Journal of Product Design, Quality Engineering & Technology

Abstract

Rapid Prototyping (RP) through Additive Manufacturing (AM) has emerged as a transformative approach in modern product design and manufacturing. By enabling the quick fabrication of physical models directly from digital designs, RP accelerates product development, reduces costs, and enhances design flexibility. This review paper presents a comprehensive overview of RP technologies, materials, processes, and applications. The paper explores different additive manufacturing techniques, their advantages and limitations, and the role of RP in various industries, including automotive, aerospace, healthcare, and consumer products. Additionally, emerging trends such as hybrid manufacturing, multi-material printing, and sustainable practices are discussed. The paper concludes with future directions and challenges for RP in industrial and research settings.

Keywords: Rapid Prototyping, Additive Manufacturing, 3D Printing, Product Development, Digital Fabrication, Material Science, Industrial Applications

Abstract

Sustainable manufacturing has emerged as a critical requirement for modern industries due to increasing environmental concerns, resource scarcity, and stricter regulatory frameworks. Quality engineering plays a significant role in enabling sustainability by ensuring that products and processes meet performance requirements while minimizing waste, energy consumption, and environmental impact. This paper presents a comprehensive review of quality engineering principles, tools, and methodologies applied to sustainable manufacturing systems. Traditional quality approaches such as Statistical Process Control (SPC), Design of Experiments (DoE), and Total Quality Management (TQM) are revisited from a sustainability perspective, along with modern practices like Six Sigma, Lean, and digital quality tools. The integration of quality engineering with life cycle thinking, eco-design, and Industry 4.0 technologies is discussed in detail. Case-based insights from manufacturing sectors such as automotive, electronics, and process industries are also reviewed. The paper highlights benefits, challenges, and future research directions, emphasizing that quality engineering is not only a means of defect reduction but also a strategic driver for sustainable manufacturing performance.

Keywords: Quality engineering, sustainable manufacturing, Six Sigma, process optimization, life cycle quality, Industry 4.0

Abstract

Quality by Design (QbD) is a proactive approach that emphasizes designing quality into products and processes from the earliest stages of development rather than relying solely on post-production inspection. Originating in the pharmaceutical industry, QbD frameworks are now widely applied across multiple engineering domains, including manufacturing, software, automotive, and electronics. This paper presents a comprehensive review of QbD frameworks in engineering, highlighting their principles, methodologies, implementation strategies, and impact on product quality, process efficiency, and regulatory compliance. The paper also explores challenges, future trends, and case studies demonstrating successful QbD applications. By integrating QbD into engineering workflows, organizations can enhance reliability, reduce defects, and optimize resources, aligning with the goals of modern engineering excellence.

Keywords: Quality by Design, Engineering, Risk Assessment, Process Optimization, Design of Experiments, Quality Management, Reliability, Regulatory Compliance.

Abstract

Multi-sensory and immersive design has emerged as a critical area of research with the rapid advancement of Augmented Reality (AR) and Virtual Reality (VR) interfaces. Unlike traditional screen-based interactions, immersive systems aim to engage users through multiple sensory channels including vision, hearing, touch, and, increasingly, smell and proprioception. This shift enables deeper user engagement, improved task performance, and enhanced experiential quality across domains such as education, healthcare, manufacturing, entertainment, and product design. This review paper explores the evolution of multi-sensory immersive design, core design principles, enabling technologies, and interaction paradigms used in AR/VR interfaces. It also discusses user experience considerations, challenges related to usability and accessibility, and ethical implications. Through analysis of current literature and real-world applications, the paper highlights how multi-sensory integration can improve presence, embodiment, and emotional engagement. The paper concludes by identifying emerging research directions, including adaptive sensory systems, AI-driven personalization, and sustainable immersive design frameworks.

Keywords: Multi-sensory design, immersive interfaces, augmented reality, virtual reality, human–computer interaction, user experience

Abstract

Virtual prototyping has emerged as a critical methodology in modern product development, enabling engineers and designers to evaluate product performance, functionality, and manufacturability before physical realization. With the advancement of CAx (Computer-Aided technologies) and CAE (Computer-Aided Engineering) systems, virtual prototypes now represent not only geometry but also behavior, physics, and lifecycle characteristics of products. This paper presents a comprehensive review of virtual prototyping through CAx/CAE systems, discussing its evolution, key components, simulation techniques, workflows, and industrial applications. The integration of CAD, CAE, CAM, and PLM platforms is examined, along with benefits such as reduced development time, cost savings, and improved design quality. Challenges related to model accuracy, computational cost, and skill requirements are also highlighted. The paper concludes by identifying future trends including AI-driven simulation, real-time virtual validation, and integration with Digital Twin technologies. Overall, virtual prototyping is positioned as a foundational pillar of Industry 4.0 and next-generation product design practices.

