Journal of Product Design, Quality Engineering & Technology

Abstract

The increasing complexity of modern products and the demand for faster, cost-effective development have driven the adoption of Digital Twin (DT) technology in product design and manufacturing. Digital Twin-driven Product Development (DTPD) leverages real-time data and virtual models to simulate, test, and optimize products before physical prototypes are built. This paper presents a comprehensive review of Digital Twin technologies in product development and virtual prototyping, exploring their frameworks, benefits, integration with Industry 4.0, and associated challenges. Case studies across automotive, aerospace, and consumer electronics sectors illustrate the practical applications of DT-driven development. Additionally, the paper highlights emerging trends such as AI-enabled Digital Twins, predictive maintenance, and immersive virtual prototyping. The discussion concludes with recommendations for integrating DT frameworks effectively and future research directions.

Keywords: Digital Twin, Virtual Prototyping, Product Development, Industry 4.0, Simulation, Predictive Modeling

Abstract

Biophilic and emotional design integration is increasingly recognized as a crucial strategy in architecture and product design to enhance human well-being, productivity, and emotional satisfaction. Biophilic design emphasizes the incorporation of natural elements, patterns, and processes into built environments, while emotional design focuses on creating products and spaces that evoke positive affective responses. Integrating these two approaches allows designers to craft environments that are not only functional but also psychologically nurturing. This paper presents a comprehensive review of the principles, methodologies, and applications of biophilic and emotional design integration. It explores theoretical frameworks, case studies, technological tools, and emerging trends. The analysis highlights measurable benefits, such as improved cognitive performance, reduced stress, and enhanced creativity, while also discussing challenges in implementation, evaluation, and interdisciplinary collaboration. Finally, the paper identifies opportunities for future research and provides guidelines for effectively merging biophilic and emotional design in contemporary architecture and product development.

Keywords: Biophilic design, emotional design, human-centered architecture, well-being, user experience, design psychology, natural environments.

Abstract

Augmented Reality (AR) and Virtual Reality (VR) are increasingly transforming product design and prototyping in contemporary manufacturing and industrial design sectors. Traditional design methods often require physical prototyping, which is time-consuming and cost-intensive. AR/VR technologies provide immersive environments that allow designers and engineers to visualize, interact, and test products in real-time before manufacturing. This paper presents a comprehensive review of AR/VR applications in product design and prototyping, highlighting technological frameworks, design workflows, advantages, limitations, and future trends. Additionally, the integration of AR/VR with CAD, simulation tools, and collaborative design platforms is discussed. The study concludes with potential research directions aimed at enhancing AR/VR adoption for rapid and cost-efficient product development.

Keywords: Augmented Reality, Virtual Reality, Product Design, Prototyping, CAD Integration, Immersive Visualization, Industrial Design, Rapid Prototyping

Abstract

AI-assisted generative design has emerged as a transformative approach in modern product innovation, enabling designers and engineers to explore vast solution spaces that were previously impractical using traditional methods. By integrating artificial intelligence, optimization algorithms, and computational creativity, generative design systems can automatically generate, evaluate, and refine thousands of design alternatives based on predefined objectives and constraints. This paper presents a comprehensive review of AI-assisted generative design for product innovation, focusing on its theoretical foundations, algorithmic techniques, system architectures, and practical applications across multiple industries. The study discusses how machine learning, evolutionary algorithms, and deep generative models contribute to design automation and creativity enhancement. Challenges related to interpretability, manufacturability, data dependency, and human–AI collaboration are critically analyzed. Finally, future research directions are outlined, emphasizing the role of explainable AI, sustainable design objectives, and integration with digital manufacturing platforms. The paper aims to provide researchers and practitioners with a structured understanding of the current state and potential of AI-assisted generative design in accelerating product innovation.

Keywords:  Generative design, artificial intelligence, product innovation, design optimization, machine learning, computational creativity

Abstract

The Internet of Things (IoT) has emerged as a transformative technological paradigm that is significantly influencing product engineering across various industries. By enabling physical products to sense, communicate, and interact with their environment, IoT enhances product functionality, reliability, and user experience. In product engineering, IoT supports data-driven design, real-time monitoring, predictive maintenance, and continuous improvement throughout the product life cycle. This paper presents a comprehensive review of the role of IoT in product engineering, covering its architecture, enabling technologies, integration across design and manufacturing stages, and its impact on quality, sustainability, and innovation. Practical applications and industrial use cases are discussed to highlight real-world benefits and challenges. The paper also examines key issues such as data security, interoperability, and system complexity. Finally, future trends and research directions are outlined, emphasizing the growing importance of IoT-enabled intelligent and connected products in modern engineering practice.

