Students are introduced to the world of creative engineering product design. Through six activities, teams work through the steps of the engineering design process (or loop) by completing an actual design challenge presented in six steps. The project challenge is left up to the teacher or class to determine; it might be one decided by the teacher, brainstormed with the class, or the example provided (to design a prosthetic arm that can perform a mechanical function). As students begin by defining the problem, they learn to recognize the need, identify a target population, relate to the project, and identify its requirements and constraints. Then they conduct research, brainstorm alternative solutions, evaluate possible solutions, create and test prototypes, and consider issues for manufacturing. See the Unit Schedule section for a list of example design project topics.

Students learn about viscoelastic material behavior, such as strain rate dependence and creep, by using silly putty, an easy-to-make polymer material. They learn how to make silly putty, observe its behavior with different strain rates, and then measure the creep time of different formulations of silly putty. By seeing the viscoelastic behavior of silly putty, students start to gain an understanding of how biological materials function. Students gain experience in data collection, graph interpretation, and comparison of material properties to elucidate material behavior. It is recommended that students perform Part 1of the activity first (making and playing with silly putty), then receive the content and concept information in the associated lesson, and then complete Part 2 of the activity (experimenting and making measurements with silly putty).

Using a website simulation tool, students build on their understanding of random processes on networks to interact with the graph of a social network of individuals and simulate the spread of a disease. They decide which two individuals on the network are the best to vaccinate in an attempt to minimize the number of people infected and "curb the epidemic." Since the results are random, they run multiple simulations and compute the average number of infected individuals before analyzing the results and assessing the effectiveness of their vaccination strategies.

Students gain experience with the software/system design process, closely related to the engineering design process, to solve a problem. First, they learn about the Mars Curiosity rover and its mission, including the difficulties that engineers must consider and overcome to operate a rover remotely. Students observe a simulation of a robot being controlled remotely. These experiences guide discussion on how the design process is applied in these scenarios. The lesson culminates in a hands-on experience with the design process as students simulate the remote control of a rover. In the associated activity, students gain further experience with the design process by creating an Android application using App Inventor to control one aspect of a remotely controlled vehicle. (Note: The lesson requires a LEGO® MINDSTORMS® Education NXT base set.)

Students perform DNA forensics using food coloring to enhance their understanding of DNA fingerprinting, restriction enzymes, genotyping and DNA gel electrophoresis. They place small drops of different food coloring ("water-based paint") on strips of filter paper and then place one paper strip end in water. As water travels along the paper strips, students observe the pigments that compose the paint decompose into their color components. This is an example of the chromatography concept applied to DNA forensics, with the pigments in the paint that define the color being analogous to DNA fragments of different lengths.

Students explore the many different ways that engineers provide natural lighting to interior spaces. They analyze various methods of daylighting by constructing model houses from foam core board and simulating the sun with a desk lamp. Teams design a daylighting system for their model houses based on their observations and calculations of the optimal use of available sunlight to their structure.

In this first part of a two-part lab activity, students use triple balance beams and graduated cylinders to take measurements and calculate the densities of several common, irregularly shaped objects with the purpose to resolve confusion about mass and density. After this activity, conduct the associated Density Column Lab - Part 2 activity before presenting the associated Density & Miscibility lesson for discussion about concepts that explain what students have observed.

Concluding a two-part lab activity, students use triple balance beams and graduated cylinders to take measurements and calculate densities of several household liquids and compare them to the densities of irregularly shaped objects (as determined in Part 1). Then they create density columns with the three liquids and four solid items to test their calculations and predictions of the different densities. Once their density columns are complete, students determine the effect of adding detergent to the columns. After this activity, present the associated Density & Miscibility lesson for a discussion about why the column layers do not mix.

After students conduct the two associated activities, Density Column Lab - Parts 1 and 2, present this lesson to provide them with an understanding of why the density column's oil, water and syrup layers do not mix and how the concepts of density and miscibility relate to water chemistry and remediation. Topics covered include miscibility, immiscibility, hydrogen bonds, hydrophobic and hydrophilic. Through the density column lab activities, students see liquids and solids of different densities interact without an understanding of why the resulting layers do not mix. This lesson gives students insight on some of the most fundamental chemical properties of water and how it interacts with different molecules.

