Crimping involves creating small indentations or folds in the sheet metal to increase its rigidity.

• Rolling: Rolling the sheet metal can also increase its strength by c...read more

Snap fits are used in plastics to join two parts together without the need for additional fasteners.

• Cantilever snap fit

• Annular snap fit

• Torsion snap fit

• Snap hinge

• Snap bead

• Snap tab

• Snap lock

• Snap latch

• Snap hook

ASME B31.3, ASME B31.1, API 650, API 620 are some of the piping codes used in designing a chemical plant.

• ASME B31.3 is used for process piping

• ASME B31.1 is used for power piping

• API 650 is used for storage tanks

• API 620 is used for low-pressure storage tanks

• Other codes like ASTM, ANSI, and ISO may also be used depending on the specific requirements of the project

Yes, my skills and experience can contribute to increasing company revenue.

• I have a proven track record of improving revenue in my previous roles.

• I can bring innovative ideas and solutions to the table.

• I am a team player and can collaborate with others to achieve revenue goals.

• I am constantly learning and adapting to new technologies and market trends.

• For example, in my previous job, I implemented a new marketing strategy that increased revenue by 20% in the first quarter.

Design Engineer interview questions covering topics like design, GD&T, joints, standards, failure, material properties, vernier caliper, boiler, Bernoulli theorem, Pascal law, welding.

• Design is the process of creating a solution to a problem or need.

• GD&T (Geometric Dimensioning and Tolerancing) is a system for defining and communicating engineering tolerances.

• Joints are connections between two or more parts, types include welded, bolted, and riveted joints.

• Standards commonly ...read more

Yes, I have design knowledge in both Solidworks and Autocad software.

• I have extensive experience using Solidworks and Autocad for designing various mechanical components and systems.

• I am proficient in creating 3D models, assemblies, and detailed drawings using both software.

• I have successfully completed multiple design projects using Solidworks and Autocad, meeting all the required specifications and standards.

• I am familiar with the advanced features and tools in both softwar...read more

Creo environment has various modules for different design tasks.

• Creo Parametric for 3D modeling

• Creo Simulate for simulation and analysis

• Creo Illustrate for technical illustrations

• Creo Schematics for creating electrical schematics

• Creo View for viewing and sharing CAD files

• Creo Direct for direct modeling

• Creo Layout for 2D layout design

• Creo Options Modeler for managing design configurations

To solve short mold defects in injection molding, adjust injection speed, pressure, temperature, and cooling time.

• Adjust injection speed to ensure proper filling of the mold cavity.

• Increase injection pressure to prevent short shots.

• Optimize melt temperature to improve flow and reduce defects.

• Extend cooling time to allow the plastic to solidify properly.

• Check for any obstructions or blockages in the mold.

• Ensure proper venting to prevent air traps.

• Use mold flow analysis softwar...read more

Low beam light provides short-range visibility without blinding oncoming drivers, while high beam light provides long-range visibility but can blind others.

• Low beam light is angled downwards to illuminate the road directly in front of the vehicle.

• High beam light is angled upwards to illuminate a longer distance ahead of the vehicle.

• Low beam light is used in normal driving conditions to avoid blinding oncoming drivers.

• High beam light is used in dark, unlit areas or when there ...read more

Negative slip in reciprocating pump occurs when the pump runs faster than the synchronous speed of the motor.

• Negative slip occurs when the pump runs faster than the synchronous speed of the motor.

• This can happen if the pump is not properly matched to the motor or if there is a mechanical issue causing the pump to run faster.

• Negative slip can lead to decreased efficiency and potential damage to the pump.

A fuse is an electrical safety device that protects electrical circuits from overloading and short circuits. Its maximum rating depends on the application.

• A fuse contains a metal wire or filament that melts when the current exceeds a certain level, breaking the circuit and preventing damage to the equipment or wiring.

• Fuses are rated based on their current-carrying capacity and voltage rating.

• Examples of fuse ratings include 1A, 5A, 10A, 20A, etc.