Keywords: Virtual Prototyping, CAx Systems, CAE Simulation, Computer-Aided Design, Product Development, Digital Engineering

Abstract

The increasing environmental degradation, resource scarcity, and growing waste generation have made sustainable and circular product design a critical research and industrial focus. Traditional linear product development models based on “take–make–dispose” approaches are no longer viable in the long term. Sustainable and circular product design aims to minimize environmental impact, extend product life cycles, and promote material circularity through reuse, remanufacturing, and recycling. This paper presents a comprehensive review of sustainable and circular product design concepts, principles, and methodologies. It discusses key strategies such as eco-design, life cycle thinking, material selection, modularity, and design for disassembly. The role of circular economy frameworks and industrial implementation challenges are also examined. Case-based examples and comparative analysis are included to highlight practical design considerations. Finally, the paper outlines emerging trends and future research directions in sustainable product innovation. The study concludes that integrating sustainability and circularity at the early design stage is essential for achieving long-term environmental and economic benefits.

Keywords: Sustainable product design, Circular economy, Eco-design, Life cycle assessment, Design for disassembly, Circular manufacturing

Abstract

This project will outline the issues and approaches involved in skid design for static loads such as in pressure vessels. The project presents the study of performance characteristics of the support frame structures also called as skid frame, according to changes in their connections, considering the loads caused by machine has been done and compared with the limits of displacements of the structures. Skid Base Frame is a structural assembly consisting of beams of various cross sections and dimensions. The base frame is subjected to gravitational loading of all the components mounted like as Compressor, Air Receiver vessel etc. The frame discussed in this report was designed with conventional CAD design practices and then analysed statically with FEA software.

The analysis was carried out to determine the induced stresses and the deflections at various locations on proposed frame. The structure was optimized to reduce weight. In this project the experimental and Finite Element Analysis of skid Frame for Rigidity is been carried out. The base frame is analysed using Hyper mesh and ANSYS software. The static loads are applied on the frame and analysis is carried out. The test is carried out to check the conformance of the existing design. The skid base frame is modified for making a stiffer design within the allowable stress limits. Based on these results, best feasible design solution is proposed and validated experimentally.

Keywords: Skid Base Frame, CAD model, FEA loading, Static Analysis, Weight Optimization

Abstract

The aim of this project is experimental investigation of hydrodynamic journal bearing using nano particle added lubricating oil. Adding nanoparticles is the basic requirement to increase the viscosity of commercial lubricants in order to improve their performance characteristics. In this paper, we will present the observation of pressure distribution at the clearance space of a journal bearing.

CuO + ZnO nanoparticles were used in this project. We prepared CuO +ZnO based nano particles and used them in a lubricant at various volume ratios. It has been found that these samples exhibit good dispersion stability. An experimental analysis is  carried out using nanoparticle based  lubricant samples with different CuO + ZnO volume fractions to study the pressure generation and distribution in a lubricating layer of hydrodynamic bearing with increasing CuO + ZnO nanoparticle concentrations and varying loads on bearing. Bearing testing device will be used to carry out pressure generation and distribution of pressure related measurements. Readings were taken. Moreover, at various loads, pressure related measurements were obtained. Conventional (non nano fluid added lubricant) bearing underwent the same testing procedure.

Keywords: Nano Particle Performance, Lubricating Oil, Hydrodynamic Journal Bearing

Abstract

The aim of this project is experimental investigation of hydrodynamic journal bearing using nano particle added lubricating oil. Adding nanoparticles is the basic requirement to increase the viscosity of commercial lubricants in order to improve their performance characteristics. In this paper, we will present the observation of pressure distribution at the clearance space of a journal bearing.

CuO + ZnO nanoparticles were used in this project. We prepared CuO +ZnO based nano particles and used them in a lubricant at various volume ratios. It has been found that these samples exhibit good dispersion stability. An experimental analysis is  carried out using nanoparticle based  lubricant samples with different CuO + ZnO volume fractions to study the pressure generation and distribution in a lubricating layer of hydrodynamic bearing with increasing CuO + ZnO nanoparticle concentrations and varying loads on bearing. Bearing testing device will be used to carry out pressure generation and distribution of pressure related measurements. Readings were taken. Moreover, at various loads, pressure related measurements were obtained. Conventional (non nano fluid added lubricant) bearing underwent the same testing procedure.