Keywords: Internet of Things, Product Engineering, Smart Products, Digital Manufacturing, Product Life Cycle, Industry 4.0

Abstract

Finite element simulations have been utilized in analyses of machining process for several decades. This paper presents the development of a cutting force model for end milling process under various cutting conditions and the tool wear is measured by Scanning Electron Microscope (SEM).This novel approach combines the concept of experimental design and finite element modeling of the cutting process which allows for a fairly accurate prediction of cutting forces with a significantly lower computational cost. The simulated results are compared against the experimental observations. The results have shown that the material AISI 316 Stainless steel has affects on cutting forces and tool wear. In cutting approach, Deform 3Dv6.1 software is used to simulate the milling process. The simulation and experimentation is performed based on Taguchi design of experiments. In this research, three dimensional finite element modeling and simulation issues for vibration assisted milling are explored in detail. Machine dynamic effects are taken into account to predict the outcomes such as tool wear and cutting forces. The model can be implemented in an online tool wear monitoring system which predicts the actual state of tool wear in real time by correlating cutting force variations during machining. The comparisons of simulations with experimental results demonstrate  their  predictive  capability.  From  the  results,  useful conclusions may be drawn, and it can be stated that the proposed models can be used for industrial application.

Keywords: End milling, Cutting force, Tool Wear, Machining, Metal cutting, Modeling.

Abstract

Inclusive product design for accessibility has emerged as a critical area within contemporary design practice, driven by demographic changes, increased awareness of disability rights, and evolving regulatory frameworks. The core objective of inclusive design is to ensure that products, systems, and services can be used by the widest possible range of users, regardless of age, ability, gender, or socio-economic background. This paper presents a comprehensive review of inclusive product design with a specific focus on accessibility. It examines the theoretical foundations of inclusive and universal design, discusses different types of disabilities and user needs, and reviews established design principles, methods, and tools that support accessibility. The paper also explores the role of technology, such as digital interfaces, assistive devices, and smart products, in enabling inclusive solutions. Through selected case examples and comparative analysis, the paper highlights both the opportunities and challenges faced by designers and organizations when implementing inclusive design strategies. Finally, future directions and research gaps are identified, emphasizing the need for participatory approaches, interdisciplinary collaboration, and context-sensitive solutions. The study aims to serve as a reference for researchers, educators, and practitioners seeking to integrate accessibility as a fundamental aspect of product design rather than an afterthought.

Keywords: Inclusive design, Accessibility, Universal design, Assistive technology, Human-centered design, Product development

Abstract

To evaluate the performance of diesel engine with high grade low heat rejection combustion chamber which consisting of air gap insulated piston with 3 mm air gap, with superni (an alloy of nickel) crown, air gap insulated liner with superni insert and ceramic coated cylinder head with neat diesel with varied injection pressure experiments were carried out. Performance parameters brake thermal efficiency, exhaust gas temperature, coolant load, volumetric efficiency and sound levels were determined at different values of brake mean effective pressure (BMEP) of the LHR–3 combustion chamber and compared with neat diesel operation on conventional engine (CE) at similar operating conditions. It is also found that Engine with LHR–3 combustion chamber with neat diesel operation showed deteriorated performance at manufacturer’s recommended injection timing of 27o bTDC.The Injection pressure changed from 190bar to 270bar with an increment of 40bar.