• Fuses are commonly used in hou...read more

Warpage and sink marks are common defects in plastic parts caused by uneven cooling. Prevention methods include proper gate design, cooling system optimization, and material selection.

• Warpage is the deformation of a plastic part due to uneven cooling, leading to dimensional inaccuracies.

• Sink marks are depressions on the surface of a plastic part caused by uneven cooling and shrinkage.

• Prevention methods include proper gate design to ensure uniform filling, optimization of cool...read more

The tonnage of molding machine required to fill a 200gm piece depends on the material being used and the design of the piece.

• Calculate the volume of the 200gm piece to determine the amount of material needed.

• Consider the material properties and flow characteristics to determine the appropriate tonnage of the molding machine.

• Methods such as injection molding or compression molding can be used depending on the design and material of the piece.

To solve manufacturing problems and correlate design, it is important to analyze root causes, communicate effectively with cross-functional teams, and iterate on design improvements.

• Identify the root cause of the manufacturing problem by analyzing data and conducting tests.

• Communicate effectively with cross-functional teams including manufacturing, quality, and design engineers to understand the impact of the problem on the design.

• Iterate on design improvements based on feedb...read more

Factors to consider when designing components for sheet metal and plastic

• Material selection based on properties and application requirements

• Design for manufacturability to ensure ease of production and cost-effectiveness

• Consideration of material thickness and bending radius for sheet metal components

• Wall thickness, draft angles, and rib design for plastic components

• Integration of features like fastening methods, mounting points, and assembly considerations

• Evaluation of enviro...read more

Flow transmitter senses flow and transmits signal to controller in selected range.

• Use a flow transmitter that is capable of sensing flow and transmitting a signal.

• Connect the flow transmitter to the controller using appropriate wiring and communication protocols.

• Configure the flow transmitter to operate within the desired range.

• Ensure proper calibration of the flow transmitter to accurately measure and transmit flow data.

• Implement suitable signal conditioning techniques to en...read more

The volume of a septic tank for a residential building typically ranges from 750 to 1,250 gallons.

• The volume of a septic tank is determined based on the number of bedrooms in the residential building.

• A general rule of thumb is to allocate 250-300 gallons per bedroom.

• For example, a 3-bedroom house would require a septic tank with a volume of 750-900 gallons.

• Factors such as soil type, water usage, and local regulations also impact the tank size.

Rib thickness in plastic components is important for strength and stiffness. Ribs are used to improve structural integrity and reduce warping.

• Rib thickness affects the strength and stiffness of the plastic component

• Ribs are used to improve structural integrity and reduce warping in plastic components

• Proper rib thickness can prevent sink marks and improve mold filling during injection molding

• Rib thickness should be optimized based on the specific design requirements and materi...read more

I work as a Design Engineer using CAD software like SolidWorks and AutoCAD.

• I am responsible for creating and designing products or components using CAD software.

• I collaborate with other engineers and stakeholders to ensure designs meet requirements.

• I have experience with SolidWorks, AutoCAD, and possibly other CAD software depending on the project.

• I am proficient in creating 2D drawings and 3D models for manufacturing and prototyping.

• I also have knowledge of GD&T and engineer...read more

Plastic tolerance requirements vary depending on the specific part and its function.

• Plastic tolerance is typically specified in the design phase based on factors like material properties, part function, and assembly requirements.

• Tighter tolerances are often needed for parts that require precise fits or interfaces.

• Looser tolerances may be acceptable for parts that do not have critical dimensions or functional requirements.

• Examples include injection molded parts for consumer el...read more

Design tools include CAD software, 3D printers, prototyping equipment, and simulation software.

• CAD software such as SolidWorks, AutoCAD, and CATIA are used for creating 2D and 3D designs

• 3D printers are used for rapid prototyping and creating physical models

• Prototyping equipment such as CNC machines and laser cutters are used for creating functional prototypes

• Simulation software such as ANSYS and COMSOL are used for testing and analyzing designs

• Other tools include hand sketchi...read more

Sheet metal thickness is decided based on factors like material type, part geometry, function, and cost.

