12/22/24, 7:14 PM 500+ Design Engineer Interview Questions & Answers for Experienced (Updated 2024) | AmbitionBox

Design Engineer

500+ Design Engineer Interview Questions and Answers for Experienced

Updated 26 Nov 2024

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Q1. Which are the operations performed on sheet metal to increase the strength of it without changing thickness?
Ans. Operations like bending, folding, and crimping can increase the strength of sheet metal without changing its thickness.
Bending: This process involves bending the sheet metal along a straight line to increase its strength.
Folding: Folding the sheet metal creates multiple layers, increasing its strength.
Crimping: Crimping involves creating small indentations or folds in the sheet metal to increase its rigidity.
Rolling: Rolling the sheet metal can also increase its strength by compacting the material.

Embossing: Adding embossed patterns can strengthen the sheet metal without changing its thickness.
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Q2. 1. what are the considerations while selecting engineering materials for specific applications? 2. How would you calculate
sheer strength of a round cross section metal bar? 3. Explain your project work.
Ans. Considerations for selecting engineering materials, calculating sheer strength of a metal bar, and explaining project work.
Consider factors like strength, durability, cost, and availability when selecting materials for specific applications.
Calculate sheer strength of a round cross section metal bar using the formula: Sheer Strength = (0.5 * Ultimate Tensile Strength)
In project work, explain the objectives, methodology, results, and any challenges faced.
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Q3. What are the Piping code used in designing a chemical plant?
Ans. ASME B31.3, ASME B31.1, API 650, API 620 are some of the piping codes used in designing a chemical plant.

ASME B31.3 is used for process piping

ASME B31.1 is used for power piping

API 650 is used for storage tanks

API 620 is used for low-pressure storage tanks

Other codes like ASTM, ANSI, and ISO may also be used depending on the specific requirements of the project

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Q4. Do u have design knowledge in Solidworks and Autocad software?

Ans. Yes, I have design knowledge in both Solidworks and Autocad software.
I have extensive experience using Solidworks and Autocad for designing various mechanical components and systems.

I am proficient in creating 3D models, assemblies, and detailed drawings using both software.
I have successfully completed multiple design projects using Solidworks and Autocad, meeting all the required specifications and standards.

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I am familiar with the advanced features and tools in both software, such as parametric modeling, simulation, and rendering.

I have a strong understanding of design principles and can effectively translate concepts into practical designs using Solidworks and Autocad.
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Q5. How to solve plastic defects like: short mold in injection molding?
Ans. To solve short mold defects in injection molding, adjust injection speed, pressure, temperature, and cooling time.
Adjust injection speed to ensure proper filling of the mold cavity.

Increase injection pressure to prevent short shots.

Optimize melt temperature to improve flow and reduce defects.

Extend cooling time to allow the plastic to solidify properly.

Check for any obstructions or blockages in the mold.

Ensure proper venting to prevent air traps.

Use mold flow analysis software to identify potential issues before production.
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Q6. what is diff b/w low beam light & high beam light in automobile?
Ans. Low beam light provides short-range visibility without blinding oncoming drivers, while high beam light provides long-range visibility but can
blind others.
Low beam light is angled downwards to illuminate the road directly in front of the vehicle.

High beam light is angled upwards to illuminate a longer distance ahead of the vehicle.

Low beam light is used in normal driving conditions to avoid blinding oncoming drivers.
High beam light is used in dark, unlit areas or when there is no oncoming traffic.

Examples: Low beam light is typically used in city driving, while high beam light is used on highways or rural roads.

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Q7. the possibility of negative slip in reciprocating pump is when?

Ans. Negative slip in reciprocating pump occurs when the pump runs faster than the synchronous speed of the motor.

Negative slip occurs when the pump runs faster than the synchronous speed of the motor.

This can happen if the pump is not properly matched to the motor or if there is a mechanical issue causing the pump to run faster.

Negative slip can lead to decreased efficiency and potential damage to the pump.
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Q8. 6. what is warpage & sink marks in plastic & how to prevent?
Ans. Warpage and sink marks are common defects in plastic parts caused by uneven cooling. Prevention methods include proper gate design, cooling
system optimization, and material selection.

Warpage is the deformation of a plastic part due to uneven cooling, leading to dimensional inaccuracies.

Sink marks are depressions on the surface of a plastic part caused by uneven cooling and shrinkage.
Prevention methods include proper gate design to ensure uniform filling, optimization of cooling system to promote even cooling, and material
selection with lower shrinkage rates.

