1000+ Design Engineer Interview Questions and Answers

Strength of material and sheet metal are basic engineering concepts that deal with the properties and behavior of materials.

• Strength of material involves understanding how materials respond to external forces and stresses, and designing structures that can withstand those forces.

• Sheet metal is a thin, flat metal that is used in a variety of applications, such as in the construction of buildings, automobiles, and appliances.

• Sheet metal fabrication involves cutting, bending, an...read more

SS cladding is done on MS frame to protect it from corrosion and increase its durability.

• The MS frame is first cleaned and prepared for cladding.

• The SS sheets are cut to size and welded onto the MS frame.

• The joints are then ground and polished to ensure a smooth finish.

• The cladding thickness and welding quality are checked to ensure compliance with standards.

• The final product is inspected for any defects or imperfections.

Basic requirements for designing a product include understanding user needs, creating a concept, prototyping, testing, and refining.

• Understanding user needs and requirements

• Creating a concept or design brief

• Prototyping and testing the product

• Refining the design based on feedback

• Considering materials, manufacturing processes, and cost constraints

Tolerance stack up is the accumulation of variation in dimensions and GD&T symbols are used to specify the allowable variation.

• Tolerance stack up occurs when multiple parts are assembled together and the variation in each part adds up, potentially causing issues with fit and function.

• GD&T symbols are used to specify the allowable variation in dimensions, orientation, and form of a part or assembly.

• Examples of GD&T symbols include concentricity, perpendicularity, and flatness....read more

I mostly use the position symbol in my drawings for GD&T.

• Position symbol is used to specify the location of features on a part relative to a datum

• It is commonly used in engineering drawings to ensure proper alignment and fit of components

• Example: Position symbol with a tolerance of ±0.1mm

Manufacturing processes are methods used to convert raw materials into finished products through various techniques and operations.

• Manufacturing processes involve a series of steps such as casting, molding, machining, welding, and assembly.

• These processes can be categorized into four main types: casting and molding, machining, joining, and finishing.

• Examples of manufacturing processes include injection molding for plastic parts, CNC machining for metal components, and welding...read more

Orifice std refers to standard orifice sizes used in engineering. Types of taps include flange taps, corner taps, and D and D/2 taps.

• Orifice std refers to standard sizes of orifices used in flow measurement

• Types of taps include flange taps, corner taps, and D and D/2 taps

• Flange taps are used for large pipes, corner taps for small pipes, and D and D/2 taps for general applications

Calculations for selecting components like pneumatic cylinders, bearings, gears, hydraulics, and lm guides involve considering load requirements, operating conditions, and safety factors.

• Determine the load requirements for each component based on the application

• Consider the operating conditions such as speed, temperature, and environment

• Calculate the safety factors to ensure the components can withstand unexpected loads

• Select components with appropriate load ratings and sizes...read more

To enhance my skills and knowledge in CAD design, as Catia is commonly used in the industry.

• To broaden my skill set and increase my marketability as a design engineer

• To stay competitive in the industry and adapt to changing technology

• To work on projects that specifically required Catia knowledge, such as aerospace or automotive design

• To have a better understanding of different CAD software and their capabilities

I would rate my CAD skills at 8 out of 10.

• I have extensive experience with SolidWorks and AutoCAD.

• I am proficient in creating 3D models and assemblies.

• I am skilled in creating detailed drawings and schematics.

• I am familiar with GD&T and can apply it to my designs.

• I am constantly learning and improving my skills through online courses and tutorials.

Boundary conditions, degree of freedom, and assembly constraints are tools used in design engineering to define and analyze the behavior of a system.

• Boundary conditions are constraints that define the limits of a system's behavior or performance.

• Degree of freedom refers to the number of independent parameters that can be varied without violating the constraints of the system.

• Assembly constraints are the restrictions placed on how components can be connected or arranged in a s...read more

I have worked with various software including AutoCAD, SolidWorks, and MATLAB.

• Proficient in AutoCAD for 2D drafting and SolidWorks for 3D modeling

• Experience in MATLAB for data analysis and simulation

• Familiarity with ANSYS for finite element analysis

• Knowledge of Adobe Creative Suite for graphic design

The Relliexe principle is a concept used in industry to optimize processes using PID control and process flow diagrams.

• Relliexe principle is based on the idea of continuously optimizing processes to achieve desired outcomes.

• PID (Proportional-Integral-Derivative) control is a common method used in industry to regulate processes by adjusting inputs based on feedback.