• Consider material type and its properties (e.g. strength, ductility)

• Analyze part geometry and required structural integrity

• Evaluate function of the part and potential stresses it will endure

• Factor in cost implications of different thickness options

• Consult industry standards and guidelines for recommended thickness ranges

CATIA is a CAD software with various features. Here are the top 5:

• Advanced surface modeling

• Assembly design and management

• Kinematics simulation

• Sheet metal design

• Generative shape design

I2C is a serial communication protocol used to connect multiple devices with two wires. Pull-up resistors are necessary for proper communication.

• I2C uses a master-slave architecture where the master initiates communication.

• Each device on the bus has a unique address assigned to it.

• Data is transmitted in packets with a start and stop bit.

• Pull-up resistors are necessary to ensure proper voltage levels on the bus.

• The value of the pull-up resistor depends on the capacitance of th...read more

I can do various tasks in SolidWorks including part design, assembly, sheet metal, weldment, BOM, analysis, drawings, and details.

• Proficient in SolidWorks for part design and assembly

• Experienced in sheet metal and weldment design

• Able to create BOMs and perform analysis

• Skilled in creating detailed drawings and specifications

• Familiar with various SolidWorks add-ins and plugins

• Examples: Designed a sheet metal enclosure for a control panel, created a BOM for a complex assembly, p...read more

Number of macros in a block is calculated based on the size of the block, the size of the macros, and the desired spacing between macros.

• Calculate the area of the block

• Determine the size of the macros

• Calculate the area taken up by each macro

• Divide the block area by the macro area to get the number of macros

• Consider any spacing requirements between macros

Design considerations for plastic components include material selection, manufacturability, functionality, aesthetics, and cost.

• Material selection based on properties like strength, flexibility, and chemical resistance

• Consideration of manufacturability, such as moldability and ease of assembly

• Ensuring functionality requirements are met, such as mechanical strength or thermal resistance

• Aesthetics like color, texture, and surface finish are important for consumer products

• Cost c...read more

Yes, I have experience in part modeling and assembly designing in SolidWorks.

• I am proficient in creating 3D models of parts using SolidWorks.

• I have experience in designing assemblies and creating exploded views.

• I am familiar with creating detailed drawings and bill of materials.

• I have worked on projects involving sheet metal design and weldments.

• I am comfortable with using SolidWorks simulation tools for stress analysis and motion studies.

Yes, I have knowledge of various materials commonly used in engineering such as MS, SS, aluminum, etc.

• I have experience working with different grades of steel such as mild steel (MS) and stainless steel (SS)

• I am familiar with the properties and characteristics of aluminum and its alloys

• I understand the advantages and disadvantages of using different materials for different applications

• I have knowledge of other materials commonly used in engineering such as copper, brass, and ...read more

Yes, CAD tests can be conducted on NX Software 2306 version. Plastic parts can be developed in CAD software.

• CAD tests can be performed on NX Software 2306 version to ensure compatibility and functionality.

• CAD software allows for the design and development of plastic parts with precision and accuracy.

• Features like 3D modeling, simulation, and analysis tools in CAD software aid in the development of plastic parts.

• Examples of CAD software for plastic parts development include So...read more

To prevent plastic defects, design engineers use methods such as mold flow analysis, material selection, gate design optimization, and part geometry considerations.

• Perform mold flow analysis to identify potential issues before production.

• Select the appropriate plastic material based on the requirements of the part.

• Optimize gate design to ensure proper filling and packing of the mold.

• Consider part geometry to minimize stress concentrations and improve overall quality.

• Use desig...read more

Logic gates are fundamental building blocks of digital circuits that perform logical operations based on input signals.

• Logic gates are electronic components that take one or more binary inputs and produce a single binary output based on a specific logic function.

• Common types of logic gates include AND, OR, NOT, NAND, NOR, XOR, and XNOR gates.

• Logic gates are used in various electronic devices such as computers, calculators, and digital clocks to perform arithmetic and logical ...read more

Consider material properties, manufacturability, cost, functionality, and environmental impact when designing plastic components.

