What's the Design Philosophy Behind DesignLab?

[Rida]

Introduction:

DesignLab is an application-driven, interdisciplinary learning space where students bring their ideas to life through 3D modeling, digital fabrication, and physics-based design principles. This module goes beyond teaching students how to use design software and 3D printers —it fosters a deep understanding of engineering, physics, and material science by encouraging students to create, refine, and optimize real-world products.

By integrating spatial reasoning, structural physics, and problem-solving, DesignLab empowers students to explore how objects are designed, built, and improved —bridging concepts from MeasureLab (material properties, forces, thermodynamics) and RoboticsLab (mathematical modeling, computational logic) into a tangible, hands-on experience.

Learning Approach & Design Philosophy:

DesignLab is rooted in inquiry-based learning, where students progress from conceptualizing ideas to fabricating real-world objects while developing an engineering mindset. Rather than simply learning software tools, they engage in problem-solving and iterative design, questioning:

Why do certain structures fail while others hold up?
Why are support structures needed in 3D printing?
How do temperature and environmental factors affect materials?
How can we optimize designs for strength while reducing material waste?

Through a progressive, grade-wise curriculum, students develop the ability to:

Use industry-standard CAD software (TinkerCad → OnShape → OpenSCAD)
Understand physics-based design principles (forces, material properties, thermodynamics)
Solve real-world engineering problems through prototyping and iteration
Create replacement parts & functional designs to enhance everyday objects
Collaborate on large-scale projects, integrating mathematics, programming, and fabrication

Inquiry-Based Exploration & STEM Integration:

DesignLab seamlessly connects engineering, physics, and computational thinking with hands-on making. Key interdisciplinary links include:

MeasureLab Integration: Heat, force distribution, material stability, environmental effects on fabrication.
RoboticsLab Integration: Precision measurement, mathematical reasoning, algorithmic modeling for structural design.
Physics & Engineering Concepts: Strength optimization, structural integrity, thermodynamics, forces in material behavior.

Through guided experimentation, which follows scaffolding principles, and real-world problem-solving, to develop high-order thinking, students cultivate design thinking, making DesignLab a powerful interdisciplinary gateway to engineering, robotics, and applied science.

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This graph illustrates the Evolution of the Maker Mindset in the MeasureLab Design Lab (modeled on Vygotsky’s Zone of Proximal Development), tracing the journey from tactile exploration to professional engineering.

The Design Lab Journey:

• The Center (Grade 1 - The Tactile Maker): Represents Physical Intuition. Students start by manipulating clay and blocks, understanding that “making” is about adding material layer by layer and that stability requires a solid foundation.
• The Expanding Rings (Grades 2-7): Represent the Technical Skill Growth Zone. As learners progress, they move from physical blocks to digital voxels (TinkerCad), then to parametric sketches (OnShape). They learn to “speak the language” of manufacturing—constraints, tolerances, and assembly.
• The Outer Edge (Grade 8 - The Product Engineer): Represents System Integration. At this level, students are no longer just making “shapes”; they are engineering functional systems with moving mechanisms, optimizing for strength-to-weight ratios, and designing for mass production.

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Grade 0

• Model with Clay (5)@[/t/046]: Mold clay or play-dough to understand “additive manufacturing”—building an object by adding material layer by layer.
• Stack for Stability (5)@[/t/047]: Stack wooden blocks or LEGOs to discover gravity, balance, and the need for a wide base (foundation).
• Sort 3D Shapes (4)@[/t/048]: Tactilely distinguish between a sphere, cube, and cylinder, learning the names of the “primitive shapes” used in CAD.
• Extrude with Cutters (3)@[/t/049]: Use cookie cutters on dough to understand how a 2D shape (profile) becomes a 3D object (extrusion).
• Assemble Snap-Toys (4)@[/t/050]: Connect pop-beads or magnetic tiles to build motor skills and understand how parts join together.
• Explore Textures (3)@[/t/051]: Touch different materials (smooth plastic, rough wood, soft fabric) to begin building a vocabulary of material properties.
• Trace Patterns (3)@[/t/052]: Follow lines and shapes on paper to develop the fine motor control needed for mouse/trackpad usage later.
• Practice Tool Safety (5)@[/t/053]: Learn not to touch “hot” things and to handle blunt scissors carefully, preparing for lab safety rules.

