1000+ Design Engineer Interview Questions and Answers

Plastic and sheet metal are justified based on factors like cost, durability, weight, and design flexibility.

• Plastic is often chosen for its low cost, lightweight properties, and design flexibility.

• Sheet metal is preferred for its strength, durability, and ability to be easily formed into complex shapes.

• Plastic is commonly used in consumer products like electronics casings, while sheet metal is often used in automotive and aerospace industries.

• The choice between plastic and s...read more

DFMEA is used to identify and prioritize potential failure modes in a design process.

• Identify potential failure modes in the design process

• Prioritize the failure modes based on severity, occurrence, and detection

• Develop actions to mitigate or eliminate the identified failure modes

• Monitor and update the DFMEA throughout the design process

• Collaborate with cross-functional teams to ensure comprehensive analysis

K factor in sheet metal is a constant representing the ratio of the location of the neutral axis to the material thickness.

• K factor determines how much a sheet metal part will stretch during bending.

• It is used in calculating the bend allowance to determine the flat pattern length of the sheet metal.

• Different materials and thicknesses have different K factors.

• Typical K factor values range from 0.3 to 0.5.

Plastic shrinkage is the reduction in size of a plastic part during cooling, while draft angle is the taper applied to vertical surfaces to aid in mold release.

• Plastic shrinkage occurs as the molten plastic cools and solidifies, causing it to contract in size.

• Draft angle is the slight taper given to vertical surfaces of a mold to allow for easy removal of the part.

• Plastic shrinkage can lead to warping or distortion if not properly accounted for in the design.

• Draft angles are ...read more

I am proficient in using Solid Edge software for designing and engineering tasks.

• I have extensive experience using Solid Edge software for creating 3D models and assemblies.

• I am skilled in utilizing features such as parametric modeling, simulation, and rendering in Solid Edge.

• I have successfully completed projects using Solid Edge for product design and development.

• I am familiar with advanced tools and functionalities in Solid Edge for efficient design processes.

Various components used in the frame include tubes, joints, brackets, and fasteners.

• Tubes: provide structural support and can be made of materials like steel or aluminum

• Joints: connect tubes together at different angles

• Brackets: used to reinforce joints or provide additional support

• Fasteners: such as bolts and screws are used to secure components together

Points to consider during casting feasibility include material selection, part geometry, draft angles, wall thickness, and surface finish.

• Material selection - Choose a material suitable for the part's function and properties.

• Part geometry - Ensure the part can be easily cast without complex shapes or undercuts.

• Draft angles - Include draft angles to allow for easy removal of the part from the mold.

• Wall thickness - Maintain uniform wall thickness to prevent defects like shrinka...read more

There are three main types of defects in plastic: surface defects, physical defects, and chemical defects.

• Surface defects include scratches, sink marks, and flow marks.

• Physical defects include bubbles, voids, and warping.

• Chemical defects include discoloration, degradation, and contamination.

Draft angle in plastic is the degree of taper or slope applied to the vertical walls of a plastic part to facilitate its ejection from the mold.

• Draft angles are typically recommended to be between 1-3 degrees for most plastic parts

• Draft angles help prevent the part from getting stuck in the mold during ejection

• Examples of draft angles include adding a slight taper to the sides of a plastic cup or the walls of a plastic housing

Gate & runner in molding are channels through which molten material is injected into the mold cavity.

• Gate is the opening through which molten material enters the mold cavity

• Runner is the channel that connects the gate to the sprue or main injection point

• Proper design of gates and runners is crucial for ensuring even distribution of material and preventing defects

• Examples: Submarine gate, edge gate, hot runner system

To optimize a mechanical component for weight without compromising strength, one can use advanced materials, topology optimization, and finite element analysis.

• Utilize advanced materials with high strength-to-weight ratios, such as carbon fiber composites or titanium alloys.

• Implement topology optimization techniques to remove excess material while maintaining structural integrity.

• Conduct finite element analysis to simulate different loading conditions and identify areas where...read more

Design cost with/without simulation depends on applied codes.

• The cost of design will vary depending on the complexity of the codes applied.

• Simulation can help reduce costs by identifying potential issues before production.

• Without simulation, the cost of design may increase due to the need for physical testing.