Keywords: Conservation of diesel, conventional engine, LHR combustion chamber, Performance

The objective of this research paper is to present the new design and development of manually operated pipe bending machine which is useful to bend a pipes of different thickness in workshops as well as in engineering works. This paper gives the brief description about the design and construction of the pipe bending machine which is used to bend metal pipes into curve and the other curvature shapes, the size of machine is very convenient for portable work. It is fully made by steel. Moreover it is easy to be carry and use at any time and any place. It reduces human effort and also required low less skill to operate this machine. We designed manually operated pipe bending machine with use of dies, gears and support (frame). Our objective is to increase accuracy at low prize without affecting the pipe bending productivity. This machine works on simple kinematic system instead of complicated design. This machine can bend up-to 01-10 mm thickness of pipes. In this paper we study this machine experimentally in different workshops and as well as taken the readings at different degrees of bending which gives the opportunity to reduce cost of machine and to reduce the human efforts.

Keywords: Bending dies, Tommy bar, Piston cylinder Metal Frame, Bending pipes

Abstract

Manufacturing systems are undergoing a major transformation due to rapid advances in automation, digitalization, and artificial intelligence. One of the most significant developments in this transformation is human–robot collaboration (HRC), where humans and robots work together in shared workspaces to perform manufacturing tasks. Unlike traditional industrial automation, which relies on physical separation between humans and machines, collaborative manufacturing emphasizes safety, flexibility, and complementary strengths of human workers and robotic systems. This paper presents a comprehensive review of human–robot collaboration in manufacturing, focusing on its evolution, enabling technologies, interaction modes, safety considerations, and impact on productivity and quality. The study also discusses organizational and human factors such as skill requirements, worker acceptance, and ergonomic benefits. Current industrial applications and case examples are reviewed to highlight practical implementation challenges. Finally, future research directions and emerging trends are identified, emphasizing the role of intelligent systems and standards in shaping the next generation of collaborative manufacturing environments.

Keywords: Human–robot collaboration, collaborative robots, smart manufacturing, industrial automation, ergonomics, safety systems, Industry 4.0

Abstract

In  this  paper,  implemented  design  of  the Shirodhara  unit  using  application  of  ATMEL8  is explained. The main objective of the project is to create accuracy in the traditional Shirodhara method which cures the mental stress and gives immediate feeling of relaxing effect.

Keywords: Shirodhara, Sensors, Heater, Microcontroller

Abstract

Nowadays in India, everyone have Liquid Petroleum Gas (LPG) cylinders, which are used for cooking, heating, etc. LPG cylinder is made of low cast steel, which has more weight and it is difficult to handle by a person. LPG is filled with high pressure in the cylinder. The user cannot predict how much LPG left inside cylinder so as to order for a new LPG cylinder. This paper is focusing on developing a weighing machine which will be used to carry the cylinder easily. This will enable the user to know the weight of LPG cylinder consequently the amount of LPG is present inside the cylinder. The customer voice data compiled from the survey and plotted in the quality function deployment (QFD) chart to drive the technical voice. The concept were modeled in Catia V5 R21, Solid works 2015 and rendered in Key shot 5 tools. Final concept has been selected by weighted ranking method.

Next step was to create block diagram of product and understand function of each component and make the interface of component with one another. After understanding the interface between components parts were modelled and assembled in Catia V5 R20 and rendered in Key shot 5 to realize actual product how it looks. Further analyzed each components in Abaqus and results were found to be safe, detail drawings of each part were generated. After that fabricated load cell and tested in NI Lab view 2015, calibrated the load cell and took the results of load cell.

Keywords: LPG, cylinder weight, QFD.

Abstract

Now-a-days, plenty of hot water are used for domestic, commercial and industrial purposes. Various resources i.e. coal, diesel, gas etc., are used to heat water. Solar energy is the main alternative to replace the conventional energy sources. The solar water heating system is the technology to harness the plenty amount of free available solar energy. The solar system is designed to meet the energy demands. The size of the systems depends on availability of solar radiation, temperature requirement of customer, geographical condition and arrangement of the solar system, etc. Therefore, it is necessary to design the solar water heating system as per above parameters. The available literature is reviewed to understand the construction, arrangement, applications and sizing of the solar thermal system.

Keywords: Renewable, Fossil fuel, Active system, Passive system, photovoltaic.

