Abstract: Design space exploration at early and system-level phases often relies on low-fidelity, qualitative evaluations due to the prohibitive cost of high-precision methods. This research proposes an approach to bridge this gap by utilizing artificial intelligence (AI) and modeling tools and leveraging existing datasets and detail-level analysis to enhance system-level decision-making. Creating a platform of datasets is suggested by shared features for a product model hierarchy that mirrors the functional decomposition of the product architecture. This is achieved by integrating function mean (FM) as an early design modeling tool with an assembly of datasets acquired from finite element (FE) as a higher fidelity concept evaluation tool. This is an effort to link the early functional space to the later response space. It is shown that training prediction models on datasets from low-level product architecture, which are more viable to obtain, enables design concept evaluation at the system level. Moreover, by introducing a modular and radical change into product architecture, which represents new technologies that require performance evaluation, the built dataset platform is investigated. Finally, a metric to evaluate the platform\'s success is suggested to increase reliability. As lower levels of product architecture often experience more frequent changes than system-wide modifications. This method can be effective in scenarios where component-level innovations require rapid performance evaluations. The implications of such a dataset platform can reduce the concept evaluation cost in early phases by accelerating the testing of innovations and ideas in product architecture.

Keywords: car crashworthiness | conceptual design | data-driven design | design evaluation | machine learning | metamodeling | product platform design | simulationbased design | systems design

Abstract: This paper reviews 89 studies on AI in product platform design, further focusing on 21 multi-domain contributions. The dominant archetype is AI as a Tool × Method × Solution Proposal, with AI mainly used for automation and optimization. Collaborative roles remain rare, especially in requirements and architecture phases. Robust evaluation of AI benefits is largely missing, revealing an automation-centric paradigm and key gaps for co-intelligent, cross-domain platform development.

Keywords: artificial intelligence (AI) | co-intelligence | multi-/cross-/trans-disciplinary approaches | product platform

Abstract: This paper explores proactive manufacturing repurposing as a strategic design and business opportunity beyond traditional sustainability and crisis-driven motivations. Through the analysis of nine case studies across diverse sectors, we identify key external and internal factors that influence firms' ability to repurpose components and products across applications. At the external level, market demand, technology cycles, and infrastructure compatibility shape the feasibility of second-life applications. At the internal level (design-related factors), product design features—especially modularity and life-cycle alignment—emerge as critical enablers or constraints. The findings highlight the need for cross-application opportunity assessment tools and design methodologies that balance upstream performance requirements with downstream repurposing potential. This study opens new avenues for circular design, strategic innovation, and repurposing-aware product development.

Keywords: Cross-application innovation | Design for circularity | Manufacturing strategy | Modular product design | Proactive repurposing

Abstract: Changing environmental, societal, and business conditions shift the priority given to the ‘most valuable' design solutions to be developed, which risks causing rework and mistakes during the development process. To maintain consistency among changes in what ‘value' means in evolving business contexts, this paper presents a method – value-driven model-based systems engineering (VD-MBSE) – implemented in a software tool (named Club Design). The method is demonstrated through a case study related to aerospace electrification, highlighting its ability to maintain consistency during the iterations between business development and the design of technical solutions.

Keywords: Model-Based Systems Engineering | Requirements Traceability | Value Assessment | Value-Driven Design

Abstract: Current quantitative methods for estimating product-related environmental emissions face limitations in supporting sustainable design, particularly in second-life product strategies. This paper highlights challenges in accurately assessing emissions and environmental impacts under existing regulations, which often fail to reward designs enabling circularity. Through examples of current practices, it underscores methodological ambiguities and regulatory gaps, proposing a research agenda for improved tools and frameworks. These advancements aim to better support the design, production, and certification of sustainable, second-life-ready solutions, fostering more effective environmental impact reduction. Additionally, the paper emphasizes the need for regulatory adaptation to incentivize circular design practices, ensuring a fair evaluation of products conceived for second-life applications.

Keywords: circular economy | design for x (DfX) | ecodesign | systems engineering (SE) | uncertainty

Abstract: Products are often optimized for most likely conditions, but unexpected variations can render designs ineffective. Using examples from engineering systems, this paper explores the benefits of leveraging non-linear payoff functions, where small changes in conditions lead to disproportionate outcomes. By analyzing the direction and curvature of these functions near observed boundaries, designers could gain an understanding of behavior beyond expected ranges. Non-linear modeling can aid in assessing design margins, especially in long-lived systems. Integrating this approach into design processes can be helpful and effective in considering the preparedness of a system in the face of unexpected events of different natures.

Keywords: complexity | design for x (DfX) | design resilience | non-linear payoff functions | robust design

Abstract: Unintended technical interactions across system interfaces can lead to costly failures and rework, particularly in the early design stages of complex products. This study examines how structured risk assessment tools influence teams\' ability to identify, evaluate and mitigate risks from such indirect interactions. In a controlled experiment, 14 engineering teams (comprising professionals and graduate students) engaged in simulated design decisions across three system configurations. Tool usage - including models of direct and indirect risk propagation and value-based trade-offs - was continuously logged and linked to outcomes. Teams that engaged earlier and more deliberately with the tools identified risks sooner and selected mitigation actions with more favourable cost-benefit profiles. Results show that strategic, not merely frequent, tool use improves risk management performance, particularly when addressing cascading effects from indirect physical interactions. These findings support the use of structured supports to enhance both the efficiency of early-stage risk evaluation and the efficacy of risk treatment.

Keywords: Early-stage engineering decisions | Experimental design research | Indirect interactions | Risk management | Risk mitigation

Abstract: Morphological matrices (MMs) have traditionally been used to generate concepts by combining different means. However, exploring the vast design space resulting from the combinatorial explosion of large MMs is challenging. Additionally, all alternative means are not necessarily compatible with each other. At the same time, for a system to achieve long-term success, it is necessary for it to be flexible such that it can easily be changed. Attaining high system flexibility necessitates an elevated compatibility with alternative means of achieving system functions, which further complicates the design space exploration process. To that end, we present an approach that we refer to as multi-objective technology assortment combinatorics. It uses a shortest-path algorithm to rapidly converge to a set of promising design candidates. While this approach can take flexibility into account, it can also consider other quantifiable objectives such as the cost and performance of the system. The efficiency of this approach is demonstrated with a case study from the automotive industry.

Keywords: design space exploration | design support | engineering design | flexibility | morphological matrix | steer-by-wire | system architecture

Abstract: Society awareness and environmental goals are forcing the aerospace industry to develop new sustainable system architectures. The components in the new system have to meet new functional requirements using alternative technologies and design solutions while ensuring that the physical performance of the component is maintained. However, design space exploration of both domains is challenging due to the intrinsic differences and nature of each: functional domain exploration deals with alternative means to solve functions, while physical exploration deals with parametric values, such as geometric dimensions and material types. Here, we present a method that enables concurrent exploration of the functional and physical design space. The method is based on a review of existing design space exploration methodologies. It has been developed in collaboration with industry and validated within a use case. We expect that this method will be useful for designers in conceptual phases where there are several functions containing multiple design alternatives and incompatibilities among them. The results of the method will allow designers to narrow down the design space to a few architectural candidates, including a baseline of physical dimensioning for each candidate.

Keywords: design automation | design space exploration | enhanced function-means (EF-M) | knowledge-based engineering (KBE) | product architecture | product design

Abstract: Effective communication and stakeholder collaboration are vital for successful design reviews. Traditionally reliant on physical mediums, design reviews now predominantly use digital 3D models for their flexibility and cost-effectiveness. Recent advancements in extended reality (XR) technology allow for immersive interactions with 3D models, enhancing spatial understanding. However, research often limits the choice to XR or flat screens, overlooking task-specific needs. This paper proposes a methodology using functional modeling and activity theory to assess XR's suitability for various design review tasks. By categorizing tasks and analyzing functionalities, it guides the optimal use of XR and flat screens, enhancing design review effectiveness. Future research will empirically validate and refine this framework to support hybrid design review protocols, improving collaborative design processes. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.

