CLASS 01Need finding and requirements
Core instructionStakeholders, observation, accessibility, problem framing, measurable requirements, constraints, misuse, and acceptance criteria.
Guided practiceConvert an ambiguous community need into testable requirements without prescribing a solution.
Mastery evidenceApproved requirements specification and stakeholder map.
CLASS 02Concept generation and selection
Core instructionFunctional decomposition, morphology, analogies, trade studies, uncertainty, intellectual-property awareness, and decision transparency.
Guided practiceGenerate multiple architectures and score them against weighted requirements.
Mastery evidenceConcept portfolio, decision matrix, and dissent/risk note.
CLASS 03Safety and risk by design
Core instructionHazard identification, risk estimation, hierarchy of controls, inherently safer design, guarding, warnings, verification, and residual risk.
Guided practiceConduct a preliminary hazard analysis and revise the concept using higher-order controls.
Mastery evidenceRisk register with owners, controls, and verification methods.
CLASS 04Detailed design and design reviews
Core instructionInterfaces, calculations, tolerances, materials, drawings, BOM, configuration baselines, peer review, and action closure.
Guided practiceRun a structured preliminary design review using traceable evidence.
Mastery evidenceReview package, action log, and released design baseline.
CLASS 05Prototype, verification, and validation
Core instructionPrototype fidelity, test planning, fixtures, sample limits, measurement, anomalies, verification versus validation, and iteration.
Guided practiceWrite a test method that links each test to a requirement and objective pass/fail rule.
Mastery evidenceTest plan, raw-data form, and verification matrix.
CLASS 06Production readiness and lifecycle responsibility
Core instructionDFMA, quality planning, sourcing, cost, maintenance, repair, packaging, circularity, documentation, training, and launch decision.
Guided practicePerform a production-readiness review and identify what remains unknown.
Mastery evidenceManufacturing plan, lifecycle assessment summary, and go/no-go recommendation.
LAB 01Design-review laboratory
Present a controlled design baseline to a multidisciplinary review panel and close evidence-based actions.
- Workflow
- Prepare → brief → question → record → classify → revise → close
- Deliverable
- Review deck, minutes, action log, and updated baseline.
- Safety boundary
- Do not advance unresolved high-risk hazards to fabrication.
LAB 02Prototype and verification laboratory
Build a low-risk prototype or digital/physical surrogate and execute an approved verification plan.
- Workflow
- Authorize → inspect → build → test → record → analyze → contain anomalies → report
- Deliverable
- Prototype record, raw data, test report, and requirements matrix.
- Safety boundary
- Use qualified supervision, task-specific PPE, approved tools, and stop-work authority.
LAB 03Production-readiness laboratory
Simulate a pilot build and audit instructions, tooling, inspection, traceability, waste, and operator feedback.
- Workflow
- Plan → stage → pilot → observe → inspect → learn → revise → release/hold
- Deliverable
- Pilot report, control plan, work instruction, and release recommendation.
- Safety boundary
- A classroom pilot is not approval for public sale or safety-critical use.