• Terms related to PID include setpoint, error, control action, and tuning parameters.

• Terms related to process incl...read more

Careful consideration of material selection, part geometry, draft angles, and tooling design is essential for designing die casted parts.

• Select the appropriate material based on the desired properties and cost-effectiveness

• Design parts with uniform wall thickness to prevent defects like porosity

• Incorporate draft angles to facilitate easy ejection from the mold

• Avoid sharp corners and complex geometries that can lead to defects

• Consider the location of parting lines to minimize ...read more

AutoCAD is a computer-aided design software used for creating 2D and 3D designs.

• Line - creates a straight line between two points

• Circle - creates a circle with a specified radius

• Rectangle - creates a rectangle with specified dimensions

• Trim - removes parts of a line or object that intersect with another object

• Mirror - creates a mirrored copy of an object

ISO is an international standard while ASME is an American standard for engineering design and manufacturing.

• ISO is recognized globally while ASME is mainly used in the United States.

• ISO covers a wide range of industries while ASME is primarily focused on mechanical engineering.

• ISO standards are voluntary while ASME standards are mandatory in some industries.

• ISO standards are developed by the International Organization for Standardization while ASME standards are developed by...read more

Holes in the disc of a bike are for cooling and to prevent overheating.

• Holes allow air to flow through the disc, cooling it down.

• Prevents overheating and warping of the disc.

• Improves braking performance and reduces brake fade.

• Commonly found on high-performance bikes and in racing.

• Different hole patterns can affect noise and vibration levels.

Positive displacement pumps move fluid by trapping a fixed amount and forcing it through the discharge pipe. Negative displacement pumps move fluid by creating a vacuum to draw in and push out the fluid.

• Positive displacement pumps trap a fixed amount of fluid and force it through the discharge pipe

• Examples include gear pumps, piston pumps, and diaphragm pumps

• Negative displacement pumps create a vacuum to draw in and push out the fluid

• Examples include centrifugal pumps and rot...read more

Proficient in SolidWorks and AutoCAD. Applied software to design complex mechanical systems. Static analysis focuses on forces and stresses at rest, while dynamic analysis considers forces in motion.

• Proficient in SolidWorks and AutoCAD for 3D modeling and drafting.

• Used SolidWorks to design complex mechanical systems such as robotic arms and conveyor systems.

• Applied software to simulate stress, strain, and motion in designs to optimize performance and durability.

• Static analysi...read more

Different approaches for manufacturing composites include hand lay-up, filament winding, and resin transfer molding.

• Hand lay-up involves manually placing layers of reinforcement material in a mold and applying resin.

• Filament winding uses continuous fibers that are wound around a rotating mandrel to create a composite structure.

• Resin transfer molding involves injecting resin into a closed mold containing pre-placed reinforcement material.

• Other approaches include pultrusion, co...read more

GD&T symbols are used to communicate design specifications and tolerances in engineering drawings.

• GD&T stands for Geometric Dimensioning and Tolerancing

• GD&T symbols are used to specify the shape, size, orientation, and location of features on a part

• Tolerance is the allowable variation in a dimension or feature

• GD&T symbols and tolerances ensure that parts are manufactured to the correct specifications and fit together properly

• Examples of GD&T symbols include concentricity, per...read more

Yes, Mold Design is the process of creating the shape and structure of a mold for manufacturing products.

• Mold design involves creating a 3D model of the desired product

• The mold is then designed around the product, taking into account factors such as material, production volume, and cost

• The design must also consider factors such as cooling and ejection of the product from the mold

• Mold design is crucial for ensuring the quality and consistency of manufactured products

• Examples o...read more

I am proficient in using various 3D modelling software such as AutoCAD, SolidWorks, and SketchUp.

• I have completed courses and training in 3D modelling software

• I have experience in creating 3D models for various projects

• I am familiar with different tools and features of the software

• I am able to troubleshoot and solve issues related to 3D modelling software

• I am always willing to learn and adapt to new software and updates

Engineering Drawing is a graphical representation of an object or structure used to communicate design and manufacturing information.

• Engineering Drawing is a visual representation of an object or structure.

• It includes detailed information about dimensions, materials, and manufacturing processes.

• It serves as a communication tool between designers, engineers, and manufacturers.

• Engineering drawings can be 2D or 3D and may include various views, sections, and annotations.

• Examples...read more

Design software uses various extension files for different purposes.