Keywords: Activity Theory | Asymmetric Collaboration | Design Reviews | Functional Modeling

Abstract: The integration of novel technologies into existing product architectures poses significant challenges, especially in managing the associated technical risks that affect system functionality and reliability. Traditional methods often struggle with the unpredictability and complexity of field effects due to technological integration. To address these challenges, this study introduces a novel DSM (Design Structure Matrix)-based method that accurately accounts for and mitigates both first-order and higher-order field effects. By employing the inverse-square law, our method quantifies the attenuation of field effects with distance, thereby enhancing the precision of impact assessments across the system architecture. This approach is substantiated through a case study involving the introduction of a steer-by-wire (SbW) system in automotive design. The case study highlights the method's effectiveness in identifying and managing potential integration points for new technologies, offering a systematic framework for minimizing risk and enhancing system design in automotive engineering. The success of this method in the case study provides practical insights into the design around the impact of field effects, emphasizing its applicability and value in real-world engineering scenarios.

Keywords: design methodology | design process | product development | product platform design | risk-based design | systems design

Abstract: Traditional approaches to managing uncertainties during product development often lead to increased complexity and resource consumption. This paper introduces the concept of ‘resilient objects' as an alternative solution, designed to provide passive protection against disruptive events of different kinds, thereby reducing the necessity for complex margins at system interfaces. The paper illustrates the concept of resilient objects through practical examples, which demonstrate the objects' ability to uphold system functionality even when faced with unexpected disruptive events. By embodying resilience locally in areas of the system that are most susceptible to uncertain conditions, resilient objects offer the potential to minimise interface margins and thus the need for excessive system over-design. The concept of resilient objects offers a new perspective on how to solve the trade-offs between resilience and complexity when addressing uncertainties in the dynamic landscape of product development.

Keywords: complexity trade-offs | disruptive events | engineering design | Resilient objects | uncertainty management

Abstract: ENCORE (ENriching Circular use of OER for Education) is an Erasmus+ project. This paper introduces the ENCORE approach, a novel strategy developed to address the challenges of the digital era in engineering education. ENCORE harnesses the potential of OER combined with the advancements in Natural Language Processing (NLP) and artificial intelligence, linking educational content with relevant skills in the European Skills, Competencies, Qualifications, and Occupations (ESCO) framework. The approach is designed to enhance the reuse of OERs, integrating them with data-driven tools and pedagogical guidelines to facilitate effective course design and outcome evaluation. This paper particularly explores the integration of the ENCORE approach within the CDIO (Conceive-Design-Implement-Operate) framework, highlighting how it can assist educators in incorporating green digital and entrepreneurial skills into engineering courses. The core elements of ENCORE, including a specialized database and ENCORE enablers, are outlined, emphasizing their role in crafting relevant learning paths and enriching engineering education. The paper concludes with a forward-looking perspective on the future development of ENCORE, focusing on its testing and refinement in engineering education through upcoming staff development activities and pilot testing, underscoring the importance of its alignment with the CDIO framework in enhancing the learning experience in the rapidly evolving landscape of engineering education.

Keywords: Digital Skills Development | Engineering Education | Natural Language Processing | Open Educational Resources | Standards: 2, 6, 9 | Sustainable Educational Practices

Abstract: This paper investigates the use of Large Language Models (LLMs) in engineering complex systems, demonstrating how they can support designers on detail design phases. Two aerospace cases, a system architecture definition and a CAD model generation activities are studied. The research reveals LLMs\' challenges and opportunities to support designers, and future research areas to further improve their application in engineering tasks. It emphasizes the new paradigm of LLMs support compared to traditional Machine Learning techniques, as they can successfully perform tasks with just a few examples.

Keywords: artificial intelligence (AI) | complex systems | computer-aided design (CAD) | knowledge-based engineering (KBE) | large language model (LLM)

Abstract: Engineering companies face the challenge of optimising margins within product platforms while balancing individual product optimisation and maximising platform commonality. Key obstacles include organisational silos, diverse design variables, design space allocation, and varying time perspectives. This paper proposes a value-based modelling methodology that integrates both internal and external variety within the manufacturer. Using an automotive Head-Up Display (HUD) case study, we demonstrate how to effectively utilise platform margins to maximise technological variety and minimise internal variety, thereby enhancing long-term system value. This approach helps design teams understand the implications of their decisions, optimise platform margins to meet evolving technological demands, reduce costs, and maximise value. Our findings advance the understanding of margin optimisation in product platforms and support informed decision-making for engineering companies facing conflicting objectives.

Keywords: engineering design | Margin optimisation | product platforms | technology integration | value modelling design margins

Abstract: Technology selection as part of the complex system design process involves multiple teams focusing on different subsystems, which in turn brings on interoperability challenges, extends design evaluations, and complicates design cycles. Utilizing function-mean modeling and the ensemble of surrogate model techniques, the paper reveals how low-level input parameters in the design can be instrumental in predicting higher-level performance outcomes. Applying the suggested framework to a case study from the space industry, surrogates trained on system level and component levels in a flow management system are shown to be generalizable. Exploring the methods for aggregating surrogates into ensembles shows how such an assembly can be built and utilized for navigating through the early fuzzy phases of design.

Keywords: Conceptual Design | Data-Driven Design | Functional Modeling | Product Architecture | Surrogate Models | Technology Selection

Abstract: Despite the recognized importance of datasets in data-driven design approaches, their extensive study remains limited. We review the current landscape of design datasets and highlight the ongoing need for larger and more comprehensive datasets. Three categories of challenges in dataset development are identified. Analyses show critical dataset gaps in design process where future studies can be directed. Synthetic and end-to-end datasets are suggested as two less explored avenues. The recent application of Generative Pretrained Transformers (GPT) shows their potential in addressing these needs.

Keywords: artificial intelligence (AI) | data-driven design | dataset gap | design research | generative design

Abstract: In conceptual design studies engineers typically utilize data-based surrogate models to enable rapid evaluation of design objectives that otherwise would be too computationally expensive and time-consuming to simulate. Due to the computationally expensive simulations, the data-based surrogate models are often trained using small sample sizes, resulting in low-fidelity models which can produce results that are not trustworthy. To mitigate this issue, a similarity-assisted design space exploration method is proposed. The similarity is measured between design points that have been evaluated through lower-fidelity data-based surrogate models and design points that have been evaluated using higher-fidelity physics-based simulations. This similarity information can then be used by design engineers to better understand the trustworthiness of the data produced by the low-fidelity surrogate models. Our numerical experiments demonstrate that such a similarity measurement can be used as an indicator of the trustworthiness of the lower-fidelity model predictions. Moreover, a second similarity metric is proposed for measuring the similarity of new designs to legacy designs, thus highlighting the potential to reuse knowledge, analysis models, and data. The proposed method is demonstrated by means of an aero-engine structural component conceptual design study. An open-source software tool developed to assist in data visualization is also presented.

Keywords: Aero-engine structures | Design space exploration | Design support | Engineering design | Similarity metrics

Abstract: The industrial need to predict the behaviour of radically new products brings renewed interest in how to set up and make use of physical prototypes and testing. However, conducting physical testing of a large number of radical concepts is still a costly approach. This paper proposes an approach to actively use digital twins in the early phases where the design can be largely changed. The approach is based on creating a set of digital twin modules that can be reused and recomposed to create digital twin variants. However, this paper considers that developing a digital twin can be very costly. Therefore, the approach focuses on supporting the decisions about the optimal mix of modules, and about whether a new digital twin module should be developed. The approach is applied to an industrial case derived from the collaboration with two space manufacturers. The results highlight how the design of the modular platform has an impact on the cost of the digital twin, if commonality and reusability aspects are considered. These results point at the cost-efficiency of applying a modular approach to digital twin creation, as a means to reuse the results from physical testing to validate new designs and their ranges of validity

Keywords: Data-Driven Design | Digital Twin | Modular Digital Twin Platform | Modular Platform Development

Abstract: In design research, parallelization and anticipation of tasks are crucial to having an effective impact on industry and society. In practice, however, parallelization and anticipation are difficult due to high inter-dependency among research problems and design supports. This paper proposes a framework to use the Design Structure Matrix combined with Axiomatic Design to isolate research problems and their design supports. This modular independence is an important building block to plan for quick and parallel agile design research “sprints”. The application of the approach is illustrated through two practical examples. The results highlight the importance to control a limited number of interfaces to work “agile” in design research without wasteful rework.

