Design Department Incorporated

Complicated designs are too easy I’m sure many of you have seen this iconic image of the progression of SpaceX’s Raptor engine. As an engineer it is hard to imagine how anyone can look at that and not get excited. It is a master class in design refinement.   When I was fresh out of school and starting my professional career one of my early mentors, George Broughton, drew this graph out for me. The Curve of Complexity. The Raptor progression is a quintessential example of this in real life.   When you are innovating & designing something new the complexity of the design increases rapidly until first meeting the design requirements. At this point there is always a temptation to move forward. Pressure to get to market first, pressure for faster ROI, pressure to limit development expenditures, etc. However, this is not the time to stop!   Up front investment in design refinement pays dividends later. Simplifying the design and providing a more elegant solution can reduce # parts, reduce cost of parts, reduce assembly labor, improve customer experience, minimize warranty claims, etc etc. The list goes on and on.   This graph isn’t fixed in proportion and the ideal ‘off ramp’ can vary widely based on industry and product but the base principle remains the same. Fortunately, having a refined design doesn’t have to double or triple development time. There are sure fire ways to move through this progression faster. One of which is effectively leveraging prototyping. I will follow up with an additional post on that topic soon.

𝐒𝐮𝐬𝐭𝐚𝐢𝐧𝐚𝐛𝐢𝐥𝐢𝐭𝐲: 𝐑𝐞𝐝𝐮𝐜𝐢𝐧𝐠 𝐌𝐚𝐭𝐞𝐫𝐢𝐚𝐥 & 𝐌𝐚𝐱𝐢𝐦𝐢𝐳𝐢𝐧𝐠 𝐈𝐦𝐩𝐚𝐜𝐭 Sustainability is no longer just a buzzword—it’s a necessity in today’s world.  The days of slapping a green leaf on your packaging and calling it environmentally friendly are over.  For product designers, one of the most effective ways to make a positive environmental impact is through efficient material use, starting at the beginning of the design process. At Design Department, we specialize in designing products that use less material, cost less to produce, and deliver maximum performance. 𝐌𝐚𝐭𝐞𝐫𝐢𝐚𝐥 𝐌𝐚𝐭𝐭𝐞𝐫𝐬 Reducing material usage isn’t just about saving costs—it’s about conserving resources. By using less material, we decrease the environmental burden of extraction, processing, shipping, storage and manufacturing. At scale, the impact is staggering. For example, shaving just 1 gram off a high-volume part can result in millions of pounds of material savings annually. This not only reduces waste but also lowers cost throughout the entire product life cycle. 𝐒𝐭𝐫𝐚𝐭𝐞𝐠𝐢𝐞𝐬 At Design Department, we use cutting-edge tools like advanced Finite Elements Analysis (FEA) software to optimize designs, ensuring every gram of material is necessary. A perfect example is our work in the Surgical Suction Canister market. By rethinking the shape of a suction canister, we drastically reduced material usage while maintaining core functionality and improving structural integrity.  𝐋𝐢𝐟𝐞𝐥𝐨𝐧𝐠 𝐒𝐮𝐬𝐭𝐚𝐢𝐧𝐚𝐛𝐢𝐥𝐢𝐭𝐲 Designing for sustainability goes beyond reducing material usage. It’s about thinking holistically. Can the product be recycled or reused? Is it designed to ship and store in as small of a volume as possible, reducing energy consumption in shipping? By addressing these questions, we create solutions that benefit both the environment and our clients’ bottom lines. One recent project involved optimizing a product’s weight, leading to significant fuel savings during transportation while meeting strict durability requirements. 𝐉𝐨𝐢𝐧 𝐭𝐡𝐞 𝐌𝐨𝐯𝐞𝐦𝐞𝐧𝐭 𝐓𝐨𝐰𝐚𝐫𝐝 𝐒𝐮𝐬𝐭𝐚𝐢𝐧𝐚𝐛𝐢𝐥𝐢𝐭𝐲 At Design Department, we believe that great design isn’t just about how a product looks or functions—it’s about how it impacts the world. By reducing material usage and maximizing efficiency, we help our clients achieve their sustainability goals while staying ahead in the market. Are you ready to make a difference with your next product? Let’s design something extraordinary together. 𝐁𝐫𝐢𝐚𝐧 𝐋𝐞𝐚𝐝𝐢𝐧𝐠𝐡𝐚𝐦, 𝐏𝐫𝐞𝐬𝐢𝐝𝐞𝐧𝐭 𝐨𝐟 𝐃𝐞𝐬𝐢𝐠𝐧 𝐃𝐞𝐩𝐚𝐫𝐭𝐦𝐞𝐧𝐭 𝐈𝐧𝐜𝐨𝐫𝐩𝐨𝐫𝐚𝐭𝐞𝐝