Keywords: Hydrodynamic journal bearing, Nanolubricant, CuO nanoparticles, ZnO nanoparticles, Pressure distribution, Viscosity enhancement, Bearing performance, Load variation, Nano-additive lubricants

Abstract

Mixed Reality (MR), an integration of Augmented Reality (AR) and Virtual Reality (VR), is increasingly transforming prototyping workflows in design and manufacturing domains. This paper reviews the current trends, methodologies, and applications of MR in prototyping, highlighting its advantages over traditional workflows. By enabling immersive visualization, interactive simulations, and real-time collaboration, MR facilitates faster iteration, cost reduction, and enhanced design accuracy. The paper also discusses technical frameworks, software tools, hardware systems, and challenges associated with MR adoption. Finally, future directions and potential innovations in MR-based prototyping are outlined.

Keywords: Mixed Reality, Prototyping, Augmented Reality, Virtual Reality, Digital Prototyping, Workflow Optimization, Immersive Design, Human-Computer Interaction

Abstract

Lean Six Sigma (LSS) has emerged as one of the most influential managerial and technical approaches for improving quality systems across manufacturing and service industries. By integrating the waste-reduction philosophy of Lean with the variation-reduction and data-driven rigor of Six Sigma, organizations are able to achieve sustainable performance improvements in quality, cost, delivery, and customer satisfaction. This paper presents a comprehensive review of Lean Six Sigma within the context of quality systems. It discusses the historical evolution of Lean and Six Sigma, the core principles and tools of Lean Six Sigma, and its alignment with modern quality management systems such as ISO 9001 and Total Quality Management (TQM). The paper further explores the DMAIC methodology, organizational roles, critical success factors, and challenges in implementation. Applications across different sectors, including manufacturing, healthcare, and services, are reviewed to highlight practical benefits and limitations. The study concludes that Lean Six Sigma remains a relevant and adaptable framework for quality systems, especially when supported by leadership commitment, employee engagement, and a culture of continuous improvement, though contextual adaptation is often necessary.

Keywords: Lean Six Sigma, Quality Systems, Continuous Improvement, DMAIC, Process Optimization

Abstract

Predictive design optimization has emerged as a critical area in modern engineering and product development due to increasing system complexity, shorter development cycles, and rising demand for customized products. Traditional design optimization techniques, while effective for small-scale problems, often struggle with high-dimensional design spaces, nonlinear interactions, and uncertain operating conditions. Machine Learning (ML) offers a powerful alternative by learning patterns from historical and simulated data to predict performance outcomes and guide design decisions. This review paper explores the role of machine learning techniques in predictive design optimization, covering key algorithms, workflows, data requirements, and integration with simulation-based design. Applications across manufacturing, automotive, aerospace, civil engineering, and consumer product design are discussed in detail. The paper also highlights current challenges such as data scarcity, model interpretability, and generalization, along with future research directions. Overall, machine learning-driven predictive design optimization represents a shift from reactive trial-and-error approaches to proactive, data-informed design strategies.

Keywords: Predictive design, machine learning, design optimization, surrogate models, data-driven design, intelligent engineering systems

Abstract

Heat transfer enhancement by adding solid nano-particles to liquids for many industrial applications has gained a lot of interest of late. This paper discusses nanoparticles dispersed in water as a base fluid conducted in a car radiator experimentally. Four different concentrations of Nano fluids (Al2O3) in the range of 2%, 2.5%, 3% and 3.5% were used in the experiment. The flow rate changed in the range of 550 LPH to 650 LPH. There are many different applications of thermal-fluid systems, including automotive cooling systems. Base fluids, such as water, ethylene glycol and glycerol were used as conventional coolants in automobile radiators. The results showed that as the concentration of Nano fluid increases, temperature difference also increases the cooling effect.

Keywords: Nano fluid , Heat transfer, Fluid Flow

Abstract

A solar dryer was modified with application of force convection to develop a more efficient drier by using a flat plate collector for multiple fruits. In the last decade or two, many solar dryers have been invented in which the span of drying is about 3 to 5 days, but these conventional methods don’t maintain purity of fruits. In this paper, the invention of a new dryer, in which time span was reduced to some extent, is discussed. The solar dryer which we have fabricated reduces drying time by 1 to 2 days and also maintains purity and nutrition.

In our project entitled “Design and Development of Solar Dryer for Multiple Fruits”, we used force convection method which differs from conventional methods. Solar dryer was fabricated with force convection in order to improve the efficiency and productivity of food crops to a large extent. In a solar dryer, when the sun rays are incident over flat plate collector, the black coated surface of the collector gets heated and temperature inside it increases. The fan placed in front of the collector blows the hot air from collector to the drying chamber. Due to this, the grapes placed on the first grate get heated, which in turn reduces the moisture of the fissured content in the grapes. The remaining hot air is then passed to the next grate and so on. After hot air passes from the third grate, this air is then recirculated with the help of a PVC pipe. The first end of this pipe is connected to the top of the drying chamber and last end is connected to the fan. All these modifications help to increase the efficiency of a solar dryer.

Keywords: Solar Dryer, Force Convection, Flat Plate Collector