Using ribbing or thicker sections in the design can help reduce warpage and sink marks.

Adjusting processing parameters such as injection speed and pressure can also help prevent warpage and sink marks.

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Q9. How much tonnage molding machine are required fill 200gm peace? Which method are used?
Ans. The tonnage of molding machine required to fill a 200gm piece depends on the material being used and the design of the piece.

Calculate the volume of the 200gm piece to determine the amount of material needed.

Consider the material properties and flow characteristics to determine the appropriate tonnage of the molding machine.
Methods such as injection molding or compression molding can be used depending on the design and material of the piece.

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Q10. How to solve manufacturing problems & how to co-relate the design?
Ans. To solve manufacturing problems and correlate design, it is important to analyze root causes, communicate effectively with cross-functional
teams, and iterate on design improvements.

Identify the root cause of the manufacturing problem by analyzing data and conducting tests.

Communicate effectively with cross-functional teams including manufacturing, quality, and design engineers to understand the impact of the
problem on the design.

Iterate on design improvements based on feedback from manufacturing and quality teams to prevent future issues.

Use tools such as Failure Mode and Effects Analysis (FMEA) to anticipate potential manufacturing problems during the design phase.

Implement Design for Manufacturing (DFM) principles to ensure that the design is optimized for efficient and cost-effective production.
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Q11. From your experience what are the factors that needs to be considered while designing a component for sheet metal and
plastic?
Ans. Factors to consider when designing components for sheet metal and plastic

Material selection based on properties and application requirements

Design for manufacturability to ensure ease of production and cost-effectiveness

Consideration of material thickness and bending radius for sheet metal components
Wall thickness, draft angles, and rib design for plastic components

Integration of features like fastening methods, mounting points, and assembly considerations

Evaluation of environmental factors like temperature, humidity, and chemical exposure

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Design

Q12. how to sense flow transmitter to transmit signal to controller in selected range?
Ans. Flow transmitter senses flow and transmits signal to controller in selected range.
Use a flow transmitter that is capable of sensing flow and transmitting a signal.
Connect the flow transmitter to the controller using appropriate wiring and communication protocols.

Configure the flow transmitter to operate within the desired range.

Ensure proper calibration of the flow transmitter to accurately measure and transmit flow data.

Implement suitable signal conditioning techniques to ensure reliable transmission of the signal.
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Q13. what is rib thickness consideration in plastic component? why are use rib in plastic component?

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Ans. Rib thickness in plastic components is important for strength and stiffness. Ribs are used to improve structural integrity and reduce warping.
Rib thickness affects the strength and stiffness of the plastic component

Ribs are used to improve structural integrity and reduce warping in plastic components
Proper rib thickness can prevent sink marks and improve mold filling during injection molding
Rib thickness should be optimized based on the specific design requirements and material properties

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Q14. Tell about the tools used for design

Ans. Design tools include CAD software, 3D printers, prototyping equipment, and simulation software.
CAD software such as SolidWorks, AutoCAD, and CATIA are used for creating 2D and 3D designs

3D printers are used for rapid prototyping and creating physical models
Prototyping equipment such as CNC machines and laser cutters are used for creating functional prototypes

Simulation software such as ANSYS and COMSOL are used for testing and analyzing designs
Other tools include hand sketching, whiteboards, and brainstorming sessions
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Design

Q15. How I2C communication protocol works what things needs to be taken care while designing for I2C peripheral ,pull-up
resistors etc
Ans. I2C is a serial communication protocol used to connect multiple devices with two wires. Pull-up resistors are necessary for proper
communication.

I2C uses a master-slave architecture where the master initiates communication.

Each device on the bus has a unique address assigned to it.

Data is transmitted in packets with a start and stop bit.

Pull-up resistors are necessary to ensure proper voltage levels on the bus.
The value of the pull-up resistor depends on the capacitance of the bus and the speed of communication.

Care should be taken to avoid bus contention where multiple devices try to communicate at the same time.
I2C supports multiple speeds and modes of operation.