• Common design software extensions include .dwg, .dxf, .pdf, .ai, .eps, .psd, .indd, .skp, .3ds, .obj, .stl, .fbx, .max, .blend, .c4d, .rvt, .ifc, .step, .iges, .sat, .sldprt, .sldasm, .prt, .asm, .catpart, .catproduct, .iam, .ipt, .idw, .dwf, .dwfx, .rfa, .rvt, .dwg, .dxf, .stl, .obj, .fbx, .3ds, .skp, .ai, .eps, .pdf, .psd, .indd

• Different extensions are used for different types of files, such as 2D drawings,...read more

Creo is a powerful tool for sheet metal and casting part 3D modelling and detailing.

• Creo offers a range of tools for sheet metal design, including flanges, bends, and punches.

• For casting parts, Creo allows for the creation of complex geometries and the ability to simulate casting processes.

• Creo also offers advanced detailing capabilities, including the ability to create 2D drawings and annotations.

• Users can easily switch between sheet metal and casting modes within Creo to op...read more

Plastic material selection is crucial for design engineers due to factors like mechanical properties, cost, environmental impact, and manufacturability.

• Consider mechanical properties such as strength, stiffness, impact resistance, and temperature resistance.

• Evaluate cost factors including material cost, processing cost, and tooling cost.

• Assess environmental impact by looking at recyclability, biodegradability, and sustainability.

• Take into account manufacturability aspects lik...read more

Abs and nylon are justified for their unique properties and applications in various industries.

• ABS is known for its impact resistance and toughness, making it suitable for applications like automotive parts and electronic housings.

• Nylon is valued for its strength, flexibility, and chemical resistance, making it ideal for products like gears, bearings, and medical devices.

Distillation and cofermentation towers are used in chemical engineering to separate and purify components of a mixture.

• Distillation tower is used to separate components of a liquid mixture based on their boiling points.

• Cofermentation tower is used in bioengineering to simultaneously ferment multiple substrates.

• Both towers play a crucial role in various industries such as petrochemical, pharmaceutical, and food processing.

• Distillation tower example: Fractional distillation of ...read more

Fits are the allowable clearances between mating parts in an assembly to ensure proper functionality.

• Fits are used in engineering to determine the type of clearance between mating parts

• Common types of fits include clearance fit, interference fit, and transition fit

• Fits are important for ensuring proper functionality, ease of assembly, and longevity of the components

• Examples include press fit for bearings, sliding fit for pistons, and force fit for gears

NPD (New Product Development) plays a crucial role in the industry by bringing innovative products to market.

• NPD involves the entire process of bringing a new product from concept to market launch.

• It includes market research, design, development, testing, and commercialization of the product.

• NPD helps companies stay competitive by introducing new and improved products to meet customer needs.

• Examples of NPD in industry include the development of new smartphones, automotive tec...read more

I am currently working on AutoCAD and SolidWorks for designing mechanical components.

• Working on AutoCAD for 2D drafting and design

• Using SolidWorks for 3D modeling and simulation

• Creating detailed drawings and models for mechanical components

• Collaborating with team members to ensure design accuracy

Metal properties include high strength, conductivity, ductility, and malleability.

• High strength: Metals have high tensile strength and can withstand heavy loads.

• Conductivity: Metals are good conductors of electricity and heat.

• Ductility: Metals can be stretched into wires without breaking.

• Malleability: Metals can be hammered or rolled into thin sheets without breaking.

• Examples: Iron, copper, aluminum

Aluminum is lighter and less dense than stainless steel, but not as strong. Stainless steel is heavier, denser, and stronger.

• Aluminum is a good conductor of electricity and heat, while stainless steel is not

• Stainless steel is more resistant to corrosion than aluminum

• Aluminum is more malleable and easier to shape than stainless steel

• Stainless steel is more expensive than aluminum

• Examples: Aluminum is used in aircraft and beverage cans, while stainless steel is used in kitchen ...read more

Yes, I can handle pressure effectively by staying calm, prioritizing tasks, and seeking support when needed.

• I have experience working on high-pressure projects and meeting tight deadlines.

• I am able to stay calm and focused under stressful situations.

• I prioritize tasks and manage my time effectively to handle multiple responsibilities.

• I communicate effectively with team members and seek support when needed.

• I have successfully handled pressure in previous roles, such as when we...read more

A tri nip press concept drawing for efficient material processing.

