1000+ Design Engineer Interview Questions and Answers

LMC & MMC refer to the conditions in which a part has the least or maximum amount of material respectively.

• LMC is the condition where a part has the least amount of material, ensuring the smallest size of the feature.

• MMC is the condition where a part has the maximum amount of material, ensuring the largest size of the feature.

• These conditions are important in engineering design to ensure proper fit and function of parts.

• For example, in a hole and shaft assembly, LMC for the h...read more

Understanding material properties, strength, deflections, and modes of heat transfer is crucial in designing efficient systems.

• Material properties such as density, elasticity, and thermal conductivity affect the behavior of a material under different conditions.

• Strength is the ability of a material to withstand external forces without breaking or deforming.

• Deflections refer to the amount of bending or deformation a material undergoes under load.

• Modes of heat transfer include ...read more

Baud rate is the rate at which data is transmitted over a communication channel.

• Baud rate is measured in bits per second (bps).

• Higher baud rates allow for faster data transmission.

• Baud rate must be set the same on both ends of the communication channel.

• Incorrect baud rate settings can result in data corruption or loss.

• Examples of communication channels that use baud rate include UART, SPI, and I2C.

Stress is the force per unit area that a material experiences when subjected to external loads or forces.

• Stress is a measure of the internal resistance of a material to deformation.

• It is calculated as the force applied divided by the cross-sectional area of the material.

• Stress can be tensile (pulling apart), compressive (pushing together), or shear (sliding past each other).

• High levels of stress can lead to material failure or deformation.

• Stress analysis is important in engin...read more

Beads and darts are decided based on design requirements, manufacturing constraints, and structural considerations in BIW members.

• Consider design requirements such as stiffness, strength, and crashworthiness.

• Take into account manufacturing constraints like tooling limitations and cost.

• Evaluate structural considerations such as load distribution and stress concentrations.

• Use simulation software to optimize bead and dart placement for desired performance.

• Consult with manufactur...read more

Discussion on soil mechanics starting from modulus of elasticity to liquifaction

• Modulus of elasticity is a measure of soil stiffness

• Soil strength is important in determining its ability to withstand loads

• Liquifaction occurs when soil loses strength and behaves like a liquid

• Factors affecting soil strength include soil type, moisture content, and stress history

• Liquifaction can lead to soil failure and damage to structures built on it

CAD software is used to create, modify, analyze, and optimize designs in 2D or 3D format.

• CAD stands for Computer-Aided Design

• It is used in various industries such as architecture, engineering, and manufacturing

• CAD software allows for precise measurements and calculations

• Examples of CAD software include AutoCAD, SolidWorks, and CATIA

Pump discharge flow rate can be calculated using the formula Q = A * V, where Q is the flow rate, A is the cross-sectional area of the pipe, and V is the velocity of the fluid.

• Calculate the cross-sectional area of the pipe using the formula A = π * r^2, where r is the radius of the pipe.

• Determine the velocity of the fluid by measuring the speed at which the fluid is flowing through the pipe.

• Multiply the cross-sectional area of the pipe by the velocity of the fluid to calculat...read more

Plastic weight in CAD software can be calculated by determining the volume of the plastic part and multiplying it by the density of the plastic material.

• Create a 3D model of the plastic part in the CAD software.

• Calculate the volume of the plastic part using the CAD software's tools.

• Determine the density of the plastic material being used.

• Multiply the volume of the plastic part by the density of the plastic material to get the weight.

ABS is a thermoplastic polymer while nylon is a synthetic polymer. ABS is more rigid and impact-resistant, while nylon is more flexible and durable.

• ABS is a thermoplastic polymer, while nylon is a synthetic polymer

• ABS is more rigid and impact-resistant, while nylon is more flexible and durable

• ABS is commonly used in 3D printing and automotive parts, while nylon is used in textiles and industrial applications

I have designed various parts in Creo for applications in automotive, aerospace, and consumer electronics industries.

• Designed engine components for automotive industry

• Designed aircraft structural components for aerospace industry

• Designed smartphone casings for consumer electronics industry

Principles of fixture designing involve ensuring accuracy, repeatability, accessibility, and safety.