Abstract

Mixing process is a simple yet critical process used in almost field of applications ranging from mechanical, chemical and pharmaceutical industry. A wide spectrum of machines and method are available in market to achieve a good quality of mixture. The most common being a stirrer attached to a geared motor that rotate freely in the container carrying the fluids to be mixed, rate of mixing can be varied by changing the speed of the stirrer. But in process a powder is too mixed with a fluid and if the specific gravity of powder is slightly higher than the vehicle fluid, then the above mentioned stirrer proves ineffective due to effect of centrifugal force on the particles of the powder. In such cases an entirely different approach to mixing is needed where in the stirrer should also have an up-down or to-from motion to ensure that the particles do not settle down in container and there is an enough agitation and turbulence to carry out uniform dispersion of the powder particles all over the mixture. The paper introduces to twin crank agitator mixing mechanism coupled to a rotating container mechanism. The object is to carry out design and analysis of critical components of the twin crank mechanism and also to carry out the productivity test of the machine under consideration.

Keywords: - Powder, Vehicle fluid, Agitator, To -from motion

Abstract                                                 

Digital prototyping and Digital Twin technologies have emerged as transformative tools in modern product development and manufacturing ecosystems. Digital prototyping enables designers and engineers to visualize, simulate, and validate product concepts in virtual environments before physical realization. Digital Twins extend this capability by creating dynamic, data-driven virtual replicas of physical assets that evolve throughout the product lifecycle. The integration of digital prototyping with Digital Twin frameworks has significantly enhanced design accuracy, reduced development time, minimized costs, and improved decision-making across industries such as manufacturing, healthcare, automotive, and smart infrastructure. This paper presents a comprehensive review of digital prototyping techniques, Digital Twin architectures, integration strategies, and industrial applications. Key challenges related to data interoperability, model fidelity, computational complexity, and organizational adoption are discussed. The paper also highlights emerging trends, including AI-driven twins, real-time simulation, and Industry 5.0 alignment. The study concludes that integrated digital prototyping and Digital Twin systems represent a critical enabler for intelligent, sustainable, and resilient product development in the digital era.

Keywords: Digital Prototyping, Digital Twin, Virtual Product Development, Simulation, Industry 4.0, Smart Manufacturing

Abstract

With the rapid digitalization of product design processes and quality management systems, cybersecurity has emerged as a critical concern for manufacturing and engineering organizations. Modern product design environments rely heavily on interconnected tools such as computer-aided design (CAD), product lifecycle management (PLM), digital quality management systems (QMS), and cloud-based collaboration platforms. While these technologies improve efficiency, traceability, and innovation, they also introduce new cyber risks that can compromise intellectual property, product integrity, compliance, and customer safety. This paper reviews the role of cybersecurity in product design and quality systems, highlighting key threats, vulnerabilities, and risk factors across the product development lifecycle. The integration of cybersecurity principles into quality management frameworks is discussed, along with standards, best practices, and emerging technologies supporting secure-by-design and quality-by-design approaches. Challenges faced by organizations, particularly small and medium enterprises, are examined. The paper concludes by emphasizing the need for a holistic strategy that aligns cybersecurity with product quality objectives to ensure sustainable and resilient manufacturing systems.

Keywords: Cybersecurity, Product Design, Quality Management Systems, Secure-by-Design, Digital Manufacturing, Risk Management

Abstract

Industry 4.0 and digital transformation represent a paradigm shift in modern manufacturing, production, and business operations. These concepts leverage cyber-physical systems, Internet of Things (IoT), artificial intelligence (AI), cloud computing, and data analytics to create smart, adaptive, and interconnected systems. As businesses strive for competitiveness, efficient resource utilization, and sustainability, design methods that align with Industry 4.0 principles have become crucial. This paper reviews the latest design methods adopted for Industry 4.0 and digital transformation, emphasizing model-based design, simulation-driven approaches, human-centric design, and agile methodologies. Additionally, challenges, opportunities, and case studies are discussed, providing a comprehensive overview for researchers and practitioners in the field.

Keywords: Industry 4.0, digital transformation, design methods, cyber-physical systems, IoT, smart manufacturing, simulation-driven design, human-centric design.