• Understand the material properties of the plastic being used (e.g. strength, flexibility, durability)

• Consider manufacturability factors such as moldability, tooling requirements, and production processes

• Evaluate cost implications including material costs, production costs, and assembly costs

• Ensure the functionality of the component meets the design ...read more

Plastic defects are imperfections in plastic materials that can affect the quality and functionality of the final product.

• Common plastic defects include sink marks, weld lines, voids, and warping.

• To solve plastic defects, proper material selection, mold design optimization, and processing parameters adjustment are essential.

• Using additives like flow enhancers or mold release agents can help improve the quality of plastic parts.

• Regular maintenance of molds and equipment can pr...read more

Common manufacturing processes for plastics include injection molding, extrusion, blow molding, and thermoforming.

• Injection molding involves injecting molten plastic into a mold to create a desired shape.

• Extrusion is used to create continuous lengths of plastic with a specific cross-sectional profile.

• Blow molding is commonly used for producing hollow plastic parts, such as bottles.

• Thermoforming involves heating a plastic sheet and shaping it using a mold.

• Other processes like ...read more

I regularly use a variety of plastics in my design work, including ABS, polycarbonate, and nylon.

• ABS is commonly used for its strength and impact resistance

• Polycarbonate is known for its transparency and high heat resistance

• Nylon is valued for its durability and flexibility

Considerations for supporting cryogenic piping systems

• Proper insulation to prevent heat transfer

• Use of materials with low thermal conductivity

• Expansion joints to accommodate thermal contraction

• Proper anchoring to prevent excessive movement

• Avoidance of sharp bends and abrupt changes in direction

• Regular maintenance and inspection to prevent leaks and ensure integrity

I will assess the extent of damage and plan the repair accordingly. The repair process will involve removing the damaged portion and replacing it with new RCC slab.

• Assess the extent of damage

• Plan the repair process

• Remove the damaged portion

• Replace with new RCC slab

• Ensure proper curing of the repaired portion

The basic needs of an electrical industry include reliable power supply, efficient equipment, skilled workforce, and safety measures.

• Reliable power supply to ensure uninterrupted operations

• Efficient equipment to optimize production and reduce costs

• Skilled workforce to design, install, and maintain electrical systems

• Safety measures to prevent accidents and ensure compliance with regulations

Answering a question on angle of projection and difference between Wave Geometry Linker and Wave Interface Linker.

• Angle of projection refers to the angle at which an object is projected into the air.

• Wave Geometry Linker is used to connect geometric shapes in a waveguide, while Wave Interface Linker is used to connect waveguide interfaces.

• Wave Geometry Linker is used in designing waveguide components, while Wave Interface Linker is used in designing waveguide systems.

• Wave Geom...read more

The manufacturing procedure for a big welded and machined frame made of stainless steel involves several steps.

• Design the frame using CAD software

• Cut the stainless steel sheets into required sizes using plasma or laser cutting machines

• Weld the cut pieces together using TIG or MIG welding techniques

• Machine the welded frame to achieve the desired shape and dimensions using CNC machines

• Perform surface finishing operations such as grinding, polishing, and painting

• Perform quality ...read more

The maximum load a lathe can take depends on its capacity and the material being machined.

• Check the lathe's specifications for its maximum weight capacity

• Consider the material being machined and its density

• Calculate the cutting forces involved in the machining process

• Ensure the lathe is properly maintained and in good working condition

To remove Setup violation, hold violation, I would optimize the timing constraints and perform timing analysis.

• Optimize timing constraints to ensure that setup and hold times are met

• Perform timing analysis to identify and resolve any timing violations

• Use delay constraints to ensure that signals arrive at the correct time

• Use clock skew optimization to minimize clock skew and improve timing

• Use clock gating to reduce power consumption and improve timing

• Use multi-cycle paths to r...read more

Plastic parts are developed using methods like injection molding, blow molding, and thermoforming.

• Injection molding is a common method where molten plastic is injected into a mold.

• Blow molding is used for hollow parts like bottles, where plastic is blown into a mold.

• Thermoforming involves heating a plastic sheet and shaping it over a mold.

• Other methods include rotational molding, extrusion, and compression molding.