• Examples of codes that may affect design cost include building codes, safety codes, and environmental codes.

Valves are made of materials that can withstand high pressure, temperature, and corrosive environments.

• Materials used in valves include stainless steel, brass, bronze, and plastic.

• Stainless steel is commonly used due to its strength, durability, and resistance to corrosion.

• Brass and bronze are used for their excellent thermal conductivity and resistance to corrosion.

• Plastic valves are used in applications where chemical resistance and low cost are important.

• Other materials ma...read more

Geometric Dimensioning and Tolerancing (GD&T) is a system for defining and communicating engineering tolerances through symbols on engineering drawings.

• GD&T allows engineers to clearly communicate design intent and requirements for manufacturing

• It includes symbols for features like flatness, perpendicularity, concentricity, and more

• Engineering drawings use GD&T to specify the allowable variations in dimensions and geometry of a part

• Understanding GD&T is essential for design e...read more

Yes, I am open to being located in a remote location for the right opportunity.

• I am willing to relocate for the right job opportunity

• I have experience working remotely or in different locations

• I am adaptable and can thrive in new environments

Types of currents in signal EM include direct current (DC) and alternating current (AC).

• Direct current (DC) flows in one direction constantly.

• Alternating current (AC) changes direction periodically.

• Other types include pulsed current and square wave current.

• DC is commonly used in electronics, while AC is used in household electricity.

• Pulsed current is used in medical devices for muscle stimulation.

The LT side breaker size for a 1000 KVA transformer would typically be around 800A and the cable size would be around 400mm2.

• LT side breaker size is usually around 80% of the transformer rating, so for a 1000 KVA transformer, it would be around 800A.

• Cable size for the LT side would depend on the current carrying capacity required, typically around 2 times the breaker size, so around 400mm2.

• It is important to consult with electrical standards and regulations to determine the e...read more

Plastic defects can be controlled through proper material selection, process optimization, and quality control measures.

• Selecting the right type of plastic material for the specific application can help prevent defects.

• Optimizing the manufacturing process parameters such as temperature, pressure, and cooling time can reduce defects.

• Implementing quality control measures like regular inspections and testing can help identify and address defects early on.

Tyre pressure is less in front and more in rear wheel in bikes for better handling, stability, and traction.

• Better handling: Lower pressure in front tire allows for easier steering and maneuverability.

• Stability: Higher pressure in rear tire helps distribute weight evenly and maintain stability during acceleration and braking.

• Traction: Higher pressure in rear tire increases the contact patch with the road, improving traction for better grip.

• Example: In sports bikes, front tire...read more

Major/minor projects are design projects undertaken by engineering students to apply their theoretical knowledge in practical applications.

• Major projects are usually more complex and require a longer duration to complete than minor projects.

• Design parameters include factors such as cost, functionality, safety, and aesthetics.

• Projects may involve designing and building a prototype, conducting experiments, or developing software.

• Examples of major projects include designing a so...read more

Different types of reinforcement used in RS wall include steel bars, welded wire mesh, and fiber reinforcement.

• Steel bars are commonly used as reinforcement in RS walls due to their strength and durability.

• Welded wire mesh is another type of reinforcement that is often used to reinforce the RS wall.

• Fiber reinforcement, such as glass or polypropylene fibers, can also be added to the concrete mix to improve its strength and durability.

• Other types of reinforcement that may be us...read more

A beam is a horizontal or inclined structural member that carries loads perpendicular to its longitudinal axis, while a slab is a flat, horizontal structural element that is typically used in floors and roofs.

• Beams are used to support vertical loads, while slabs are used to support horizontal loads.

• Beams are typically deeper than they are wide, while slabs are typically wider than they are deep.

• Beams are often used in bridges, buildings, and other structures, while slabs are ...read more

The least count of a vernier caliper is 0.02 mm and the least count of a micrometer screw gauge is 0.01 mm.

• Vernier caliper least count: 0.02 mm

• Micrometer screw gauge least count: 0.01 mm

GD&T is essential in engineering design to communicate the required dimensions and tolerances for manufacturing and inspection.

• GD&T ensures clear communication of design requirements between designers, manufacturers, and inspectors.

• It allows for more precise control of dimensions and tolerances, leading to improved quality and consistency in manufactured parts.