Grade 1

• Explore 3D Shapes (3)@[/t/46]: Handle physical and digital 3D shapes (cubes, cones) to understand how complex objects are built from simple blocks.
• Try Virtual Modeling (5)@[/t/46]: Use TinkerCad to drag, drop, and stack “virtual blocks” to create their first digital model.
• Personalize Designs (4)@[/t/46]: Modify a basic shape (like a coin or badge) by adding initials or symbols to make it unique.
• Observe Printing (2)@[/t/46]: Watch a 3D printer in action to understand how digital files become physical objects layer by layer.
• Finish & Decorate (2)@[/t/46]: Paint and clean up printed objects to learn that post-processing is part of the making process.
• Assemble Parts (4)@[/t/46]: Work in groups to combine simple printed parts into a larger structure (e.g., a toy house).
• Identify Lab Safety (5)@[/t/46]: Learn the basic “Do’s and Don’ts” of the 3D printing lab, focusing on hot nozzles and moving parts.
• Spark Design Curiosity (1)@[/t/46]: Discuss “how things are made” to shift mindset from consumer to creator.

Grade 2

• Manipulate Digital Forms (5)@[/t/47]: Master resizing, rotating, and aligning shapes in TinkerCad to create recognizable objects like houses.
• Design Functional Art (4)@[/t/47]: Create a personalized keychain, learning to combine text and geometry into a single printable object.
• Analyze Print Failures (6)@[/t/47]: Examine failed prints to understand “overhangs” and why gravity matters in 3D design.
• Plan for Scale (3)@[/t/47]: Understand that the size on the screen must match the desired size in the real world.
• Collaborate on Cities (4)@[/t/47]: Design individual buildings that fit together into a class “Village,” introducing spatial planning.
• Practice File Hygiene (2)@[/t/47]: Learn to name, save, and export files correctly for the printing process.
• Safely Remove Prints (3)@[/t/47]: Practice using a spatula to detach prints from the bed without damaging the object or the machine.
• Iterate Designs (5)@[/t/47]: Modify a design after seeing a test print to fix errors or improve the look.

Grade 3

• Measure for Fit (6)@[/t/48]: Use calipers and rulers to measure real-world objects and replicate those dimensions in TinkerCad.
• Design Replacement Parts (7)@[/t/48]: Solve a real problem by designing a simple part (like a missing button or game piece) that fits an existing object.
• Understand Tolerances (5)@[/t/48]: Learn that a 5mm peg won’t fit in a 5mm hole; introduce the concept of “clearance” or “gap.”
• Use Alignment Tools (4)@[/t/48]: Move beyond manual placement to use software “Align” tools for perfect centering and symmetry.
• Group & Subtract (5)@[/t/48]: Master the “Hole” function to create complex shapes by subtracting geometry (e.g., making a cup).
• Optimize Print Orientation (4)@[/t/48]: Rotate digital models to minimize the need for support structures and speed up printing.
• Explore Infill & Shells (3)@[/t/48]: Learn that 3D prints are mostly hollow; decide how strong (infill %) an object needs to be.
• Critique Peer Designs (3)@[/t/48]: Offer constructive feedback on a classmate’s design to improve functionality.

Grade 4

• Design Simple Mechanisms (7)@[/t/50]: Create objects with moving parts, such as a simple hinge or a wheel that spins on an axle.
• Master “Snap-Fits” (6)@[/t/50]: Design parts that connect without glue, relying on friction or flexible tabs (snap-fits).
• Create Boxes & Lids (5)@[/t/50]: Design a container with a fitted lid, applying knowledge of offset and tolerance.
• Reverse Engineer (6)@[/t/50]: Take apart a simple toy to analyze how it was designed, then recreate a component digitally.
• Use Mirroring Patterns (4)@[/t/50]: Use the “Mirror” and “Duplicate” tools to create complex, symmetrical patterns efficiently.
• Prepare Slicer Settings (5)@[/t/50]: Learn to slice a model for printing, adjusting layer height for speed vs. quality.
• Troubleshoot Adhesion (4)@[/t/50]: Identify why prints curl or detach (warping) and apply brims or rafts to fix it.
• Document Design Process (3)@[/t/50]: Keep a design log sketching the idea before modeling it.

Grade 5

• Design for Assembly (DFA) (7)@[/t/52]: Create multi-part projects (like a robot) where 3+ parts must screw or snap together.
• Introduction to Threads (6)@[/t/52]: Model basic screw threads or recesses for nuts and bolts to create strong mechanical connections.
• Optimize Material Use (5)@[/t/52]: Redesign a bulky object to use less plastic without losing strength (topology optimization basics).
• Explore Flexible Materials (4)@[/t/52]: Experiment with TPU (flexible filament) design constraints compared to rigid PLA.
• Master Support Structures (5)@[/t/52]: Manually place or block supports in the slicer to ensure clean overhangs and bridges.
• Conduct Stress Tests (6)@[/t/52]: Print and break structural beams to test which infill pattern is strongest.
• Import External Vectors (4)@[/t/52]: Import SVG files (logos/shapes) into TinkerCad to extrude 2D drawings into 3D.
• Pitch a Product (3)@[/t/52]: Present a design concept as a “product” to the class, explaining its features and benefits.

