Abstract
This case study presents an approach for bridging the persistent gap between design education and manufacturing practice. The module combines reverse engineering, simulated production planning, and cross-functional collaboration within a dual-track structure of theoretical lectures and a hands-on Planspiel (simulation game). It aims to strengthen students’ Design for Manufacturing knowledge and foster an interrelated mindset that enables effective collaboration across the product development process (PDP) and supports informed, strategic design decisions early on. Weekly collaborative sessions simulate authentic professional interactions, while students assume distinct industry roles, mirroring real-world team dynamics and reinforcing the systemic integration of design and production. Despite limited prior knowledge, design students successfully reverse-engineered a product, designed and operated an assembly line, gained insights into manufacturing processes, and developed a deeper understanding of cross-functional roles in product development. Evaluation results indicate strong engagement and highly positive outcomes, with students consistently emphasizing how the course helped them recognize the direct impact of design decisions on downstream operations. This study offers a potential framework for educators seeking to bridge design education and manufacturing practice, equipping future product designers with the technical competencies, collaborative skills, and process-oriented thinking required in modern industrial environments.
DOI
https://doi.org/10.21606/drslxd.2025.112
Citation
Hodrius, M.(2025) Using Reverse Engineering to Bridge Design Theory and Manufacturing Practice, in Clemente, V., Gomes, G., Reis, M., Félix, S., Ala, S., Jones, D. (eds.), Learn X Design 2025, 22-24 September 2025, Aveiro, Portugal. https://doi.org/10.21606/drslxd.2025.112
Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License
Conference Track
Case Study
Using Reverse Engineering to Bridge Design Theory and Manufacturing Practice
This case study presents an approach for bridging the persistent gap between design education and manufacturing practice. The module combines reverse engineering, simulated production planning, and cross-functional collaboration within a dual-track structure of theoretical lectures and a hands-on Planspiel (simulation game). It aims to strengthen students’ Design for Manufacturing knowledge and foster an interrelated mindset that enables effective collaboration across the product development process (PDP) and supports informed, strategic design decisions early on. Weekly collaborative sessions simulate authentic professional interactions, while students assume distinct industry roles, mirroring real-world team dynamics and reinforcing the systemic integration of design and production. Despite limited prior knowledge, design students successfully reverse-engineered a product, designed and operated an assembly line, gained insights into manufacturing processes, and developed a deeper understanding of cross-functional roles in product development. Evaluation results indicate strong engagement and highly positive outcomes, with students consistently emphasizing how the course helped them recognize the direct impact of design decisions on downstream operations. This study offers a potential framework for educators seeking to bridge design education and manufacturing practice, equipping future product designers with the technical competencies, collaborative skills, and process-oriented thinking required in modern industrial environments.