• Design fixtures to hold the workpiece securely and accurately

• Ensure repeatability by designing fixtures that can be easily replicated

• Make fixtures easily accessible for loading and unloading of workpieces

• Ensure safety by designing fixtures that prevent accidents and injuries

• Consider factors such as material selection, cost, and manufacturing processes

• Examples include jigs, clam...read more

To take design to an advanced level, one should focus on continuous learning, exploring new technologies, collaborating with others, and seeking feedback.

• Continuously learn and stay updated with the latest design trends and technologies.

• Explore new tools and software that can enhance the design process and improve efficiency.

• Collaborate with other designers, engineers, and stakeholders to gain different perspectives and insights.

• Seek feedback from users, clients, and colleagu...read more

Cylindricity refers to the overall 3D form of a cylinder, while roundness refers to the deviation of a circle from a perfect circle.

• Cylindricity is a 3D tolerance that controls the overall form of a cylinder, ensuring that all points on the surface lie within a specified tolerance zone.

• Roundness is a 2D tolerance that controls the deviation of a circle from a perfect circle, ensuring that the entire circle lies within a specified tolerance zone.

• Cylindricity is used when the f...read more

I know and have worked with several design software. I am highly efficient in using them.

• I am proficient in using AutoCAD, SolidWorks, SketchUp, and Adobe Creative Suite

• I have completed several projects using these software with high accuracy and efficiency

• I am always eager to learn and explore new design software to enhance my skills

I primarily used CAD software such as AutoCAD and SolidWorks for designing and modeling.

• AutoCAD - Used for creating 2D and 3D designs, drafting, and documentation.

• SolidWorks - Used for 3D modeling, simulation, and creating detailed engineering drawings.

• Other software - Used various software tools for analysis, prototyping, and project management.

Undercut angle in plastic is the angle between the side wall of a mold and the vertical direction.

• Undercut angle is important in plastic injection molding to ensure proper release of the part from the mold.

• It is typically measured in degrees and affects the draft angle required for the mold.

• A larger undercut angle allows for easier part ejection but may require more complex mold design.

• Examples of parts with undercut angles include bottle caps and snap-fit connectors.

Selection of motors and hydraulic cylinders depends on the application requirements and specifications.

• Determine the required torque, speed, and power for the motor

• Consider the environment and operating conditions

• Select a motor with appropriate size and type

• For hydraulic cylinders, determine the required force and stroke length

• Choose a cylinder with appropriate bore and rod diameter

• Consider the operating pressure and fluid type

• Ensure compatibility between the motor and hydrau...read more

Product design involves a series of steps to create a functional and aesthetically pleasing product.

• Understand the problem or need that the product will address

• Research existing products and technologies

• Brainstorm ideas and create sketches or prototypes

• Iterate on designs based on feedback and testing

• Finalize design for production

Identifying root cause of new products involves thorough analysis and investigation.

• Conduct thorough testing and analysis of the product

• Collect feedback from users and stakeholders

• Investigate any reported issues or failures

• Use tools like root cause analysis (RCA) to identify underlying issues

• Consider factors such as design, materials, manufacturing process, and user interaction

• Collaborate with cross-functional teams to gather insights and perspectives

To make a laser cutting drawing in sheet metal, you need to create a CAD file with the desired design and specifications.

• Create a CAD file of the design you want to cut using laser cutting technology.

• Specify the material type and thickness in the CAD file for accurate cutting parameters.

• Include dimensions, tolerances, and any special instructions in the drawing.

• Convert the CAD file into a format compatible with the laser cutting machine, such as DXF or DWG.

• Send the file to th...read more

The procedure for new product development involves idea generation, concept development, design and testing, and commercialization.

• Idea generation: Brainstorming sessions, market research, customer feedback

• Concept development: Creating prototypes, feasibility studies

• Design and testing: Iterative design process, testing for functionality and durability

• Commercialization: Marketing strategies, production planning, launch

GD&T is a system for defining and communicating engineering tolerances. Cpk and Cmk are statistical measures of process capability. Lean manufacturing is a philosophy of minimizing waste and maximizing efficiency.

• GD&T stands for Geometric Dimensioning and Tolerancing, which is a system for defining and communicating engineering tolerances

• Cpk and Cmk are statistical measures of process capability, used to determine if a process is capable of producing parts within specified to...read more

There are seven main categories of plastic materials.