• GD&T helps reduce manufacturing costs by specifying only necessary tolerances, rather than over-constraining the desi...read more

Cell balancing ensures equal charge distribution in batteries. BLDC motor driver controls the operation of brushless DC motors.

• Cell balancing is the process of equalizing the charge levels of individual cells in a battery pack to maximize performance and lifespan.

• It is achieved by transferring charge between cells or by adjusting the charging/discharging rates of individual cells.

• Cell balancing prevents overcharging or over-discharging of cells, which can lead to reduced capa...read more

Heat load calculation can be done using Excel sheet E-20

• Open Excel sheet E-20

• Enter the relevant data such as room dimensions, insulation, and equipment

• Use formulas to calculate the heat load

• Consider factors such as solar gain and occupancy

• Review and adjust calculations as necessary

Soil Bearing Capacity (S.B.C.) is the maximum pressure that can be applied to the soil without causing shear failure.

• S.B.C. is a crucial factor in determining the foundation design of structures.

• It is influenced by factors such as soil type, moisture content, and compaction.

• The S.B.C. is usually expressed in units of force per unit area, such as kN/m^2 or psi.

• It is important to conduct soil tests to determine the S.B.C. before construction.

• Exceeding the S.B.C. can lead to set...read more

First projection is a front view of an object, while third projection is a side view.

• First projection shows the front view of an object, while third projection shows the side view.

• First projection is typically labeled as 'F' on engineering drawings, while third projection is labeled as 'T'.

• First projection is used to show the overall shape and size of an object, while third projection is used to show the depth and height.

Casting process involves pouring molten metal into a mold to create a desired shape. Sheet metal is metal formed into thin, flat pieces. GD&T stands for Geometric Dimensioning and Tolerancing.

• Casting process involves melting metal and pouring it into a mold to create a specific shape.

• Sheet metal is metal that has been formed into thin, flat pieces, often used in manufacturing for various applications.

• GD&T is a system for defining and communicating engineering tolerances, used...read more

Best efficiency of a pump is the point where it operates at maximum output with minimum energy consumption.

• Best efficiency is the point on the pump curve where the highest flow rate is achieved with the lowest power consumption.

• It is important to operate the pump at or near its best efficiency point to reduce energy consumption and increase the lifespan of the pump.

• Factors that affect the best efficiency point include pump design, impeller diameter, and system resistance.

• For ...read more

Preparation for safety includes risk assessment, safety training, use of personal protective equipment, and emergency response planning.

• Conducting a thorough risk assessment to identify potential hazards

• Providing safety training to all employees on proper procedures and protocols

• Ensuring the use of personal protective equipment such as helmets, gloves, and safety goggles

• Developing an emergency response plan and conducting regular drills to ensure preparedness

• Regularly reviewi...read more

Various methods such as stamping, welding, and bonding are used for making BIW in manufacturing processes.

• Stamping: involves pressing a sheet of metal into a die to create the desired shape

• Welding: joining metal pieces together using heat or pressure

• Bonding: using adhesives to attach metal components

• Riveting: joining metal parts using rivets

• Hydroforming: shaping metal using fluid pressure

I would rate myself as highly proficient in AutoCAD.

• I have extensive experience using AutoCAD in various design projects.

• I am skilled in creating detailed 2D and 3D models using AutoCAD.

• I am familiar with advanced features and tools in AutoCAD, such as parametric modeling and rendering.

• I have successfully completed complex design projects using AutoCAD, meeting all requirements and deadlines.

• I continuously update my knowledge and skills in AutoCAD through self-learning and pr...read more

The least count of micrometer, vernier calipers, and height gauge varies depending on their precision.

• Micrometer least count ranges from 0.001mm to 0.0001mm

• Vernier calipers least count ranges from 0.02mm to 0.05mm

• Height gauge least count ranges from 0.02mm to 0.05mm

• Least count is the smallest measurement that can be read on the device

• The precision of the device determines the least count

I would draw the shape of the component shown in AutoCAD software.

• I would ask for clarification on the specific component being referred to.

• I would use the AutoCAD software to accurately draw the shape of the component.

• I would ensure that the dimensions and proportions of the component are correct.

• I would label the drawing with any relevant information, such as part numbers or materials.