Grade 6

• Intro to Parametric CAD (8)@[/t/54]: Transition from TinkerCad to OnShape/Fusion360; learn to sketch 2D profiles and extrude.
• Apply Geometric Constraints (7)@[/t/54]: Use constraints (parallel, tangent, coincident) to lock sketches instead of just dragging lines.
• Use Revolve & Sweep (6)@[/t/54]: Create cylindrical or tubular shapes (like bottles or pipes) using advanced modeling tools.
• Design Ergonomic Grips (5)@[/t/54]: Design a handle or grip that fits comfortably in a human hand, focusing on organic shapes.
• Loft Complex Shapes (6)@[/t/54]: Connect two different shapes (e.g., circle to square) using the Loft tool.
• Analyze Slicer G-Code (4)@[/t/54]: Preview the toolpath (G-code) to understand exactly how the nozzle will move.
• Manage Filament Changes (3)@[/t/54]: Learn to pause a print to change colors for a multi-colored effect.
• Collaborative Assembly (5)@[/t/54]: Work as a team where each student designs one component of a larger machine.

Grade 7

• Master Advanced Sketching (8)@[/t/52]: Use splines, offsets, and patterns in OnShape to create professional-grade sketches.
• Iterate Prototypes (9)@[/t/52]: Print a “rough draft,” identify flaws, modify the CAD, and print a V2 (rapid prototyping cycle).
• Maintain 3D Printers (6)@[/t/52]: Perform basic maintenance: unclog nozzles, level the bed, and lubricate axes.
• Design for Manufacturing (7)@[/t/52]: Optimize designs to be mass-produced (e.g., no supports needed, stackable).
• Integrate Electronics (8)@[/t/52]: Design casings that fit PCBs, batteries, and switches (integrating with electronics labs).
• Analyze Wall Thickness (5)@[/t/52]: Determine the minimum wall thickness required for structural integrity vs. flexibility.
• Simulate Material Loads (7)@[/t/52]: Use basic simulation (if available) or calculation to predict where a part will break.
• Showcase Innovation (4)@[/t/52]: Present a final project that solves a community problem using Design Thinking.

Grade 8

• Engineer Compliant Mechanisms (9)@[/t/55]: Design mechanisms that move by bending (living hinges) rather than using separate joints.
• Optimize for Strength/Weight (8)@[/t/55]: Challenge: Design the lightest possible bridge that can hold a specific weight.
• Master Assembly Mates (7)@[/t/55]: Use “Mates” in OnShape to digitally assemble and animate parts to check for collisions before printing.
• Reverse Engineer Complex Parts (8)@[/t/55]: Use calipers to measure a complex broken part (e.g., a car handle) and recreate it perfectly.
• Design Custom Gears (7)@[/t/55]: Calculate and model functional spur or bevel gears for a transmission system.
• Explore Sacrificial Molds (6)@[/t/55]: 3D print a mold to cast silicone or plaster, extending making beyond plastic.
• Lead Design Reviews (5)@[/t/55]: Critique other students’ CAD files for “printability” and efficiency errors.
• Execute Capstone Project (10)@[/t/55]: Identify a real-world client/problem, interview them, design a solution, and deliver a functional prototype.

Grade 9

• Master Surface Modeling (5)@[/t/946]: Use advanced CAD (Rhino/Fusion 360) to create Class-A ergonomic surfaces with complex curvature (NURBS).
• Run FEA Simulations (5)@[/t/947]: Perform Finite Element Analysis to digitally stress-test a part and predict failure points before printing.
• Design for Molding (4)@[/t/948]: Design parts specifically for injection molding, incorporating draft angles, uniform wall thickness, and parting lines.
• Utilize Generative Design (4)@[/t/949]: Use AI-driven tools to generate organic, topology-optimized structures that minimize weight and maximize strength.
• Print with Composites (5)@[/t/950]: Print with advanced materials like Carbon Fiber Nylon or Polycarbonate for functional, end-use parts.
• Reverse Engineer Scans (4)@[/t/951]: Take 3D scan data (point clouds) and convert it into a clean, editable solid body CAD model.
• Automate with Scripts (3)@[/t/952]: Use Python or CAD-specific scripting (FeatureScript) to automate the creation of repetitive design features.
• Execute Product Launch (5)@[/t/953]: Capstone: Take a product from concept to “shelf-ready” prototype, including packaging design and bill of materials (BOM).

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