Chapter 12: Reference

Quick reference guide for industrial design fundamentals.

Design Process

DISCOVER → DEFINE → DEVELOP → DELIVER
   ↓         ↓         ↓          ↓
Research  Problem   Ideate    Refine
Observe   Frame     Prototype Engineer
Empathize Criteria  Test      Manufacture

Key Actions:

• Research: 5-10 user interviews minimum
• Define: Problem statement template: "[User] needs [need] because [insight]"
• Develop: Generate 20+ concepts before selecting
• Deliver: Validate with high-fidelity prototype

Ergonomic Guidelines

Critical Body Dimensions

Force Limits

Handle Dimensions

Material Properties

Common Plastics

Metals

Manufacturing Processes

Process Selection Guide

Injection Molding Guidelines

Design Rules:

• Wall thickness: 2-4mm (consistent)
• Draft angle: 1-3° minimum
• Corner radius: 0.5-1mm minimum
• Avoid undercuts (or plan for slides)
• Gate placement: Hidden if possible

Cost Breakdown:

Tooling: $5,000-$100,000 (one-time)
Per part (at 10,000): $1-5
Per part (at 100,000): $0.50-2

Design Principles

The 9 Core Principles

1. Balance: visual equilibrium
2. Proportion: harmonious relationships
3. Unity: elements belong together
4. Contrast: create visual interest
5. Emphasis: clear focal point
6. Rhythm: repetition and flow
7. Movement: guide the eye
8. Pattern: repeated elements
9. Negative Space: intentional emptiness

Dieter Rams' 10 Principles

1. Innovative
2. Useful
3. Aesthetic
4. Understandable
5. Unobtrusive
6. Honest
7. Long-lasting
8. Thorough
9. Environmentally friendly
10. As little design as possible

"Weniger, aber besser": less, but better.

Color Theory

Color Psychology

Color Standards

Pantone:

• Industry standard for design
• Physical swatch books
• Example: Pantone 294 C

RAL:

• European standard
• Industrial design common
• Example: RAL 9001 (cream white)

CMF (Color, Material, Finish)

Surface Finishes

Sustainability

Lifecycle Stages

1. Material extraction
2. Material processing
3. Manufacturing
4. Distribution
5. Use phase
6. End of life

Design for Sustainability

Strategies:

• Longevity: make it last
• Repair: enable fixing
• Recycling: single materials
• Disassembly: screws over glue
• Sustainable materials: recycled, renewable
• Energy efficiency: minimize use-phase energy
• Minimal packaging: right-size, recyclable

Carbon Estimates:

• Aluminum: 8 kg CO₂/kg
• Plastic: 3 kg CO₂/kg
• Steel: 2 kg CO₂/kg
• Recycled aluminum: 0.5 kg CO₂/kg (95% savings)

Prototyping

Fidelity Levels

3D Printing

FDM Settings:

• Layer height: 0.2mm (speed) or 0.1mm (detail)
• Infill: 20% for prototypes
• Material: PLA (easy), PETG (strong), TPU (flexible)

Post-Processing:

1. Remove supports
2. Sand (80 → 120 → 220 grit)
3. Prime (filler primer)
4. Paint (acrylic or spray)

Essential Formulas

Golden Ratio

φ = 1.618
a/b = (a+b)/a = φ

Rectangle: 1.618 : 1
Ideal for many proportions

Fibonacci Sequence

1, 1, 2, 3, 5, 8, 13, 21, 34, 55...

Use for spacing, sizing hierarchy

Rule of Thirds

Divide composition 3×3
Place focal points at intersections

Cost Estimation

Total Cost = Material + Processing + Tooling + Assembly + Overhead

Material = Volume × $/unit
Processing = Time × Rate
Tooling = Cost / Quantity
Assembly = Time × Labor rate
Overhead = 20-50% of above

Tools & Software

CAD Software

Rendering

• KeyShot: fast, easy, professional
• V-Ray: industry standard, powerful
• Blender Cycles: free, open source

2D Design

• Adobe Illustrator: vector graphics
• Photoshop: image editing, rendering enhancement
• Figma: collaborative, UI focus

Testing Checklist

Appearance

• [ ] Proportions pleasing from all angles?
• [ ] Finish quality consistent?
• [ ] Colors work together?
• [ ] Details refined?

Functionality

• [ ] All features work as intended?
• [ ] Intuitive without instructions?
• [ ] No unexpected failures?
• [ ] Meets performance targets?

Ergonomics

• [ ] Comfortable for extended use?
• [ ] Fits range of users (5th-95th %ile)?
• [ ] Forces within acceptable limits?
• [ ] No pressure points or discomfort?