Abstract

Social sustainability has emerged as a critical dimension of sustainable design, alongside environmental and economic considerations. While much of early sustainability discourse focused on ecological efficiency and cost optimization, recent years have seen growing recognition of the social impacts of design decisions on individuals, communities, and societies. Design for Social Sustainability (DfSS) addresses issues such as equity, inclusion, well-being, cultural preservation, labor conditions, and community resilience through responsible design practices. This paper presents a comprehensive review of the concept of social sustainability in design, its theoretical foundations, key principles, and methodologies. It explores how social sustainability is interpreted across product design, service design, and system-level interventions. The paper also reviews practical tools, assessment frameworks, and real-world case examples that demonstrate socially sustainable design approaches. Challenges, limitations, and future research directions are discussed, highlighting the need for context-sensitive, participatory, and ethically grounded design processes. The study aims to provide designers, researchers, and policymakers with a structured understanding of how social sustainability can be effectively embedded into contemporary design practice.

Keywords: Social sustainability, inclusive design, ethical design, participatory design, sustainable development

Abstract

Design Knowledge Management (DKM) and Automation have emerged as critical enablers in modern product development, engineering, and creative industries. Effective management of design knowledge ensures that organizations can capture, store, retrieve, and reuse critical intellectual assets, thereby enhancing innovation and reducing design cycles. Automation, facilitated by AI, machine learning, and advanced computational tools, further accelerates the design process, improves accuracy, and supports decision-making. This paper reviews current methodologies, frameworks, and technologies for DKM and automation, highlighting integration with collaborative platforms, product lifecycle management (PLM) systems, and digital twins. It also examines challenges in knowledge standardization, intellectual property management, and the balance between human creativity and automated design processes. Case studies across manufacturing, automotive, and aerospace industries illustrate practical applications, and future research directions are discussed to strengthen the synergy between knowledge management and automation.

Keywords: Design Knowledge Management, Knowledge Reuse, Automation, Product Lifecycle Management, Digital Twin, AI in Design, Knowledge Standardization

Abstract

The increasing complexity of global supply chains, combined with rising consumer demand for product transparency, has highlighted the need for innovative technologies that ensure traceability, security, and quality assurance. Blockchain, a decentralized and immutable ledger technology, offers a promising solution to address these challenges by enabling transparent, tamper-proof records of transactions and product histories. This paper reviews the role of blockchain in enhancing supply chain visibility and quality transparency, discussing its principles, applications, challenges, and integration with existing supply chain and quality management systems. The paper also evaluates case studies across industries, including food, pharmaceuticals, and manufacturing, demonstrating blockchain's potential to reduce fraud, improve compliance, and strengthen consumer trust. Finally, recommendations are provided for organizations seeking to adopt blockchain for supply chain and quality management.

Keywords: Blockchain, Supply Chain, Quality Transparency, Traceability, Smart Contracts, Decentralized Ledger, Product Authentication, Digital Twin, Compliance

Abstract

Engineering workflows are becoming increasingly complex due to the growing demand for high product quality, shorter development cycles, and greater customization. Traditional on-premise computing infrastructures often struggle to support these requirements because of limited scalability, high capital cost, and restricted accessibility. Cloud computing has emerged as a powerful solution by offering elastic resources, centralized data management, and collaborative platforms. However, cloud-only architectures face challenges such as latency, bandwidth dependency, and data security concerns, especially in real-time and mission-critical engineering applications. To address these limitations, edge computing has been introduced to bring computation closer to data sources such as machines, sensors, and embedded systems. This paper reviews the role of cloud and edge computing infrastructures in modern engineering workflows, including design, simulation, manufacturing, quality engineering, and maintenance. The study discusses architectural models, key technologies, benefits, challenges, and integration strategies for cloud–edge systems. Practical use cases from engineering domains are analyzed, and future research directions are highlighted. The paper aims to provide a structured understanding of how hybrid cloud and edge computing infrastructures can enhance efficiency, flexibility, and decision-making in engineering workflows.