Keywords: agile development | Design methodology | Design methods | Research methodologies and methods | validation

Abstract: One of the obstacles to the ability of research to make an impact on industry resides on the research process itself. Today, there is a need to accelerate the means for research to support industrial transformation. At the same time, there is the need to maintain scientific rigorousness, which often requires time. To solve this trade-off, this paper evaluates existing research approaches through the lenses of agile development. The analysis is based on a simulation of research process architectures, and on observations made over several research projects with industry. The results of this analysis highlight five light-but-sufficient rules of research project behavior to keep momentum, motivation and trust when doing research with industry. The paper demonstrates the use of these five rules in a research sprint conducted iwith two automotive OEMs.

Keywords: agile development | Design methodology | Design methods | Research methodologies and methods | validation

Abstract: Decisions made in the concept generation phase have a significant effect on the product. While product- related risks typically can be considered in the early stages of design, risks such as supply chain and manufacturing methods are rarely easy to account for in early phases. This is because the currently available methods require mature data, which may not be available during concept generation. In this paper, we propose an approach to address this. First, the product and the non-product (manufacturing and/or supply chain) attributes are modelled using the enhanced function means (EF-M) modelling method. The EF-M method provides the opportunity to model alternative solutions-set for functions. Dependencies are then mapped within the product and the manufacturing models, and also in between them. An automatic combinatorial method of concept generation is employed where each generated instance is a design concept-manufacturing method pair. A risk propagation algorithm is then used to assess the risks of all the generated alternatives.

Keywords: Decision making | Early design phases | Functional modelling | Product architecture | Risk management

Abstract: The current ways of coping with uncertainty such as changes during product design or use have been through methods such as easy restructuring (e.g., modularity with buffer in interface definition), by overdesign and so on. The present investments on maintaining products in the economy for as long as possible is challenging these strategies from a cost and environmental perspective. Moreover, these strategies often lead to highly overdesigned products. An alternative strategy is to introduce features in a design, called resilient objects, which are able to absorb such uncertainties without wasteful overdesign of other parts. By applying a \'text-mining\' approach on patents, this paper has identified 5,552 candidates for such resilient objects that can be recombined and inserted in regions of the product that are likely to be most affected by current and future uncertainties. The application of resilient objects is demonstrated on a case study (a cooling system for battery electric vehicles). The case study highlights the ability of these objects to 1) significantly increase protection against uncertainties without the need for restructuring, 2) reduce the risk for overdesign and 3) dampen effects of change propagation.

Keywords: Product architecture | Resilient objects | Semantic data processing | Tech mining | Uncertainty

Abstract: Additive Manufacturing (AM) has traditionally been used for prototyping of products, however, in the last few decades, it has seen a rising growth in the manufacture of final products. The addition of AM as a manufacturing method in the portfolio of a company\'s production capabilities increases the complexity of decision-making. This is because the decisions are often not based on the same criteria and constraints, as related to conventional manufacturing processes. In this paper, we investigate this challenge by studying how AM affects the current workflow and the associated information flow for a design-make process in a Swedish manufacturer before and after the integration of AM. In this paper, it is argued that apart from an understanding of how to design for AM, it is equally important to consider how introducing AM alters the existing information flow and how to benefit from information available in various design-make process steps to facilitate decision making process. The result clarifies that the current process relies largely on tacit and experiences-based knowledge, whereas to take advantage of AM, more precision is required to capture and process the available information.

Keywords: Additive Manufacturing | Decision making | Industialisation | Information management

Abstract: The static relation between business and engineering design hinders the pace of innovation. While program managers often evaluate innovation in terms of financial value generated over a number of business scenarios, engineering design teams base their activities on improving product functionality and meeting technical requirements. This results in an insufficient common understanding during gate meetings about the business implications of alternative technological tradeoffs, thus negatively impacting the pace of innovation. This article presents the results from the introduction of a methodology-based on value and functional modeling-into the practice of design teams working with next-generation electric propulsion systems for satellite applications. The introduction of the methodology was evaluated via interviews, workshops, and observations with nine industrial partners. The results indicate business stakeholders and technology-focused design teams\' bidirectional interest in the methodology. In particular, the results highlight the benefits of the methodology in creating cross-boundary representations that can be used by stakeholders to share knowledge and find common ground in gate meetings. The dynamic interaction with such representations enables a faster decision-making pace during the management of innovation initiatives.

Keywords: Engineering management | innovation | value-based development (VBD) | value-driven design (VDD)

Abstract: The use of Additive Manufacturing (AM) can bring opportunities for industry, but several challenges need to be addressed, specifically the digital infrastructure comprising the AM value chain. A combination of a systematic literature review and an industrial use case study concludes that there is low consideration of the digital infrastructure in Design for Additive Manufacturing (DfAM) methods and tools which has a negative impact on the industrialisation of AM. It is therefore recommended that further studies are to be made on how to manage the digital infrastructure in DfAM processes.

Keywords: additive manufacturing | design tools | digital design | industrialisation

Abstract: The uncertainties and variation of additive manufacturing (AM) material properties and their impact on product quality trouble designers. The lack of experience in AM technologies renders the experts\' assessment of AM components and the establishment of safety margins difficult. Consequently, unexpected qualification difficulties resulting in expensive and lengthy redesign processes might arise. To reduce the risk of qualification failure, engineers might perform copious time-consuming and expensive specimen testing in early phases, or establish overconservative design margins, overriding the weight reduction benefits of AM technologies. In this article, a model-based design method is proposed for the conceptual design of AM space components with affordable test phases. The method utilizes fuzzy logics to systematically account for experts\' assessment of AM properties variation, and to provide an early estimation of a product qualification likelihood related to design parameters of interest, without the need for copious testing. The estimation of qualification likelihood can also point out which are the unique AM material uncertainties that require further specific testing, to enable the design of a product with a better performance and more affordable test phases. The method is demonstrated with the design for AM gridded of ion thrusters for satellite applications.

Keywords: Additive Manufacturing | Fuzzy logics | model-based design | qualification

Abstract: Uncertainty about the market, environment, and technological landscape of the future challenges the ways companies utilize the notion of “product platforms” to gain efficiency during development and production. This paper reviews design approaches to cope with uncertainties and highlights the benefit of designing a platform to enable “resilience” to deal with uncertain situation without the need to change the structure or configuration of the product platform. To achieve resilience, the paper proposes to introduce “resilient objects” in regions of the product platform that are likely to be most affected by change. Resilient design objects are already common in practice, such as a spring-damper system in mechanical systems. However, since product platform are multi-technological, this paper proposes a way of representing generic resilient objects (along five different design domains) for multi-technological systems. This proposal is supported by illustrative examples. Future research opportunities are identified around extending the matrix of generic multi-technological resilient objects, and defining a systematic method to design, select and evaluate which resilient objects are more valuable to be inserted in specific regions of the product platform.

Keywords: characteristics | design objects | multi-/cross-/trans-disciplinary approaches | product platform | properties

Abstract: Requirement changes can result in substantial overdesign because of the way design margins are allocated at the beginning of the design process. We present a design optimization method for minimizing overdesign by making use of additive remanufacturing and recently defined constituents of design margins (buffer and excess). The method can be used to obtain a set of design decisions for different changing requirement scenarios. We demonstrate our method by means of a turbine rear structure design problem where changes in the temperature loads are met by depositing different types of stiffeners on the outer casing. The results of the case study are visualized in a tradespace, which allows for comparison between sets of optimal, flexible, and robust designs. Results show that the optimized set of design decisions balances flexibility and robustness in a cost-effective manner.

Abstract: Product architectures are often designed as evolutions or modifications of existing product platforms by adding new functionalities. However, there is still a limited ability to simultaneously modify the functions and the physical elements of a system (and the corresponding links between them). These relationships, which are usually static, limit the ability to discover new architectures, as well as to analyse architectures by simulation. In this paper, we demonstrate how DSMs can be connected to function-means models to enable 1) the simultaneous modification of functions, solutions and links of a product's architecture and 2) the ability to export multiple DSMs from function models to use in simulations of non-functional properties of a product's architecture (e.g., supply chain resilience) in digital design experiments. The initially identified multiple instances of architectures can be exported and communicated with other simulation and analysis tools, thereby enriching existing models with additional and more detailed information.