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Q16. What can you di in solid works? Bom, Weldment, Sheetmetal, Part design, assembly, analysis, drawings, details?
Ans. I can do various tasks in SolidWorks including part design, assembly, sheet metal, weldment, BOM, analysis, drawings, and details.
Proficient in SolidWorks for part design and assembly

Experienced in sheet metal and weldment design

Able to create BOMs and perform analysis
Skilled in creating detailed drawings and specifications

Familiar with various SolidWorks add-ins and plugins

Examples: Designed a sheet metal enclosure for a control panel, created a BOM for a complex assembly, performed stress analysis on a critical
component
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CAD Software

Q17. when you make a design in any plastic component. what you are design consideration?
Ans. Design considerations for plastic components include material selection, manufacturability, functionality, aesthetics, and cost.

Material selection based on properties like strength, flexibility, and chemical resistance
Consideration of manufacturability, such as moldability and ease of assembly
Ensuring functionality requirements are met, such as mechanical strength or thermal resistance

Aesthetics like color, texture, and surface finish are important for consumer products
Cost considerations including material cost, production cost, and tooling cost
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Design

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Q18. Can you work on part modeling and assembly designing in solid works?
Ans. Yes, I have experience in part modeling and assembly designing in SolidWorks.
I am proficient in creating 3D models of parts using SolidWorks.

I have experience in designing assemblies and creating exploded views.

I am familiar with creating detailed drawings and bill of materials.

I have worked on projects involving sheet metal design and weldments.

I am comfortable with using SolidWorks simulation tools for stress analysis and motion studies.
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CAD Software

Q19. Do you have a material Knowledge like MS, SS, aluminum etc.?
Ans. Yes, I have knowledge of various materials commonly used in engineering such as MS, SS, aluminum, etc.
I have experience working with different grades of steel such as mild steel (MS) and stainless steel (SS)

I am familiar with the properties and characteristics of aluminum and its alloys
I understand the advantages and disadvantages of using different materials for different applications

I have knowledge of other materials commonly used in engineering such as copper, brass, and titanium
I keep myself updated with the latest developments in materials science and engineering
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Q20. Cad test on NX Software 2306 version? Plastic parts devlop in cad softwares?
Ans. Yes, CAD tests can be conducted on NX Software 2306 version. Plastic parts can be developed in CAD software.
CAD tests can be performed on NX Software 2306 version to ensure compatibility and functionality.
CAD software allows for the design and development of plastic parts with precision and accuracy.

Features like 3D modeling, simulation, and analysis tools in CAD software aid in the development of plastic parts.
Examples of CAD software for plastic parts development include SolidWorks, AutoCAD, and CATIA.

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CAD Software

Q21. How to prevent plastic defects, which design consideration method are used?
Ans. To prevent plastic defects, design engineers use methods such as mold flow analysis, material selection, gate design optimization, and part
geometry considerations.
Perform mold flow analysis to identify potential issues before production.

Select the appropriate plastic material based on the requirements of the part.
Optimize gate design to ensure proper filling and packing of the mold.

Consider part geometry to minimize stress concentrations and improve overall quality.
Use design for manufacturability (DFM) principles to simplify production processes and reduce the risk of defects.
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Q22. How to consider if you design any plastic component?

Ans. Consider material properties, manufacturability, cost, functionality, and environmental impact when designing plastic components.
Understand the material properties of the plastic being used (e.g. strength, flexibility, durability)
Consider manufacturability factors such as moldability, tooling requirements, and production processes

Evaluate cost implications including material costs, production costs, and assembly costs
Ensure the functionality of the component meets the design requirements and specifications

Assess the environmental impact of the plastic component throughout its lifecycle
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Design

Q23. What is Plastic defects & how to solve this problem?

Ans. Plastic defects are imperfections in plastic materials that can affect the quality and functionality of the final product.

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Common plastic defects include sink marks, weld lines, voids, and warping.

To solve plastic defects, proper material selection, mold design optimization, and processing parameters adjustment are essential.
Using additives like flow enhancers or mold release agents can help improve the quality of plastic parts.
Regular maintenance of molds and equipment can prevent defects from occurring.

Conducting thorough quality control inspections during production can help identify and address defects early on.
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Q24. Which manufacturing process are used to making any plastic?

Ans. Common manufacturing processes for plastics include injection molding, extrusion, blow molding, and thermoforming.

Injection molding involves injecting molten plastic into a mold to create a desired shape.
Extrusion is used to create continuous lengths of plastic with a specific cross-sectional profile.

Blow molding is commonly used for producing hollow plastic parts, such as bottles.
Thermoforming involves heating a plastic sheet and shaping it using a mold.
Other processes like rotational molding and compression molding are also used for specific applications.