• I would double-check my work for accuracy before submitting the drawing.

Solar industry involves the production and distribution of solar energy through various technologies.

• Solar industry is a rapidly growing sector globally

• It includes the production of solar panels, solar cells, and other related equipment

• Solar energy is used for various purposes such as electricity generation, heating, and cooling

• The industry is heavily dependent on government policies and incentives

• Major players in the industry include companies like SunPower, First Solar, and...read more

Valves are mechanical devices used to control the flow of fluids or gases in a system. They are typically made of materials like stainless steel, brass, or PVC.

• Valves control the flow of fluids or gases in a system

• Common materials used for valves include stainless steel, brass, and PVC

• Temperature and pressure are related in that as temperature increases, pressure also tends to increase

The rho value for different conic sections varies depending on the shape of the section.

• Circle: rho = r (radius)

• Ellipse: rho = a * b / sqrt(a^2 * sin^2(theta) + b^2 * cos^2(theta))

• Parabola: rho = 2p / (1 + cos(theta))

• Hyperbola: rho = sqrt(a^2 + b^2)

I am highly capable of learning new software through tutorials and have successfully done so in the past.

• I have a strong aptitude for technology and enjoy learning new software programs.

• I have successfully learned software such as AutoCAD, SolidWorks, and MATLAB through tutorials.

• I am a self-motivated learner and can quickly adapt to new software interfaces.

I rate myself highly in UGNX as I have extensive experience using it for design and engineering projects.

• I have been using UGNX for several years and have completed numerous projects using the software.

• I am proficient in creating 3D models, assemblies, and drawings using UGNX.

• I am familiar with advanced features such as surface modeling and simulation analysis.

• I am always eager to learn new techniques and stay up-to-date with the latest software updates.

• Overall, I am confiden...read more

I use tools like Altium Designer and Eagle for schematic design. These tools offer advanced features and a user-friendly interface.

• Altium Designer and Eagle are popular tools for schematic design in the industry.

• These tools offer advanced features such as real-time design synchronization, interactive routing, and 3D visualization.

• Altium Designer and Eagle have user-friendly interfaces that make it easier to create complex schematics and PCB layouts.

• They also provide extensive...read more

Geometric Dimensioning and Tolerancing (GD&T) is a system for defining and communicating engineering tolerances. It is essential for design engineers to understand GD&T for accurate manufacturing.

• GD&T is used to specify the allowable variations in form, size, and orientation of features on a part.

• Materials selection is crucial for design engineers to ensure the desired mechanical properties, corrosion resistance, and cost-effectiveness of the final product.

• Different types of ...read more

Yes, the Neutral Axis changes its position based on the shape and loading of the beam.

• The Neutral Axis is the line within a beam where there is no stress or strain.

• The position of the Neutral Axis depends on the shape of the beam and the distribution of loads.

• For example, in a simply supported beam with a uniform load, the Neutral Axis will be at the centroid of the beam's cross-section.

Static IR analysis is a technique used to analyze the resistance of a circuit or system to direct current (DC) signals.

• Static IR analysis helps in identifying potential issues such as voltage drops, power dissipation, and current flow in a circuit.

• It is important to perform static IR analysis to ensure that the circuit operates within specified limits and does not lead to overheating or malfunction.

• By analyzing the resistance of components in a circuit, designers can optimize...read more

There are seven main categories of plastics based on their chemical structure and properties.

• Polyethylene (PE)

• Polypropylene (PP)

• Polyvinyl Chloride (PVC)

• Polystyrene (PS)

• Polyethylene Terephthalate (PET)

• Polyurethane (PU)

• Polycarbonate (PC)

The weight of a particular component can be found by using a scale or by referring to the component's specifications.

• Use a scale to directly measure the weight of the component.

• Refer to the component's specifications or documentation for the weight information.

• If the weight is not provided, consider using a formula to calculate it based on the material and dimensions of the component.

Circularity and circular run out are both measurements of how well a circular object conforms to its intended shape.

• Circularity measures the overall roundness of a circle, while circular run out measures the variation in the center point of the circle as it rotates.

• Both measurements are important in ensuring the proper functioning of rotating parts in machinery.

• For example, in a car engine, circularity ensures that pistons move smoothly within cylinders, while circular run ou...read more