𝐅𝐫𝐨𝐦 𝐂𝐨𝐧𝐜𝐞𝐩𝐭 𝐭𝐨 𝐂𝐫𝐞𝐚𝐭𝐢𝐨𝐧: 𝐓𝐡𝐞 𝐏𝐨𝐰𝐞𝐫 𝐨𝐟 𝐃𝐞𝐭𝐚𝐢𝐥 𝐢𝐧 𝐌𝐞𝐜𝐡𝐚𝐧𝐢𝐜𝐚𝐥 𝐃𝐞𝐬𝐢𝐠𝐧 Imagine having a groundbreaking product idea with immense potential, only to see it stumble during development due to overlooked details. This scenario is all too common, especially in the early stages of developing innovative new medical devices, an industry where reliability is non-negotiable. At Design Department, we know that meticulous attention to detail is what separates an innovative product moving towards mass production from a failure to launch. With over 25 years of experience, I’ve seen firsthand how focusing on the finer points of mechanical design transforms ideas into success stories. 𝐃𝐞𝐭𝐚𝐢𝐥 𝐒𝐭𝐚𝐫𝐭𝐬 𝐄𝐚𝐫𝐥𝐲 Design is most successful when attention to detail begins in the earliest stages. At this phase, it’s about understanding the problem space, design constraints, anticipating challenges, and addressing them before they arise. Advanced CAD tools allow us to model every component, every fit, and every stress point. This kind of precision isn’t just theoretical—it’s practical. For example, during a recent client project, our detailed modeling uncovered a potential interference issue that could have caused production delays. Catching it early saved our client both time and money. 𝐃𝐞𝐭𝐚𝐢𝐥 𝐚𝐬 𝐚 𝐂𝐨𝐦𝐩𝐞𝐭𝐢𝐭𝐢𝐯𝐞 𝐄𝐝𝐠𝐞 In today’s competitive market, the smallest details can make the biggest difference. Products designed with care are easier to manufacture, perform better, and last longer. They inspire confidence in customers and outshine competitors. I recall a client who came to us frustrated with recurring product failures from a previous design team. By focusing on overlooked aspects—tolerances, material choices, and assembly processes—we delivered a design that not only worked but exceeded their expectations. 𝐈𝐧𝐭𝐞𝐠𝐫𝐚𝐭𝐢𝐧𝐠 𝐃𝐞𝐭𝐚𝐢𝐥 𝐢𝐧𝐭𝐨 𝐃𝐞𝐬𝐢𝐠𝐧 Attention to detail isn’t just a skill; it’s a philosophy. It starts with collaboration—bringing together engineers, designers, and stakeholders to evaluate every aspect of the design. Prototyping also plays a critical role, allowing us to validate concepts and refine them iteratively. And, of course, experience matters. With decades in the field, I’ve learned that even the most minor adjustments can lead to significant improvements. 𝐀 𝐁𝐞𝐭𝐭𝐞𝐫 𝐎𝐮𝐭𝐜𝐨𝐦𝐞 𝐟𝐨𝐫 𝐘𝐨𝐮𝐫 𝐏𝐫𝐨𝐝𝐮𝐜𝐭𝐬 At Design Department, detail is in our DNA. It’s how we help our clients bring innovative, reliable products to market faster and with fewer headaches. If you’re ready to elevate your product designs, we’d love to help. Let’s work together to turn your vision into a reality—one detail at a time. 𝐁𝐫𝐢𝐚𝐧 𝐋𝐞𝐚𝐝𝐢𝐧𝐠𝐡𝐚𝐦, 𝐏𝐫𝐞𝐬𝐢𝐝𝐞𝐧𝐭 𝐨𝐟 𝐃𝐞𝐬𝐢𝐠𝐧 𝐃𝐞𝐩𝐚𝐫𝐭𝐦𝐞𝐧𝐭 𝐈𝐧𝐜𝐨𝐫𝐩𝐨𝐫𝐚𝐭𝐞𝐝

Let’s be honest, the engineers today suck at problem-solving. Actually, it's not just engineers—it's everyone. However, in the engineering world, we see the effects most prominently. When engineers face a challenge, especially a complex one, they often gather in a room with a healthy supply of coffee and start brainstorming. In most cases, they don't spend a single moment trying to understand the problem space or even understand how their own system works. We (the engineers) jump right into generating solutions. Everyone knows the process, right? To me, it's exactly like playing in a casino. But instead of betting money, we're betting on the quality, speed, and overall outcome of our efforts. We have a name for this—Engineering Guessing. "But this is how we've been finding solutions for many years, and it works great for us!" you might say. Does it really work? Let's consider: How many times have you had to tell management about overlooked details, request additional resources, or negotiate project scope due to unforeseen complications? We all know the answer. In my entire career, I haven't seen a single project delivered on time, on budget, and without compromises. I challenge everyone to reflect on this. Was it always this way? Absolutely not! There are a few reasons for this. In the past, technology was simpler, engineers were more patient, and intellectual work was better rewarded, leading to more effective problem-solving and decision-making approaches. Today, we teach engineers math, physics, statistics, and all the rest of this important stuff. But, we don’t teach them what to do with all that, and how we can use all this knowledge to solve problems in at work and in life. We teach people to execute, but not what and how to execute. We've shifted from using our conscious mind for decision-making to being driven by emotions. However, emotions can only react—they're the product of a different part of our brain, one that isn't designed for creative thinking. Food for thought… What’s your take on it? #problemsolving #decisionmaking #creativity #engineeringthinking #PRIZGuru