Students explore the densities and viscosities of fluids as they create a colorful 'rainbow' using household liquids. While letting the fluids in the rainbow settle, students conduct 'The Great Viscosity Race,' another short experiment that illustrates the difference between viscosity and density. Later, students record the density rainbow with sketches and/or photography.

Students practice the initial steps involved in an engineering design challenge. They begin by reviewing the steps of the engineering design loop and discussing the client need for the project. Next, they identify a relevant context, define the problem within their design teams, and examine the project's requirements and constraints. (Note: Conduct this activity in the context of a design project that students are working on, which could be a challenge determined by the teacher, brainstormed with the class, or the example project challenge provided [to design a prosthetic arm that can perform a mechanical function].)

Through Internet research, patent research, standards and codes research, user interviews (if possible) and other techniques (idea web, reverse engineering), students further develop the context for their design challenge. In subsequent activities, the design teams use this body of knowledge about the problem to generate product design ideas. (Note: Conduct this activity in the context of a design project that students are working on, which could be a challenge determined by the teacher, brainstormed with the class, or the example project challenge provided [to design a prosthetic arm that can perform a mechanical function]. This activity is Step 2 in a series of six that guide students through the engineering design loop.)

Brainstorming is a team creativity activity that helps generate a large number of potential solutions to a problem. In this activity, students participate in a group brainstorming activity to generate possible solutions to their engineering design challenge. Students learn brainstorming guidelines and practice within their teams to create a poster of ideas. The posters are used in a large group critiquing activity that ultimately helps student teams create a design project outline. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 3 in a series of six that guide students through the engineering design loop.)

Engineering analysis distinguishes true engineering design from "tinkering." In this activity, students are guided through an example engineering analysis scenario for a scooter. Then they perform a similar analysis on the design solutions they brainstormed in the previous activity in this unit. At activity conclusion, students should be able to defend one most-promising possible solution to their design challenge. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 4 in a series of six that guide students through the engineering design loop.)

Students learn about the manufacturing phase of the engineering design process. They start by building prototypes, which is a special type of model used to test new design ideas. Students gain experience using a variety of simple building materials, such as foam core board, balsa wood, cardstock and hot glue. They present their prototypes to the class for user testing and create prototype iterations based on feedback. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 5 in a series of six that guide students through the engineering design loop.)

As students learn more about the manufacturing process, they use the final prototypes created in the previous activity to evaluate, design and manufacture final products. Teams work with more advanced materials and tools, such as plywood, Plexiglas, metals, epoxies, welding materials and machining tools. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 6 in a series of six that guide students through the engineering design loop.)

Students design and create their own nano-polymer smartphone or tablet case. Students choose their design, mix their nano-polymer (based in silicone) with starch and add coloring of their choice. While thinking critically about their design, students embed strings in the nano-polymer to optimize both case strength and flexibility. Students may apply strings in a variety of ways in order to maximize their individual design’s potential. Determining the best mixing ratio is also key for success in this challenge.

Students are introduced to the biomechanical characteristics of helmets, and are challenged to incorporate them into designs for helmets used for various applications. By doing this, they come to understand the role of enginering associated with saftey products. The use of bicycle helmets helps to protect the brain and neck in the event of a crash. To do this effectively, helmets must have some sort of crushable material to absorb the collision forces and a strap system to make sure the protection stays in place. The exact design of a helmet depends on the needs and specifications of the user.

Students are given a biomedical engineering challenge, which they solve while following the steps of the engineering design process. In a design lab environment, student groups design, create and test prototype devices that help people using crutches carry things, such as books and school supplies. The assistive devices must meet a list of constraints, including a device weight limit and minimum load capacity. Students use various hand and power tools to fabricate the devices. They test the practicality of their designs by loading them with objects and then using the modified crutches in the school hallways and classrooms.