Keywords: Cloud computing, Edge computing, Engineering workflows, Digital engineering, Smart manufacturing, Hybrid infrastructure

Abstract

In recent market and global requirements, the desires to provide higher level of quality in products and services for increasing market shares continues competitively among the manufacturers to ensure customer satisfaction will return with consistent orders. The important of product and process optimization has caused manufacturers focus greater attention to design optimization in order to stay competitive in the world market. The understanding on the fundamental of basic experimentation will be a starting point to improve process yield, product performance and productivity of company-wide operation. Thus, a more reliable and effective experimental approach subsequently will be the right choice to study the possible design factors that satisfy customers and process compatibility. This study presents the philosophy and method applied for Taguchi method design of experiment. The concept such as quality should be designed into the product, quality loss function, determining the optimization condition for the product or process, designing product and process that insensitive to the influence of uncontrollable factors or noise, signal-to-noise ratio and orthogonal arrays among the important terms in application of Taguchi method design of experiment. Robust Design method, also called the Taguchi Method, pioneered by Dr. Genichi Taguchi, greatly improves engineering productivity. By consciously considering the noise factors (environmental variation during the product’s usage, manufacturing variation, and component deterioration) and the cost of failure in the field the Robust Design method helps ensure customer satisfaction. Robust Design focuses on improving the fundamental function of the product or process, thus facilitating flexible designs and concurrent engineering. Indeed, it is the most powerful method available to reduce product cost, improve quality, and simultaneously reduce development interval.

Keywords: Robust, flexible. improvement, loss function, quality, cost, noise factors, design, strategy, signal, parameter, dynamic, design of experiment, nominal, smaller, larger, etc.

Abstract

India is an agriculture based country which takes various types of crops. Similarly in Maharashtra millet, jowar, wheat, paddy and maize are the main crops. Now days various agricultural machines are available which are very costly .due to this it is not suitable for poor farmers. And all farmers remove crops by hands which has very effort is fully and time consuming process. Some times while cutting or removing crops by hand results into damage due to blisters on hands. Because of this the labours are not available for work, in order to overcome this situation we introduce a new simple but more efficient machine for a farmers.

This machine targets the small scale farmers who have land area of less than 2or3 acres. This machine is compact and can cut up to two rows of wheat, millet, jowar crops. It has cutting blades which cut the crop in a scissoring type of motion. It runs on petrol engine, this power from engine, is provided through shaft, pulley and belt drive arrangement to the cutting blades. This compact crop cutter is manufactured using locally available spare parts and thus, it is easily maintainable. This crop cutter might be the solution to the problems faced by a small scale farmer regarding cost and labour implementation.

Keywords: Crop cutter, Maize, Jowar, Millet, Blister, Harvesting, Reaper.etc

Abstract

Increased urbanization and increase in population has led to an increased demand for fuels. The result is the prices of fuels are reaching new heights every day. The diesel engines has led to the  emission of hazardous gases like Sulphur oxides, nitrogen oxides and carbon monoxide, which can further led to problems like acid rain. These emissions can also affect human health and increase global warming which has led to the need for alternate fuels. Biodiesel is one of the alternatives which are being widely studied and its production from oil seeds is limited by crop land displacement. Production of biodiesel from algae is a promising option. The present work aims to focus on the performance of diesel engine with algae oil as fuel. The properties of algae oil blends with diesel are tested in a variable compression ratio engine (VCR engine) and its performance and emission characteristics are studied.

Keywords: - VCR engine, Algae Oil, Sulphur oxides, Algae Biofuel

Abstract

The environmental pollution is a major concern today as the contaminants are introduced into the natural environment. This, in turn causes the adverse change the environment leading to hazardous cause on human life and others. Further, the effect of the pollution is irreversible. Environmental issues can be resolved through a controlled process or through a use the natural process. The use of fossil fuels and industrialization is another factor which leads to environmental pollution.

The current work on Design and development of Hybrid Renewable Energy System is the possible solution to provide a continuous energy to the users. This work is based on the two renewable energy resources namely, solar and wind. The proposed solution utilizes a 20W solar panel and a wind turbine with maximum output of 35W. The whole system is governed and controlled by the centralized controller developed using Peripheral Interface Controller PIC16F877A.

 The Hybrid system has voltage and current measurement features to monitor the generation of the power from solar, wind and the amount of power consumed at the user end. The System is a standalone system which can supply both DC and AC load. The system has an inverter as one of its subsystem at the load side to invert DC power into AC power. System has a display system to monitor the electrical parameters such as solar voltage, solar current, wind voltage, wind current, load voltage and load current. Over above, system shows the solar power, wind power, the power delivered to the load. Thus the proposed system is complete solution of hybrid renewable energy system with all features of control and monitoring.

Keywords: Renewable energy, Hybrid, Wind generation, Wind turbine