Keywords: Change propagation | Design structure matrix | Design support | Function modelling

Abstract: The Morphological Matrix is a well-known and established method for synthesising concepts in engineering design. With the aim to improve its applicability, the method has been implemented into a software tool, which then has been introduced in engineering courses at Chalmers University of Technology. In this paper, the tool and its most important functions are presented and discussed, along with experiences from its use in design projects. It was demonstrated that the tool can ease the process of creating and modifying morphological matrices. Furthermore, the tool demonstrated the ability to generate and keep track of large quantities of solutions, which has previously been difficult as morphological matrices are typically hand drawn or created using an Excel sheet. However, less desired effects were encountered as the tool was perceived by some students as more of a screening and down-selection method, rather than as a tool for synthesising concepts. The learnings and the way forward in education and the industrial context are discussed.

Keywords: Concept synthesis | design support | morphological matrix

Abstract: Design requirements are often uncertain in the early stages of product development. Set-based design is a paradigm for exploring, and keeping under consideration, several alternatives so that commitment to a single design can be delayed until requirements are settled. In addition, requirements may change over the lifetime of a component or a system. Novel manufacturing technologies may enable designs to be remanufactured to meet changed requirements. By considering this capability during the set-based design optimization process, solutions can be scaled to meet evolving requirements and customer specifications even after commitment. Such an ability can also support a circular economy paradigm based on the return of used or discarded components and systems to working condition. We propose a set-based design methodology to obtain scalable optimal solutions that can satisfy changing requirements through remanufacturing. We first use design optimization and surrogate modeling to obtain parametric optimal designs. This set of parametric optimal designs is then reduced to scalable optimal designs by observing a set of transition rules for the manufacturing process used (additive or subtractive). The methodology is demonstrated by means of a structural aeroengine component that is remanufactured by direct energy deposition of a stiffener to meet higher loading requirements.

Keywords: additive manufacturing | design flexibility | design for remanufacturing | design optimization | setbased design

Abstract: A product is an artefact which fulfils a specific function. However, most design automation (DA) approaches wich are used to generate multiple alternative design concepts focus on the generation of CAD models. These neglect to represent the functional aspects of the product, and are furthermore deemed too rigid for the introductino of novel solutions. Pure function modellingappraoches on the other hand provides methods such as design rationale representation, introduction of novel solutions or instantiation of combinatorial alternative concepts, but the resulting models are insufficient for analysis. To alleviate this, a design space exploration (DSE) approach which couples function modelling and CAD is presented. The approachlinks the product's design rationale modelled in enhanced functionmeans (EF-M) to a DA approach via the here introduced object model for function and geometry (OMFG). The resulting method is able to automatically generate CAD models of alternative concepts based on combinations of alternative design solutions defined in the function model. The approach is presented through a case study of an aircraft engine component. Sixteen different concepts are generated based on four functions with alternative solutions. In an initial computation of the effort to generate all alternative concepts, the DA aspect of the approach's effort pays off as soon as five functions have two or more alternative solutions. Beyond the benefit of efficient instantiation of CAD models of alternative product concepts, the approach promises to provide the design rationale behind each concept, and thereby a more systematic way of exploring and evaluating alternative design concepts.

Keywords: Design automation | Design space exploration | Function modelling | Method development | Product development

Abstract: As the diversity of customer needs increases within the aerospace industry, so does the need for improved design practices to reduce quality issues downstream. When designing new products, design engineers struggle with applying tolerances to features, which often leads to expensive late design iterations. To mitigate this, one aerospace company is looking to reuse tolerance deviation data yielded during manufacturing in design. In the long term these data could provide the basis for a Digital Twin that can be used for improved product development. This article explores how data from production are used today, what issues prevents such data from being exploited in the design phase, and how they potentially could be used for design purposes in the future. To understand the current situation and identify the untapped potential of production data in design, an interview study was conducted in conjunction with a literature review. In this paper the current situation and primary barriers are presented and a possible path for further research and development is suggested.

Keywords: Data-Driven Engineering | Design methodology | Design process | Digital Twin | Industry 4.0

Abstract: Often, coping with changing requirements results in substantial overdesign, because of the ways in which design margins are allocated at the beginning of the design process. In this paper, we present a design optimization method for minimizing overdesign using additive manufacturing. We use recently defined constituents of design margins (buffer and excess) as metrics in a design optimization problem to minimize overdesign. The method can be used to obtain optimal design decisions for changing requirements. We demonstrate our method by means of a turbine rear structure design problem where changes in the temperature loads are met by depositing different types of stiffeners on the outer casing. The optimal decisions obtained by optimization minimize overdesign but ensure that requirements are met throughout the product\'s lifecycle.

Abstract: Test and qualification (T&Q) phases take a significant portion of the time to market for critical products in the space industry, especially when introducing new technologies. Since T&Q are treated as standard procedures, they tend to be independent of the architectural design phases and kept away from design decisions. However, when introducing new technologies, qualification procedures may differ from those established in regular design scenarios, and the estimation of qualification costs and duration is problematic. There is a lack of design for qualification methods capable of modelling these activities in early phases and use those models to support the architecture design of products with affordable test and qualification phases. In this article, a computer-assisted, model-based design method to model T&Q activities concerning early product architecture designs is proposed. Product architecture alternatives, test schedules and cost are connected through the quantification of T&Q drivers and driver rates. The design method is demonstrated using a case study about electric propulsion for satellites. The method is applicable for design situations where the choice of technology has a strong dependence on the qualification procedure.

Keywords: model-based design | product architecture | Qualification | space industry

Abstract: Aeroengine manufacturers need to better include assessment of risk and cost for realising the novel products needed to meet the ambitions sustainability driven targets for air transport. Radical technologies are needed that simultaneously require critical manufacturing processes to be assessed already in conceptual design. In this paper, a multi-domain framework for conceptual design and evaluation is proposed that provide the ability to interactively explore the concepts that simultaneously allow a wider range of architectures can be assessed and still include weldability of the concepts. It has been demonstrated how high level, and function driven conceptual design alternatives can be modelled and evaluated to analyse risk and resilience of architectures. Geometrical concepts generated for the most interesting regimes using design of experiments covering a desired design space. For each CAD-model the welding process can be simulated to assess feasibility and lead time for welding, and return quantified results to be included in an integrated results data set for interactive decision making. The paper is the first report from a research project that improve concurrent design of product and production concepts.

Keywords: Conceptual design | Design for X (DfX) | Early design phases | Multi-Cross-Trans-disciplinary processes

Abstract: The higher satellite production rates expected in new megaconstellation scenarios involve radical changes in the way design trade-offs need to be considered by electric propulsion companies. In relative comparison, flexibility and qualification ability will have a higher impact in megaconstellations compared to traditional businesses. For these reasons, this paper proposes a methodology for assessing flexible propulsion architectures by taking into account variations in market behavior and qualification activities. Through the methodology, flexibility and qualification ability can be traded against traditional engineering attributes (such as functional performances) in a quantitative way. The use of the methodology is illustrated through an industrial case related to the study of xenon vs. krypton architectures for megaconstellation businesses. This paper provides insights on how to apply the methodology in other case studies, in order to enable engineering teams to present and communicate the impact of alternative architectural concepts to program managers and decision-makers.

Keywords: Electric propulsion | Flexibility | Megaconstellations | Qualification | Value driven design

Abstract: The design of aircraft and engine components hinges on the use of computer aided design (CAD) models and the subsequent geometry-based analyses for evaluation of the quality of a concept. However, the generation (and variation) of CAD models to include radical or novel design solutions is a resource intense modelling effort. While approaches to automate the generation and variation of CAD models exist, they neglect the capture and representation of the product's design rationale—what the product is supposed to do. The design space exploration approach Function and Geometry Exploration (FGE) aims to support the exploration of more functionally and geometrically different product concepts under consideration of not only geometrical, but also teleological aspects. The FGE approach has been presented and verified in a previous presentation. However, in order to contribute to engineering design practice, a design method needs to be validated through application in industrial practice. Hence, this publication reports from a study where the FGE approach has been applied by a design team of a Swedish aerospace manufacturers in a conceptual product development project. Conceptually different alternatives were identified in order to meet the expected functionality of a guide vane (GV). The FGE was introduced and applied in a series of workshops. Data was collected through participatory observation in the design teams by the researchers, as well as interviews and questionnaires. The results reveal the potential of the FGE approach as a design support to: (1) Represent and capture the design rationale and the design space; (2) capture, integrate and model novel solutions; and (3) provide support for the embodiment of novel concepts that would otherwise remain unexplored. In conclusion, the FGE method supports designers to articulate and link the design rationale, including functional requirements and alternative solutions, to geometrical features of the product concepts. The method supports the exploration of alternative solutions as well as functions. However, scalability and robustness of the generated CAD models remain subject to further research.