Durability

• [ ] Survives drop test?
• [ ] Withstands expected use cycles?
• [ ] Appropriate material choices?
• [ ] No obvious weak points?

Manufacturing

• [ ] Manufacturable at target cost?
• [ ] Appropriate tolerances?
• [ ] Assembly straightforward?
• [ ] Design for Manufacturing principles applied?

Sustainability

• [ ] Materials recyclable/sustainable?
• [ ] Repairable/serviceable?
• [ ] Minimal packaging?
• [ ] Energy efficient (if powered)?

Terminology

Affordance: Visual cue about how to use something

Anthropometrics: Study of human body measurements

BOM (Bill of Materials): List of all components and quantities

CAD: Computer-Aided Design

CMF: Color, Material, Finish

DFM: Design for Manufacturing

DfD: Design for Disassembly

Draft Angle: Taper for part ejection from mold

Ergonomics: Science of designing for human use

Fidelity: Level of prototype refinement

Iteration: Repeated refinement cycles

LCA: Lifecycle Assessment (environmental impact)

Minimum Viable Product (MVP): Simplest version that works

Parting Line: Mold separation line (visible on part)

Rapid Prototyping: Fast prototype creation (3D printing)

Tolerance: Acceptable variation in dimension

Undercut: Feature that prevents mold ejection

User-Centered Design: Design driven by user needs

Industry Resources

Books

Essential:

• The Design of Everyday Things, Don Norman
• Sketching: Drawing Techniques for Product Designers, Koos Eissen
• Materials and Design, Mike Ashby

Advanced:

• The Art of Product Design, Hardi Meybaum
• Product Design and Development, Ulrich & Eppinger
• Cradle to Cradle, McDonough & Braungart

Websites

News & Inspiration:

• Core77.com: design news, community
• Yanko Design: product concepts
• Dezeen: design and architecture
• Behance: portfolio inspiration

Technical Resources:

• Engineering Toolbox: properties, formulas
• MatWeb: material database
• McMaster-Carr: parts catalog with specs

Learning:

• Coursera: online courses
• Skillshare: creative tutorials
• YouTube: free tutorials (search specific topics)

Organizations

• IDSA: Industrial Designers Society of America
• Design Council: UK design organization
• IDEO: design consultancy, thought leadership

Conferences

• IDSA International Conference: annual, US
• Dutch Design Week: Eindhoven, Netherlands
• Milan Design Week: Italy, largest globally

Career Resources

Portfolio Guidelines

What to Include:

• 5-10 projects (quality over quantity)
• Process documentation (not just glamour shots)
• Sketches, prototypes, final products
• Written explanation of each project
• Problem, solution, impact

What to Avoid:

• Too many projects (overwhelming)
• Only final renderings (no process)
• Unclear explanations
• Poor photography
• Projects without context

Salary Ranges (US, 2024)

Varies by location, industry, company size

Job Titles

• Junior/Entry Industrial Designer
• Industrial Designer
• Senior Industrial Designer
• Lead Industrial Designer
• Principal Designer
• Design Manager
• Creative Director
• VP of Design

Quick Start Projects

Beginner

1. Redesign a door handle: simple form, clear function
2. Improve a water bottle: grip, opening, cleaning
3. Create a desk organizer: balance form and utility

Intermediate

4. Design a flashlight: electronics, ergonomics, materials
5. Portable speaker: form, function, technology integration
6. Kitchen gadget: specific problem-solving

Advanced

7. Furniture piece: structure, comfort, manufacturing
8. Medical device: safety, ergonomics, regulation
9. Consumer electronics: complex assembly, high finish

Final Thoughts

Remember:

1. Always design for real users
2. Iterate more than you think necessary
3. Prototype early and often
4. Manufacturing constraints inspire creativity
5. Details matter enormously
6. Sustainability is not optional
7. Simplicity is the ultimate sophistication

Keep Learning:

• Sketch daily
• Study products constantly
• Take things apart
• Build prototypes
• Test with users
• Stay curious

"Good design is obvious. Great design is transparent." Joe Sparano

Further Study

After completing this course, continue learning:

1. Specialize: pick an area (furniture, tech, medical) and go deep
2. Practice: do one project per month minimum
3. Community: join design communities, get feedback
4. Read: one design book per quarter
5. Conferences: attend at least one per year
6. Mentorship: find a mentor or mentor others
7. Portfolio: keep updating with new work

You're now equipped with industrial design fundamentals. Go make great products!