Mechanical Product Design

Mechanical Product Design: An Ultimate Guide

What is mechanical product design?

Mechanical product design is the amalgam of mechanical knowledge of an engineer and designing a product for the market. The aim is to create functional products that meet all the requirements as well as appear aesthetic and marketable. The process requires multiple skills and is highly iterative in nature. We can categorize it as communication-intensive activity. Some important skills include problem-solving ability, creativeness, and good communication.

Purpose of mechanical product design

Mechanical design engineer deals with producing parts, components, or mechanical systems. The main goal is to solve a problem or to plan for meeting a need. The process has a high scope and is very innovative. Decision-making ability is significant for creating mechanical products for the market. The new product needs to be functional, reliable, safe, competitive, manufacturable, and marketable.

Mechanical Product Design Process

The process is a complex one. Certain factors play a significant role in the overall process. Dimensions, units, calculations, tolerances are some considerations in mechanical design. Similarly, codes and standards, liability, safety, cost, etc., are also important factors. Moreover, the design’s reliability is dealt with using absolute and statistical approaches. The design process constitutes various steps that are discussed below:

Considering the need

It is the initial step to beginning the process. Identifying the need is crucial. It may be challenging because the need is not always clearly evident. For example, there is a food-packaging machine, and something needs to be done regarding the machine. This need is influenced by certain factors such as the noise produced, variation in package weight, or the finished wrap quality.

Definition of the issue/problem

Definition of the need is a crucial and more specific stage as compared to consideration of the need. It constitutes all the specifications that are required to design the product. These specifications include cost, time, reliability, life span, etc.

This stage also deals with the specified characteristics such as speed, optimum range, temperature limitations, weight limitations, etc. Other factors are environmental and material constraints. Anything that hinders the freedom of the designer is termed as a constraint. There would be many materials mentioned in the supplier’s catalog, you should decide based on availability and economics.


This phase involves synthesizing the concept design. A system of components is utilized for the invention of this concept design. Hence, the system performance is analyzed. It is discarded or improved if it’s not up to the mark. Different competing schemes are formulated, and the one that leads to the most successful outcomes is adopted.

Analysis and optimization

This step is closely associated with synthesis. Analyzation and optimization are important for the system to function effectively. Suppose the stress or force the part can bear must be known for a certain part. It means the specification of the components is important to be known. For instance, if force is transmitted from gear to a shaft, we need to understand gear specifications to estimate the transmitted force. For this purpose, mathematical models are constructed before finalizing the design.


Evaluation is the step towards finalizing. It includes testing the prototype in a laboratory. This will confirm its success, reliability, practicality, and other concerning factors.


Presentation is just like marketing. It deals with presenting the product effectively for successful sales. While presenting, selling your skill at the right place, right time, and in the right manner is important.

What does a mechanical product design engineer do?

product design process
Product design process

The role of mechanical engineers is quite complex and challenging compared to other responsibilities of an engineer. Some major responsibilities are listed below:

  • They select the most practical designs and concepts using decision-making tools.
  • Their objective is to create finished products that meet the industrial and market requirements.
  • They design keeping in mind reliability, usability, and tolerance variations.
  • Design engineers perform functional dimensioning and tolerancing using different tools and machines.
  • They are also responsible for creating the best products cost-effectively.
  • These engineers also study failure modes and other challenges to overcome them. Simulation teams also play a major role along with engineers to ensure structural improvement.
  • Dealing with stakeholders to ensure that product has met all the requirements and is now ready to be launched commercially.

Do Estop solutions offer product development services? 

“Estop solutions” is committed to providing the best mechanical product design and product development services. The major services we provide include industrial design services, 3D CAD design services, as well as analysis and simulation services. Our highly professional and skilled team produces conceptual designs that result in greater functionality and practicality in everyday use.

Additionally, our engineers aim to produce products with greater detailing and fine finish. The use of the best tools and up-to-date technology ensures the best products. The final products also go through a process of analysis so that our team can observe the physical behavior of the components, and then finally, our team drafts the design with technical detailing.

5 top-notch mechanical product design ideas

5 top-notch ideas are listed below:

1.MATLAB for hybrid vehicle design

Hybrid vehicles are created to reduce cost, control pollution, and increase efficiency. Both IC and electric engines are fitted to the vehicle for powering it. MATLAB software can be utilized to examine the performance of the hybrid vehicle in different environments. Hence, a hybrid vehicle design can be created using MATLAB.

2.Airfoil’s CFD Analysis

Airflow can be examined on the aerofoil using software like JAVAFOIL, CATIA, etc. Aerofoils play a major role in lift generation and hence play a crucial role in fuel consumption by reducing it while at the same time increasing the lift.

3.Utilizing elbow mechanism for gearless transmission

The primary role of gears is to transmit force from one component to the other. The phenomenon is governed by friction. Hence, the elbow mechanism can be used to produce a gearless transmission.

4.A 3D Printer

A 3D printer is also an innovative device. It can produce 3D objects from a digital file with the help of a computer. The items needed include a motor driver shield, Arduino board, stepper motor, etc.

5.Automobile prototyping

Automobile prototyping is another best idea for mechanical designs. The concepts such as transmission system, locomotion, suspension system, powertrain, etc., will be used in the process.


The mechanical design process is a complex phenomenon. It is a mixture of technical and mechanical knowledge and creativity and functionality. Several stages govern the design process as explained above. Mechanical design engineers have a major role to play in the process. They are responsible for cost-effective product design, along with ensuring reliability and functionality. Lastly, the technology and the expert team perform in coordination to meet all product design requirements.

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