Keywords: Aerospace | CAD | Design space exploration | Function modelling | Product development process

Abstract: Additive manufacturing (AM) opens the vision of decentralised and individualised manufacturing, as a tailored product can be manufactured in proximity to the customers with minimal physical infrastructure required. Consequently, the digital infrastructure and systems solution becomes substantially more complex. There is always a need to design the entire digital system so that different partners (or stakeholders) access correct and relevant information and even support design iterations despite the heterogenous digital environments involved. This paper describes how the design and integration of a digital thread for AM can be approached. A system supporting a digital thread for AM kayak production has been designed and integrated in collaboration with a kayak manufacturer and a professional collaborative product lifecycle management (PLM) software and service provider. From the demonstrated system functionality, three key lessons learnt are clarified: (1) The need for developing a process model of the physical and digital flow in the early stages, (2) the separation between the data to be shared and the processing of data to perform each parties' task, and (3) the development of an ad-hoc digital application for the involvement of new stakeholders in the AM digital flow, such as final users. The application of the digital thread system was demonstrated through a test of the overall concept by manufacturing a functional and individually customised kayak, printed remotely using AM (composed of a biocomposite containing 20% wood-based fibre).

Keywords: Additive manufacturing | Design automation | Digital thread

Abstract: Additive manufacturing (AM) is being used increasingly for repair and remanufacturing of aeroengine components. This enables the consideration of a design margin approach to satisfy changing requirements, in which component lifespan can be optimized for different lifecycle scenarios. This paradigm requires lifecycle cost (LCC) modeling; however, the LCC models available in the literature consider mostly the manufacturing of a component, not its repair or remanufacturing. There is thus a need for an LCC model that can consider AM for repair/remanufacturing to quantify corresponding costs and benefits. This paper presents a dynamic LCC model that estimates cumulative costs over the in-service phase and a nested design optimization problem formulation that determines the optimal component lifespan range to minimize overall cost while maximizing performance. The developed methodology is demonstrated by means of an aeroengine turbine rear structure.

Keywords: Additive remanufacturing | Design optimization | Dynamic design margins | Flexible component design | Lifecycle cost

Abstract: Integrating new technologies in existing product platforms presents challenges not only when the decision of going ahead with the integration is taken, but also in the earlier design of the platform structure to accommodate hypothetical changes in the future. Common heuristics do no guarantee that the optimum solution can be found to these kinds of problems, and biases lead to systematic distortions in decision-making. Additionally with the global zeitgeist around sustainable development, decision makers will increasingly ask for paths to many different versions of success, not just the traditional profit maximization one. A set of common models that accompanies the product platform all through its lifecycle to support decision makers can enable better fulfilment of the expectations of all stakeholders. But it is difficult to unify and objectively gather the views of multiple stakeholder simultaneously. An interactive modelbased decision making support system is proposed as a tool to solve the mentioned challenges. In this paper we describe and experiment with the main technological foundations of such a tool. These include an web-based front end, and a real-Time NoSQL database in the back end. The client web application (webapp) enables user inputs, runs quantitative models, and visualizes results. The database records results and enables the use of common inputs and common visualization of the results. The models that run directly in the client are developed offline and can be continuously deployed with no downtime for concurrent users. The technology stack used demonstrates that rapid prototyping of tools using state-of-The-Art web technologies provides quick results and enables researchers to make quick iterations that can be easily deployed in industrial use cases. The presented method is a new approach to providing digital support to the design process, by enabling better informed decisions during the product development process early phases. In this paper, an introduction and background to the problem and current state of the art is summarized, a method to approaching the topic is described, an experiment performed in front of a life audience is presented, and hints for future developments are considered in the discussion and conclusion sections.

Keywords: Decision making | Design support system | Digital design | Model based engineering

Abstract: Platform design has been firmly established in the automotive industry as a strategy to provide wider product variety while maintaining cost effective production. But this strategy can struggle to keep up with the pace and nature of emerging technologies. This paper reviews the existing approaches to modelling product platforms, and showcases the challenges at OEMs introducing new technological innovations in their platforms. A gap is identified in the methods to assess the ability of existing platforms to integrate new technologies whenever they become available.

Keywords: decision making | innovation | product architecture | product platform | technology development

Abstract: Nowadays, product designers find difficulties and uncertainties when assessing how complex a product will be when introducing new functionalities and technologies or when integrating multiple functionalities into a single component. There is a limited number of studies correlating functionality increase to product complexity. In this paper, the impact of functionality on complexity is quantitatively analyzed in two different case studies: one regarding a set of valves to study how complexity is affected when adding new functionalities, and another one related to three alternative designs of computer mice that features different degrees of functional integration. In the first case study, it has been found that adding new functionalities leads to a super-linear increase of complexity. In the second case study, it has been found that integrating functionality through the introduction of new electronic elements allows to reduce the total number of components, suggesting a decrease in complexity. However, the case study shows an increase in the product\'s overall complexity through an increased number of interactions between the components themselves. This means that possessing a quantitative methodology to evaluate the impact of functionality increase in product complexity can be an important means for designers to avoid misconceptions and risks during the early phases of product development.

Keywords: Complexity | Functional modelling | Integrated architecture product | Integrated product development

Abstract: Many research students find challenges when validating their research. Especially when they have expectations to contribute to both practice and the research body of knowledge. This paper argues that a key to successful validation of design research lies in the ability to focus on what to validate in advance of how to validate. The paper provide a set of guidelines to support a discussion on how to converge to a claim that actually can be validated. The paper reports on experiences from PhD level course on validation in design research.

Keywords: design research | evaluation | research methodologies and methods

Abstract: During the last decades, the aerospace industry has been interested in converting some of its production from traditional manufacturing to metal additive manufacturing. This technology is attractive to the aerospace industry due to the low production volumes and the need to minimize product mass that characterize the industry. The transition from traditional to additive manufacturing technologies requires designers to take heed of a new set of design and manufacturing constraints. A well-known limitation for the implementation of additive manufacturing is the need for support structures which increase material consumption and post processing time. The research presented in this paper suggests a novel algorithm for automatically altering the geometry of the product to reduce the need for support structures. The algorithm operates directly on the vertices of the 3D mesh by relocating them to mitigate overhang issues. A proof of concept in the form of a software prototype was developed using the Python programming language to demonstrate the algorithm, and how it can be applied to 3D models. The prototype software utilizes a 3D STL-file as input, and it outputs an altered file of the same format. In the process of developing the software prototype some issues surfaced, the most prominent of which was the inability of the algorithm to handle overhangs parallel to the substrate of the powder bed printer. Such overhangs are also referred to as 0°-overhangs due to their normal vector being parallel to the z-Axis, thus resulting in an overhang of 0°. Aside from that the algorithm also struggled with models of high complexity, which in some cases resulted in invalid or malformed STL geometries. The research conducted for this paper indicates that further research and development is required. Future research concerning automatic geometry alteration should focus on how to deal with the 0°-overhangs. It should also involve investigating the possibility to alter the geometry of CAD-models instead of STL-files, as CAD-models can contain more information, such as constraints. Information of that nature could enable the algorithm to take customer requirements into consideration as it alters the geometry, thus improving its ability to maintain product functionality.

Keywords: Additive manufacturing | Automation | Geometry alteration | Support structures

Abstract: Function and constraints modelling are implemented to design two gridded ion thrusters for additive manufacturing (AM). One concept takes advantage of AM design freedom, disregarding AM limitations and is not feasible. The other concept considers AM limitations and is manufacturable and feasible. Constraints modelling highlights AM capabilities that can be improved, showing where future investment is needed. Constraints representation can also support the creation of technology development roadmaps able to identify areas of AM technologies that must be improved.