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Q25. Which type of Plastic you are used in regular practice?

Ans. I regularly use a variety of plastics in my design work, including ABS, polycarbonate, and nylon.
ABS is commonly used for its strength and impact resistance

Polycarbonate is known for its transparency and high heat resistance

Nylon is valued for its durability and flexibility

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Q26. What are the consideration to be taken care to support a cryogenic Piping systems
Ans. Considerations for supporting cryogenic piping systems
Proper insulation to prevent heat transfer

Use of materials with low thermal conductivity

Expansion joints to accommodate thermal contraction
Proper anchoring to prevent excessive movement

Avoidance of sharp bends and abrupt changes in direction

Regular maintenance and inspection to prevent leaks and ensure integrity

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Q27. what are the basic needs of an electrical industry

Ans. The basic needs of an electrical industry include reliable power supply, efficient equipment, skilled workforce, and safety measures.

Reliable power supply to ensure uninterrupted operations

Efficient equipment to optimize production and reduce costs
Skilled workforce to design, install, and maintain electrical systems
Safety measures to prevent accidents and ensure compliance with regulations
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Q28. How to devloped plastic parts? what method are used?

Ans. Plastic parts are developed using methods like injection molding, blow molding, and thermoforming.
Injection molding is a common method where molten plastic is injected into a mold.
Blow molding is used for hollow parts like bottles, where plastic is blown into a mold.

Thermoforming involves heating a plastic sheet and shaping it over a mold.

Other methods include rotational molding, extrusion, and compression molding.
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Q29. Material properties, strength, deflections, modes of heat transfer, how to reduce heat transfer rate etc
Ans. Understanding material properties, strength, deflections, and modes of heat transfer is crucial in designing efficient systems.
Material properties such as density, elasticity, and thermal conductivity affect the behavior of a material under different conditions.
Strength is the ability of a material to withstand external forces without breaking or deforming.

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Deflections refer to the amount of bending or deformation a material undergoes under load.

Modes of heat transfer include conduction, convection, and radiation.

Reducing heat transfer rate can be achieved through insulation, reflective coatings, or increasing the surface area for heat dissipation.
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Q30. What is baud rate? How does it affect communication ?

Ans. Baud rate is the rate at which data is transmitted over a communication channel.

Baud rate is measured in bits per second (bps).

Higher baud rates allow for faster data transmission.
Baud rate must be set the same on both ends of the communication channel.
Incorrect baud rate settings can result in data corruption or loss.
Examples of communication channels that use baud rate include UART, SPI, and I2C.

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Networking

Q31. What is stress? What is finite element analyses? What is vibration? What is CNC machine and what are codes used in CNC
m/c? How to find the torque? What is shear force and bending movement?
Ans. Stress is the force per unit area that a material experiences when subjected to external loads or forces.

Stress is a measure of the internal resistance of a material to deformation.

It is calculated as the force applied divided by the cross-sectional area of the material.
Stress can be tensile (pulling apart), compressive (pushing together), or shear (sliding past each other).
High levels of stress can lead to material failure or deformation.
Stress analysis is important in engineering to ensure the structural integrity of components and systems.

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Q32. how to calculate pump discharge flow rate?

Ans. Pump discharge flow rate can be calculated using the formula Q = A * V, where Q is the flow rate, A is the cross-sectional area of the pipe, and V
is the velocity of the fluid.

Calculate the cross-sectional area of the pipe using the formula A = π * r^2, where r is the radius of the pipe.
Determine the velocity of the fluid by measuring the speed at which the fluid is flowing through the pipe.
Multiply the cross-sectional area of the pipe by the velocity of the fluid to calculate the pump discharge flow rate.
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Q33. How to calculate plastic weight in cad software?

Ans. Plastic weight in CAD software can be calculated by determining the volume of the plastic part and multiplying it by the density of the plastic
material.
Create a 3D model of the plastic part in the CAD software.

Calculate the volume of the plastic part using the CAD software's tools.
Determine the density of the plastic material being used.
Multiply the volume of the plastic part by the density of the plastic material to get the weight.
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CAD Software

Q34. what is diff b/w abs & nylon plastic material?