• Consider the size and shape of the material being processed

• Include three rollers with adjustable pressure

• Incorporate safety features such as emergency stop buttons

• Include a control panel for adjusting pressure and speed

• Consider the material of the rollers for durability

• Ensure the design allows for easy maintenance and cleaning

Cantilevering procedure in wire section involves supporting a wire on one end while the other end is being worked on.

• The wire is clamped or held in place on one end

• The other end is then bent or cut to the desired shape

• Examples include creating hooks or loops on the end of a wire

• Cantilevering can also be used to create a spring-like effect in a wire

The type of clamp and locator used in a checking fixture depends on the specific application and requirements.

• The clamp and locator should be chosen based on the part being checked and the desired level of accuracy.

• Common types of clamps include toggle clamps, pneumatic clamps, and hydraulic clamps.

• Locators can be pins, blocks, or other features that ensure proper positioning of the part.

• The checking fixture may also include sensors or gauges to measure part dimensions or fea...read more

A design engineer should possess creativity, technical knowledge, attention to detail, problem-solving skills, and communication abilities.

• Creativity to come up with innovative solutions

• Technical knowledge to understand the feasibility of designs

• Attention to detail to ensure accuracy and precision

• Problem-solving skills to overcome design challenges

• Communication abilities to collaborate with team members and stakeholders

Industrial standards are guidelines and specifications set by regulatory bodies to ensure safety, quality, and consistency in manufacturing processes.

• Industrial standards cover a wide range of areas such as materials, processes, and products.

• Examples of industrial standards include ISO 9001 for quality management, ASTM for materials testing, and ANSI for product safety.

• Adherence to industrial standards is often required by law and can help companies improve efficiency and red...read more

Hardware grades are typically classified based on material composition, strength, and corrosion resistance.

• Hardware grades are often denoted by a combination of letters and numbers, such as Grade 8.8 or Grade 316.

• Higher grade numbers generally indicate a higher tensile strength or corrosion resistance.

• Common grades for screws include Grade 2, Grade 5, and Grade 8, with Grade 8 being the strongest.

• For nuts and washers, common grades include Grade 2, Grade 5, and Grade 8, with ...read more

Straight length requirements for orifice flow element ensure accurate measurement by allowing flow to stabilize before reaching the element.

• Straight length requirements typically range from 10 to 44 pipe diameters upstream and 5 to 22 pipe diameters downstream of the orifice.

• These requirements help prevent flow disturbances and ensure accurate measurement of flow rate.

• For example, if the pipe diameter is 4 inches, the straight length requirements upstream could be 40 to 176 i...read more

PV solar technology converts sunlight into electricity using semiconductor materials.

• PV cells absorb sunlight and generate direct current (DC) electricity.

• An inverter converts DC electricity into alternating current (AC) electricity for use in homes and businesses.

• Excess electricity can be stored in batteries or fed back into the grid.

• Examples of PV solar technology include rooftop solar panels and solar farms.

Design involves creating solutions to problems through the use of creativity and technical knowledge. AutoCAD is a software used for drafting and design.

• Design is the process of creating solutions to problems through the use of creativity and technical knowledge.

• AutoCAD is a software used for drafting and design.

• Design involves understanding user needs, creating concepts, prototyping, testing, and refining solutions.

• AutoCAD is used in various industries such as architecture, ...read more

There are various types of plastic materials used in engineering, including thermoplastics, thermosets, and elastomers.

• Thermoplastics can be melted and reformed, such as polyethylene and PVC

• Thermosets are rigid and do not melt, like epoxy and phenolic resins

• Elastomers are flexible and elastic, such as silicone and rubber

The 3-2-1 principle is a fundamental concept in engineering design. Front wheel drive and rear wheel drive have different layouts and performance characteristics. GD&T symbols are used for precise communication in engineering drawings. Sheet metal design involves creating components from thin metal sheets.

• The 3-2-1 principle states that a part must be constrained in at least 3 directions to prevent translation, 2 directions to prevent rotation, and 1 direction to prevent furt...read more

CG, Moment of Inertia, and Bending Moment can be calculated using mathematical formulas and physical measurements.

• CG can be calculated by finding the weighted average of the individual CGs of each component in a system.

• Moment of Inertia can be calculated using the formula I = mr^2, where m is the mass and r is the distance from the axis of rotation.

• Bending Moment can be calculated using the formula M = F*d, where F is the force applied and d is the distance from the point of ...read more