Keywords: additive manufacturing | architectural design | technology development

Abstract: The advent of additive manufacturing (AM) brings many benefits in terms of lightweight design. However, there is no established design for additive manufacturing (DfAM) method available, nor are all the impacts and constraints on the product and development process known. Therefore, a method to redesign existing products for AM is proposed. It consists of functional decomposition enhanced by constraints identification, and analyses of the impact on the design space. Furthermore, the approach defines a coupling of function and geometry models to support an inter-domain redesign process. The approach has been successfully applied in an industrial collaboration project with three aerospace companies, where the support of the method for design space exploration has been recognised. Future work sees the use of this method for design space exploration even outside the AM domain, but a more methodical definition of the relationship between the functional and geometrical domain is required to do so.

Keywords: Additive manufacturing | Constraint modelling | Design for additive manufacturing | Dfam | Function modelling | Functional decomposition

Abstract: Engineering design problems often have open-ended requirements, especially in the early stages of development. Setbased design is a paradigm for exploring, and keeping under consideration, several alternatives so that commitment to a single design can be delayed until requirements are settled. In addition, requirements may change over the lifetime of a component or a system. Novel manufacturing technologies enable designs to be remanufactured to meet changed requirements. By considering this capability during the set-based design optimization process, solutions can be scaled to meet evolving requirements and customer specifications even after commitment. Such an ability can also support a circular economy paradigm based on the return of used or discarded components and systems to working condition. We propose a set-based design methodology to obtain scalable optimal solutions that can satisfy changing requirements through remanufacturing. We first use design optimization and surrogate modeling to obtain parametric optimal designs. This set of parametric optimal designs is then reduced to scalable optimal designs by observing a set of transition rules for the manufacturing process used (additive or subtractive). The methodology is demonstrated by means of a structural aeroengine component that is remanufactured by direct energy deposition of a stiffener to meet higher loading requirements.

Abstract: Supporting designers is one of the main motivations for design research. However, there is an ongoing debate about the ability of design research to transfer its results, which are often provided in form of design methods, into practice. This article takes the position that the transfer of design methods alone is not an appropriate indicator for assessing the impact of design research by discussing alternative pathways for impacting design practice. Impact is created by different means – first of all through the students that are trained based on the research results including design methods and tools and by the systematic way of thinking they acquired that comes along with being involved with research in this area. Despite having a considerable impact on practice, this article takes the position that the transfer of methods can be improved by moving from cultivating method menageries to facilitating the evolution of method ecosystems. It explains what is understood by a method ecosystem and discusses implications for developing future design methods and for improving existing methods. This paper takes the position that efforts on improving and maturing existing design methods should be raised to satisfy the needs of designers and to truly support them.

Keywords: design method | design methodology | design research | transfer | validation

Abstract: For space manufacturers, additive manufacturing promises to dramatically reduce weight and costs by means of integral designs achieved through part consolidation. However, integrated designs hinder the ability to change and service components over time – actually increasing costs – which is instead enabled by highly modular designs. Finding the optimal trade-off between integral and modular designs in additive manufacturing is of critical importance. In this article, a product modularisation methodology is proposed for supporting such trade-offs. The methodology is based on combining function modelling with optimisation algorithms. It evaluates product design concepts with respect to product adaptability, component interface costs, manufacturing costs and cost of post-processing activities. The developed product modularisation methodology is derived from data collected through a series of workshops with industrial practitioners from three different manufacturer companies of space products. The implementation of the methodology is demonstrated in a case study featuring the redesign of a satellite antenna.

Keywords: additive manufacturing | modularisation | optimisation algorithm | product architecture | satellite components

Abstract: Novel product concepts are often down-selected in favour of the incremental development of available designs. This can be attributed to the fact that for the development of a new product, simulations and analysis based on high-fidelity CAD models are required, which are expensive to create. To solve this problem, the use of a function model (FM) as intermediate step between ideation and embodiment is suggested. The approach has been examined in a case study with an aerospace company for the development of a turbine rear assembly, using multiple workshops and interviews with practitioners from the company. A multitude of novel solutions, even extending the functionality of the legacy design, were captured. The FM approach proved to support the representation, analysis, and configuration of 102 different concepts. Although supported by the FM model, the embodiment still showed to be a bottle neck for further development. The subsequent interviews with practitioners showed that the benefits of the approach were seen, but experienced as too complex. Further work will concern a more systematic connection between the FM and CAD model, in order to automate of the embodiment process.

Keywords: Computer Aided Design (CAD) | Design engineering | Functional modelling | Models | Product modelling

Abstract: This paper contributes to the discussion on value models as decision support in early design. Emerging from data collected through semi-structured interviews with 20 professionals in 3 manufacturing companies, the paper highlights the limitation of current development practices to promote crossfunctional knowledge sharing about the stakeholders\' lifecycle expectations to be met. This limits the ability to make decisions about aspects of value that are difficult to assess and quantify. The objective of the paper is then to propose the use of value models as \'boundary objects\' to increase shared awareness about the design intent, triggering negotiations towards more value-adding design decisions. This role of the value model as a boundary object is studied through design experiments, using a combination of protocol analysis and observation technique on the video-recorded material.

Keywords: Boundary objects | Conceptual design | Cross-functional collaboration | Engineering design | Value driven design | Value models

Abstract: One common strategy to include more downstream lifecycle dimensions in early design is to enrich modelling and simulation techniques embedded in decision support systems. However, downstream dimensions are difficult to trade against more traditional engineering objectives. This research studied through individual interviews how six disciplines use models to negotiate design trade-offs. References to models were categorised according to whether models supported or hampered the duration of trade-off identification and how they impacted the duration of trade-off resolution. The results point to the difficulty of applying downstream lifecycle issues earlier in the design process because of the characteristics of the models that are used. A list of characteristics promoting and limiting the use of four models as boundary objects (CAD models, simulation results, total cost of ownership and decision matrices) is provided. The cross-analysis of these characteristics provides insights into how models need to be organised in decision support systems.

Keywords: Boundary object | Collaborative design | Decision-making | Engineering design | Product development

Abstract: In recent years, reducing cost and lead time in product development and qualification has become decisive to stay competitive in the space industry. Introducing Additive Manufacturing (AM) could potentially be beneficial from this perspective, but high demands on product reliability and lack of knowledge about AM processes make implementation challenging. Traditional approaches to qualification are too expensive if AM is to be used for critical applications in the near future. One alternative approach is to consider qualification as a design factor in the early phases of product development, potentially reducing cost and lead time for development and qualification as products are designed to be qualified. The presented study has identified factors that drive qualification activities in the space industry and these “qualification drivers” serve as a baseline for a set of proposed strategies for developing “Design for Qualification” guidelines for AM components. The explicit aim of these guidelines is to develop products that can be qualified, as well as appropriate qualification logics. The presented results provide a knowledge-base for the future development of such guidelines.

Keywords: Additive Manufacturing | Design for Qualification | Design for X (DfX) | New product development | Space Applications

Abstract: Additive manufacturing (AM) is becoming increasingly attractive for aerospace companies due to the fact of its increased ability to allow design freedom and reduce weight. Despite these benefits, AM comes with manufacturing constraints that limit design freedom and reduce the possibility of achieving advanced geometries that can be produced in a cost-efficient manner. To exploit the design freedom offered by AM while ensuring product manufacturability, a model-based design for an additive manufacturing (DfAM) method is presented. The method is based on the premise that lessons learned from testing and prototyping activities can be systematically captured and organized to support early design activities. To enable this outcome, the DfAM method extends a representation often used in early design, a function-means model, with the introduction of a new model construct-manufacturing constraints (Cm). The method was applied to the redesign, manufacturing, and testing of a flow connector for satellite applications. The results of this application-as well as the reflections of industrial practitioners-point to the benefits of the DfAM method in establishing a systematic, cost-efficient way of challenging the general AM design guidelines found in the literature and a means to redefine and update manufacturing constraints for specific design problems.