Ans. ABS is a thermoplastic polymer while nylon is a synthetic polymer. ABS is more rigid and impact-resistant, while nylon is more flexible and
durable.
ABS is a thermoplastic polymer, while nylon is a synthetic polymer
ABS is more rigid and impact-resistant, while nylon is more flexible and durable
ABS is commonly used in 3D printing and automotive parts, while nylon is used in textiles and industrial applications

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Q35. Giving a 3-4 component & create their 3D Design & Drawing In Computer software. manufacturing process or
Cost.
Ans. I would use computer-aided design software to create 3D designs and drawings for 3-4 components, considering manufacturing processes and
cost.
Identify the components and their specifications
Choose appropriate CAD software
Create 3D models and drawings
Consider manufacturing processes and cost

Refine designs based on feedback and testing

Finalize designs for production
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Design

Q36. What are the parts that you've designed in creo and what is the application?
Ans. I have designed various parts in Creo for applications in automotive, aerospace, and consumer electronics industries.

Designed engine components for automotive industry

Designed aircraft structural components for aerospace industry
Designed smartphone casings for consumer electronics industry
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Creo CAD Software

Q37. What would you suggest to take design to an advance level?

Ans. To take design to an advanced level, one should focus on continuous learning, exploring new technologies, collaborating with others, and
seeking feedback.
Continuously learn and stay updated with the latest design trends and technologies.
Explore new tools and software that can enhance the design process and improve efficiency.
Collaborate with other designers, engineers, and stakeholders to gain different perspectives and insights.

Seek feedback from users, clients, and colleagues to improve the design and address any potential issues.
Experiment with different design approaches and techniques to push boundaries and create innovative solutions.
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Design

Q38. Details about the software you used there?

Ans. I primarily used CAD software such as AutoCAD and SolidWorks for designing and modeling.
AutoCAD - Used for creating 2D and 3D designs, drafting, and documentation.

SolidWorks - Used for 3D modeling, simulation, and creating detailed engineering drawings.
Other software - Used various software tools for analysis, prototyping, and project management.
View 1 answer

Q39. 5. How to define undercut angle in plastic?

Ans. Undercut angle in plastic is the angle between the side wall of a mold and the vertical direction.
Undercut angle is important in plastic injection molding to ensure proper release of the part from the mold.
It is typically measured in degrees and affects the draft angle required for the mold.
A larger undercut angle allows for easier part ejection but may require more complex mold design.
Examples of parts with undercut angles include bottle caps and snap-fit connectors.

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Q40. How to any products design & what is step?

Ans. Product design involves a series of steps to create a functional and aesthetically pleasing product.

Understand the problem or need that the product will address

Research existing products and technologies

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Brainstorm ideas and create sketches or prototypes
Iterate on designs based on feedback and testing
Finalize design for production

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Q41. How to identify root cause any new products?

Ans. Identifying root cause of new products involves thorough analysis and investigation.
Conduct thorough testing and analysis of the product

Collect feedback from users and stakeholders

Investigate any reported issues or failures
Use tools like root cause analysis (RCA) to identify underlying issues
Consider factors such as design, materials, manufacturing process, and user interaction
Collaborate with cross-functional teams to gather insights and perspectives
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Q42. How to make laser cutting drawing in sheet metal?

Ans. To make a laser cutting drawing in sheet metal, you need to create a CAD file with the desired design and specifications.
Create a CAD file of the design you want to cut using laser cutting technology.

Specify the material type and thickness in the CAD file for accurate cutting parameters.
Include dimensions, tolerances, and any special instructions in the drawing.
Convert the CAD file into a format compatible with the laser cutting machine, such as DXF or DWG.
Send the file to th...read more
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Design

Q43. What is Procedure of any new products devlopment?

Ans. The procedure for new product development involves idea generation, concept development, design and testing, and commercialization.
Idea generation: Brainstorming sessions, market research, customer feedback
Concept development: Creating prototypes, feasibility studies
Design and testing: Iterative design process, testing for functionality and durability
Commercialization: Marketing strategies, production planning, launch

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Q44. How many types of plastic material category?

Ans. There are seven main categories of plastic materials.
Thermoplastics

Thermosets
Elastomers
Composites
Biodegradable plastics
Engineering plastics

High-performance plastics
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Q45. How to calculate costing of complete products?

Ans. Costing of complete products can be calculated by considering materials, labor, overhead, and profit margin.

Calculate the cost of materials required for the product

Estimate the labor costs involved in manufacturing the product
Factor in overhead costs such as utilities, rent, and equipment depreciation
Add a profit margin to cover additional expenses and generate profit
Consider any additional costs such as shipping, packaging, and marketing

Use cost accounting methods to allocate costs accurately

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