• Thermoplastics

• Thermosets

• Elastomers

• Composites

• Biodegradable plastics

• Engineering plastics

• High-performance plastics

Costing of complete products can be calculated by considering materials, labor, overhead, and profit margin.

• Calculate the cost of materials required for the product

• Estimate the labor costs involved in manufacturing the product

• Factor in overhead costs such as utilities, rent, and equipment depreciation

• Add a profit margin to cover additional expenses and generate profit

• Consider any additional costs such as shipping, packaging, and marketing

• Use cost accounting methods to allocat...read more

Plastic defects can be solved by identifying root causes, adjusting processing parameters, using quality materials, and implementing proper maintenance.

• Identify root causes of defects such as improper molding conditions or poor material quality

• Adjust processing parameters like temperature, pressure, and cooling rate to optimize production

• Use high-quality materials to ensure consistency and durability of the final product

• Implement regular maintenance of molds and machinery to ...read more

The purpose of gate & runner in molding is to control the flow of molten material into the mold cavity.

• Gate controls the flow of molten material into the mold cavity

• Runner distributes the molten material throughout the mold

• They help in achieving proper filling of the mold and reducing defects like air pockets or incomplete filling

• Different types of gates and runners are used based on the molding process and material being used

To create a manufacturing drawing for a complex machined frame, precise measurements and specifications are required.

• Gather all necessary information about the frame's dimensions and specifications

• Create a detailed 2D or 3D model of the frame using CAD software

• Include all necessary annotations, dimensions, and tolerances in the drawing

• Specify the materials and finishes to be used

• Ensure that the drawing complies with industry standards and regulations

A cache is a high-speed data storage layer that stores frequently accessed data to reduce access time. A tag is used to identify the location of data in the cache.

• Cache is a temporary storage that holds frequently accessed data

• It reduces the access time by providing faster access to data

• Tag is used to identify the location of data in the cache

• Tag is a part of the cache memory address

• Cache can be implemented in hardware or software

• Examples of cache include CPU cache, browser c...read more

Engineering drawing is a graphical representation of an object or system.

• Types of fits: clearance fit, interference fit, transition fit

• Tolerance: the allowable variation in a dimension

• GD&T: Geometric Dimensioning and Tolerancing, a system for defining and communicating engineering tolerances

NPD person plays a crucial role in industry by leading the development of new products from concept to launch.

• Responsible for identifying market opportunities and consumer needs

• Leads cross-functional teams to develop new products

• Coordinates with various departments such as marketing, engineering, and manufacturing

• Manages the product development process from concept to commercialization

• Ensures products meet quality standards and are delivered on time and within budget

There are numerous materials used in engineering, each with unique properties and applications.

• Metals: strong and durable, used in construction and machinery

• Polymers: lightweight and flexible, used in packaging and consumer goods

• Ceramics: heat-resistant and hard, used in electronics and construction

• Composites: combination of materials, used in aerospace and sports equipment

• Why we use them in specific: based on their properties and intended application

• For example, metals are u...read more

The velocity of flow at the inlet of a Kaplan turbine is typically high due to the design of the turbine blades.

• The velocity of flow at the inlet of a Kaplan turbine is usually between 3 to 10 m/s.

• The high velocity at the inlet helps in maximizing the energy extraction efficiency of the turbine.

• The design of the Kaplan turbine blades allows for efficient energy conversion from the flowing water to rotational motion.

The density of ABS plastic is around 1.04 g/cm³, while the density of nylon plastic is around 1.15 g/cm³.

• ABS plastic has a density of approximately 1.04 g/cm³

• Nylon plastic has a density of around 1.15 g/cm³

To view a customer's part design sheet in Solidworks software, follow these steps:

• Open Solidworks software

• Click on 'Open' and select the customer's part design sheet

• The 3D model will be displayed in Solidworks

• Use the software's tools to manipulate and analyze the model as needed

The nominal stress for mild steel plate depends on the thickness of the plate and the yield strength of the steel.