Keywords: AM | Constraint modelling | DfAM | Function modelling | Manufacturing constraints | Space components | Test artefact

Abstract: The engineering design community needs to development tools and methods now to support emerging technological and societal trends. While many forecasts exist for technological and societal changes, this paper reports on the findings of a workshop, which addressed trends in engineering design to 2040. The paper summarises the key findings from the six themes of the workshop: societal trends, ways of working, lifelong learning, technology, modelling and simulation and digitisation; and points to the challenge of understanding how these trends affect each other.

Keywords: Design process | Societal consequences | Systems Engineering (SE) | Trends

Abstract: Aero-engine component design decisions should consider re-manufacturing and/or repair strategies and their impact on lifecycle cost. Existing design approaches do not account for alternative production technologies such as the use of additive manufacturing in life extension processes. This paper presents a modeling and optimization methodology for examining the impact of design decisions in the early development stage on component lifecycle cost during the in-service phase while considering the potential use of additive manufacturing in life extension strategies. Specifically, a system dynamics model is developed to assess different end-of-life scenarios. Finally, an optimization problem is formulated and solved to minimize lifecycle cost with respect to design variables related to remanufacturing.

Keywords: Additive Manufacturing | Computational design methods | Product-Service Systems (PSS)

Abstract: Additive Manufacturing (AM) offers the potential to increase the ability to customise large-scale plastic components. However, a substantial amount of manual work is still required during the customisation process, both in design and manufacturing. This paper looks into how the additive manufacturing of mass customised large-scale products can be supported. Data was collected through interaction with industrial partners and potential customers in a case study regarding the customisation of kayaks. As a result, the paper proposes a model-based methodology which combines design automation with a user interface. The results point to the benefit of the proposed methodology in terms of design efficiency, as well as in terms of displaying results to the end user in an understandable format.

Keywords: Additive Manufacturing | Design methods | Product modelling / models

Abstract: One problem in incremental product development is that geometric models are limited in their ability to explore radical alternative design variants. In this publication, a function modeling approach is suggested to increase the amount and variety of explored alternatives, since function models (FM) provide greater model flexibility. An enhanced function-means (EF-M) model capable of representing the constraints of the design space as well as alternative designs is created through a reverse engineering process. This model is then used as a basis for the development of a new product variant. This work describes the EF-M model\'s capabilities for representing the design space and integrating novel solutions into the existing product structure and explains how these capabilities support the exploration of alternative design variants. First-order analyses are executed, and the EF-M model is used to capture and represent already existing design information for further analyses. Based on these findings, a design space exploration approach is developed. It positions the FM as a connection between legacy and novel designs and, through this, allows for the exploration of more diverse product concepts. This approach is based on three steps-decomposition, design, and embodiment-and builds on the capabilities of EF-M to model alternative solutions for different requirements. While the embodiment step of creating the novel product\'s geometry is still a topic for future research, the design space exploration concept can be used to enable wider, more methodological, and potentially automated design space exploration.

Keywords: Concept design | design space exploration | DSM | enhanced function-means modeling | function modeling | radical innovation

Abstract: The aim of the paper is to foster a discussion in the engineering design community about its understanding of the innovation phenomena and the unique contribution that comes from engineering design. The paper reports on the dialouge originating from a series of workshops with participants from different backgrounds in engineering design, systems engineering, industrial design psychology and business. Definitions of innovation are revisited as used in business, management and engineering design contexts. The role of innovation is then discussed related to product development from (i) the management perspective, (ii) a systems architecture perspective and (iii) in relation to sustainable development as one driver of innovation. It is argued that engineering design has a central role in how to realise the novelty aspect of innovation and often plays a critical role in maturing these into the valuable products, and there is a need to articulate the role of engineering design in innovation to better resonate with the business and management research.

Keywords: Design engineering | Design management | Design process | Innovation

Abstract: This study investigates the challenge to assess value when alternative technologies - of radical nature - are integrated on complex products. The study highlights three main challenges: 1) value depends on how the overall product platform is impacted over time 2) value depends on combination effects between technologies and 3) value depends on how the technology balances internal and external stakeholders needs simultaneously. The paper describes how these challenges can be tackled by novel modelling methods, illustrated with an example related to structural batteries.

Keywords: Early design phase | Product platform | Value driven design

Abstract: This paper studied how the introduction of additive manufacturing (AM) in space applications impacts the design phases. Together with three manufacturers of space applications, the potential benefit as well as constraints are studied to identify design gaps. A literature survey is conducted to match the needs and following an analysis the impact on design practice is formulated. Results show the need to combine a wider design exploration capability, in combination with comparative modelling strategies.

Keywords: Additive manufacturing | Design analysis | Design methodology | Engineering design

Abstract: Additive manufacturing (AM) is being proposed as a revolutionary manufacturing technology, promising significant advantages both from a design and production perspective. One challenge is the disruptive nature of AM and its impact on all life cycle phases. This paper reports from a demonstrator project highlighting digitalization and process implications. A demonstrator tool was developed able to collectively capture and visualize different life cycle implications of AM products. Market expectations, technology characteristics and life cycle constraints were met in the demonstrator tool. Each individual part collected its own traceable data set, from design over manufacturing up to postproduction services. Key aspects demonstrated were 1) the need to represent any manufacturing and life cycle constraint already in design, 2) the need to integrate unique identifiers that build a digital twin and 3) the need to automate links between life cycle engineering steps.

Keywords: Lifecycle | Manufacturing system | Product Development

Abstract: Additive Manufacturing is increasingly attracting interest among manufacturers of space components, mainly due to its high design freedom, capability for achieving weight reduction and for being cost-efficiently produced in low volumes. However, AM is a less mature technology compared to established manufacturing methods. This lack of maturity concerns especially the area of AM manufacturing constraints as the knowledge about them is limited and because they mature over time, as the technology evolves. The lack of knowledge hinders designers to fully take advantage of AM, fearing that the technology will affect product reliability. This situation is particularly emphasized in space components, since they are subject to high reliability requirements. In this paper, a methodology based on function decomposition and constraint modelling is proposed as a basis for re-design of products using AM. In the methodology, the original functions, design solutions and manufacturing constraints of a product are identified. Then, the original manufacturing constraints are removed and replaced with manufacturing constraints for AM. Afterwards, functions and design solutions on the function model are modified and a new part geometry is designed and eventually realised in CAD. This methodology has been applied on a case study featuring a satellite sub-component.

Keywords: AM | DfAM | Function modelling | Functional decomposition | Manufacturing constraints

Abstract: To gain a first-mover advantage on the marketplace, manufacturers are striving to develop innovative products that meet the needs of a wide range of customers. Traditionally to support innovative design, the fuzzy concept stage has long been supported by heuristic design philosophies. In recent years, new supportive technologies have enabled concept generation based on the collection and reuse of existing data. Existing data can be collected from various sources; for example, customer reviews, historical data, or by studying existing products or other industrial assets such as production machines and tooling. Lately, the concept of Digital Twin (DT) has gained a wealth of attention as a means to construct a high-fidelity digital copy of a physical asset and to study its shape, position, gesture, status and motion. The common aim of the DT is to support the realistic model of system behavior that can support performance prediction and optimization. However, in providing sufficient support during the conceptual stages the realistic models become heavy and costly to adapt. While the emerging data-driven design approaches can be used to generate designs with alterations, there is a lack of support to generate and evaluate solutions during the conceptual stages. In this paper, a framework of a Digital Platform Twin (DPT) is proposed to fill this gap. In contrast to a sole high-fidelity digital representation, the DPT builds on abstracting multiple high-fidelity Digital Twins into a low-fidelity platform model, represented as a function model. The DPT framework proclaims the vision of supporting design engineers in the process of abstracting functionalities of existing assets, inserting new functionalities and technologies in the function structure to ultimately support the generation and evaluation of new functional concepts. To demonstrate the DPT framework, an automotive example is presented. We believe that design reuse can be enabled during platform concept development with the use of multiple DTs. To achieve this, a challenge is to practically realize the transcending in abstraction levels of the models: from Digital Twins to function model and from function model to geometry models. The transcending in abstraction levels is therefore a matter of future work.