• Nominal stress is the maximum stress that a material can withstand before it fails

• For mild steel, the nominal stress is typically calculated using the yield strength of the steel

• The thickness of the plate also plays a role in determining the nominal stress

• The formula for calculating nominal stress is: Nominal stress = Yield strength / Factor of safety

• For example, ...read more

GD&T is a system for defining and communicating engineering tolerances. Machining operations involve shaping materials using various tools and techniques.

• GD&T stands for Geometric Dimensioning and Tolerancing, used to specify the allowable variations in form and size of a part.

• Machining operations include processes like turning, milling, drilling, and grinding to shape materials into desired forms.

• Fits refer to the clearance or interference between mating parts, such as a tig...read more

I have experience in designing various types of plastic components including injection molded parts, extruded profiles, and thermoformed products.

• Injection molded parts

• Extruded profiles

• Thermoformed products

I use ASME codes such as ASME B31.1 for power piping and ASME B31.3 for process piping in my design work.

• I use ASME B31.1 for power piping design.

• I use ASME B31.3 for process piping design.

• I ensure compliance with ASME Boiler and Pressure Vessel Code for pressure vessel design.

• I refer to ASME standards for materials selection, fabrication, and testing.

• I stay updated on the latest revisions and updates to ASME codes.

Seals are mechanical devices used to prevent fluid or gas leakage between two surfaces.

• Seals are used in various industries such as automotive, aerospace, oil and gas, and manufacturing.

• They can be classified into two types: static seals and dynamic seals.

• Static seals are used in applications where there is no relative motion between the sealing surfaces, such as gaskets and O-rings.

• Dynamic seals are used in applications where there is relative motion between the sealing surf...read more

The present GD&T ASME standard is ASME Y14.5-2018.

• ASME Y14.5-2018 is the current version of the GD&T standard published by the American Society of Mechanical Engineers (ASME).

• GD&T stands for Geometric Dimensioning and Tolerancing, which is a system used to define and communicate engineering tolerances.

• The ASME Y14.5-2018 standard provides guidelines and rules for the interpretation and application of GD&T symbols, terms, and definitions.

• It covers various aspects such as datum...read more

LMC & MMC are GD&T concepts used to define the extreme sizes of a part. LMC is the smallest size while MMC is the largest size.

• LMC (Least Material Condition) is the condition where a part has the least amount of material, ensuring the smallest size possible.

• MMC (Max Material Condition) is the condition where a part has the most amount of material, ensuring the largest size possible.

• GD&T uses LMC and MMC to establish the tolerance range for a part.

• For example, if a hole has an...read more

I have used various measuring devices such as calipers, micrometers, height gauges, and dial indicators.

• Calipers for measuring length and thickness

• Micrometers for measuring small distances and thicknesses

• Height gauges for measuring heights and depths

• Dial indicators for measuring small distances and deflections

In pp plastic material, coating is preferred over painting for better adhesion and durability.

• Coating is commonly used on PP plastic material for better adhesion and durability

• Painting is less preferred on PP plastic due to poor adhesion and durability

• Examples of coatings for PP plastic include polypropylene-specific primers and adhesion promoters

Buoyancy in a balloon is not affected by the car taking a turn due to the principle of relative motion.

• Buoyancy is a force exerted by a fluid that opposes the weight of an immersed object.

• The balloon and the air inside it are both moving with the car, so the buoyant force remains constant.

• The buoyant force is determined by the displaced fluid, not the motion of the object.

• Therefore, the balloon will continue to float in the same manner regardless of the car's movement.

Mechanical properties of materials include strength, stiffness, toughness, hardness, ductility, and elasticity.

• Strength: Ability to withstand applied force without failure (e.g. tensile strength, compressive strength)

• Stiffness: Resistance to deformation under load (e.g. Young's modulus)

• Toughness: Ability to absorb energy and deform plastically before fracturing (e.g. impact toughness)

• Hardness: Resistance to indentation or scratching (e.g. Rockwell hardness)

• Ductility: Ability ...read more

Various pneumatic equipments were used in the previous organisation including air compressors, pneumatic cylinders, pneumatic valves, and pneumatic actuators.

• Air compressors were used to generate compressed air for various applications.

• Pneumatic cylinders were utilized for linear motion in different machinery.

• Pneumatic valves controlled the flow of compressed air in the system.

• Pneumatic actuators were employed for converting energy into mechanical motion.