Keywords: Conceptual development stages | Digital twin | Platform-based design

Abstract: To reduce uncertainty in decisions, engineers experiment with models, such as, exploring what-if scenarios, and thus increase knowledge. Still, because modelling is an idealisation of reality, there is often substantial uncertainty involved, and this decision makers less confident to lean onto models alone when making decisions. The aim of this paper is to conceptualize a design support for improving confidence and validity in models, by communicating uncertainties from modelling and simulation to relevant stakeholders. The paper reports on empirical data from a research profile workshop. The findings illustrate the importance of communicating uncertainties from models between relevant stakeholders in order to drive action. The paper then presents an approach to visualize model maturity levels as well as impact levels in relation to one or several aggregated models. With this approach, focus can move to discuss the knowledge about the knowledge that is created from modelling, and to facilitate discussions on a meta-level about the modelling and simulation. This is exemplified by a test scenario where a multi-disciplinary modelling and simulation of an asphalt roller is presented.

Keywords: Decision making | Modelling | Simulation | Uncertainty | Visualisation

Abstract: Due to ever increasing challenges faced by our global society, circular design and the idea of product-service systems (PSS) is gaining traction within businesses. However, \'predicting\' the value of a future PSS solution in the early design phases is difficult, since it requires the ability to balance long term potential with short term decisions. Modelling and simulation is believed to be able to support this challenging task. A simulation framework for circular design of PSS is presented. The simulation process enables the comparison between functional and non-functional performances and their life cycle contributions depending on a defined PSS-like business model strategy. Such integrated simulation framework is intended to exploit engineering models outside their specific discipline, enabling cross-functional collaboration and help decision makers understand how a design can contribute in satisfying customer and stakeholders needs during the lifecycle of a PSS.

Keywords: circular economy | multidiscplinary decision-making | product-service systems | Simulation-driven design

Abstract: Value models, in form of economical optimization functions, are often proposed to frontload engineering design activities. However, literature argues that, when qualitative data and assumptions prevail, a qualitative assessment of the \'goodness\' of a design is preferable against a numerical (and monetary-based) encoding of preferences. This paper explores how a model-based approach can support deliberation about value in cross-functional design teams. Emerging from case studies in the road compaction equipment industry, the paper analyzes preferences for value modelling support when it comes to iteratively translate customer desires into terms meaningful for engineering design decisionmaking. It further prescribes a framework for value-driven engineering design that considers the need to update the value model definition as far as new information become available in the process, moving from qualitative to quantitative. The findings highlight the role the proposed chain of value models plays in terms of providing a shared reference to stimulate value discussions across functions and organizational roles, which is something that does not naturally happen in the organization today.

Keywords: Design methods | Early design phases | Systems Engineering (SE) | Value Driven Design | Value model

Abstract: The topic of \'design for value\' has lately attracted a great deal of attention within the engineering design community. \'Predicting\' the value of a future solution is however difficult, especially in early design phases. Modelling and simulation is believed to be able to support this challenging task. A simulation process for value-driven engineering design is presented. The performances of a design concept along the lifecycle are aggregated to a monetary system value function. The results of this multi-model simulation environment for value are displayed through a colour-coded CAD model for easier interaction. Verification activities indicate that enabling effective design space exploration and visualization of cause-effect relationships become important elements in order to \'think together\' using a simulation driven design approach. Furthermore, the proposed multidisciplinary \'value model\' fosters cross-functional knowledge sharing and collective deliberation about the value, forcing stakeholders to synthetize their perceptions about the value of a design and to discuss where conclusions differ.

Keywords: Conceptual design | Design space exploration | Multi-/Cross-/Trans-disciplinary processes | Simulation | Value-driven simulation

Abstract: In recent times a service-dominant logic is permeating the design of complex systems. However, in spite of their appeal, initiatives such as Product Service Systems (PSS) have not become mainstream, and methods are lacking to support this transition. This paper argues that methodological guidance, as well as tools for decision support, may be found in the research field of Value Driven Design (VDD), which originates in the realm of Systems Engineering. The paper objective is to elaborate on gaps and opportunities for cross-pollination between VDD and PSS. The results of a systematic review of methods and tools for design decision support highlight the opportunity for introducing optimization models derived from VDD in the PSS design process, while the latter can enrich VDD research with a more qualitative value assessment logic. The paper summarizes this integration in a methodological approach, and exemplifies its application in case studies mainly from the aerospace and road construction equipment sector.

Keywords: Engineering design | Preliminary design | Product development | Product–Service Systems | Servitization | Systems Engineering | Value Driven Design

Abstract: In PSS design, hardware and service developers often have different objectives. Lacking to communicate and negotiate them across boundaries might lead to solutions unable to generate market shares and long-term profitability. This paper aims to contribute to the definition of \'boundary objects\' that facilitate the sharing of knowledge between members of cross-functional teams engaged in PSS conceptual design activities. Empirical data are gathered from three case studies in the Swedish manufacturing industry to reveal how servitization affects early stage design decision-making, and how hardware vs. service trade-offs are negotiated and solved. The analysis of the findings points to four main trends to be considered when designing such objects in the realm of PSS. These are: an underlying model-based logic, the use of metrics based on customer value, the ability to quickly generate and assess scenarios, the use of non linear relationships to map PSS features vs. customer value.

Keywords: Boundary objects | Decision making | Engineering design | Product Service Systems | Servitization | Value model

Abstract: The paper presents the results of experimental activities aiming at investigating the role of \'value models\' as \'boundary objects\' that facilitate cross-functional discussions in the PSS conceptual design phase. The experiment featured 6 separate sessions involving a total of 22 students in the final year of three different Master Programmes. In the sessions participants were asked to redesign an asphalt compactor and to use different types of design decision support for this task, namely value models vs. requirements checklists. The recordings from the experiment were analysed using protocol analysis to compare the behaviour of teams. The results confirm the hypothesis that, compared to traditional requirement checklists, value models emphasizes activities related to the clarification (1) of the problem domain and needs and (2) of the lifecycle aspects of a solution concept. Both results suggest that value models have the ability to facilitate cross-boundary discussion in the early phases of the PSS design process, and to act as boundary objects that provide a common platform for knowledge sharing within the cross-functional team.

Keywords: boundary object | conceptual design | experiment | protocol analysis | value model

Abstract: The paper presents a discussion about gaps and opportunities for cross-pollination between Value Driven Design and Lean Product Service Development to promote the use of value-driven method and tools since the preliminary design stages. In particular the paper discusses how methods and tools developed in Value Driven Design have the potential to be applied in the preliminary design stage in the context of Lean Product Service Development. The paper concludes by defining a research area on Value Innovation method and tools for preliminary Lean Product Service Development.

Keywords: Lean Product Service Development | Preliminary design | Value Driven Design | Value Innovation

Abstract: This paper presents a computer-based approach for conceptual design that aims to enhance collaborative supply chain development in the automotive sector when dealing with product-service development or radical innovations. The focus of the research has been to design a simulation approach that will enable designers and managers to simulate and evaluate the value of different design options for the different stakeholders involved in the development process and to have insights about the implications between business model innovation and the engineered aspects of the solutions early in the conceptual phase. The approach is presented using a case study within the current project, after following a team responsible for the car cockpit. Four possible scenario have been simulated and evaluated using a commercial simulation software. The main advantage of the proposed approach is to enhance the awareness among designers and managers of the value of different design options, and allow them to explore further how business and design aspects profoundly affect each other, in order to support early decision-making in the design process.

Keywords: Product-service systems | Simulation driven design | Value engineering

Abstract: No abstract

Keywords: Product-service systems | Simulation-driven design | Value engineering

Abstract: Sustainability is a complex but extremely important issue. To achieve a new industrial revolution that focuses on sustainability, we need innovation. Merely improving our technologies and our habits will not save our planet from its current gradual degradation. In recent decades many Eco-tools have been developed; this paper evaluates some of the most used methods, how they help to consider sustainability in the product development process and identify important and missing characteristics, arguing that many eco-tools were experienced by the companies as too complex and time-consuming and often not aiding a radical innovation process. These characteristics guided the development of a framework with creative methods for sustainability driven innovation based on a multidisciplinary workshop approach. It focuses on analyzing customers from a sustainable viewpoint, understanding their real needs, using ideation tools to generate ideas in areas not usually considered in current eco-tools, e.g. changing customer behavior or the business model. The method was developed, tested and evaluated in an iterative approach over a six-month period.

Keywords: Product Development | Radical Innovation | Sustainability