Critical Design Review

The purpose of this document is to help you prepare the Critical Design Review (CDR) mid-fidelity prototype review, oral presentation, and written report. Most of the items listed are just suggestions, but others, as noted, are required. A large part of your task is to decide how to use the constrained time and alloted space to best convey the status of your project to your sponsor. You must seek and gain their approval to move to the next phase, Final Design.

As you review the material and description below, you will notice the format (and some of the content) is similar to what was requested in the PDR presentation and report. Teams are encouraged to use your PDR presentation and report as the basis or point-of-departure to refine and articulate the increased progress and expanded design/analyses elements and processes used to arrive at your optimal design.

Your overall goal of the CDR is to convince your stakeholders (your sponsor and/or instructor acting as your project sponsor, and mentoring staff) that your design is complete, and it justifies moving the project forward to the build and test phase. In other words, you need to create confidence that the design/prototype has a high-probability of creating a successful product, that solves “the problem” and provide a path to a final product that will create business or society value once it is in production.

Mid-Fidelity Prototype Assessment

The mid-fidelity prototype should provide design insight and intent of at least 1 key functional requirement, while serving as the basis for integrating all systems and subsystems needed to meet all functional requirements. Using your low-fidelity prototype as a point-of-departure, your team should begin replacing low-fidelity parts and components with improved, refined parts and components to make a mid-fidelity prototype configuration. Some of the parts of the mid-fidelity may come from a 3D printer, others found from previous projects, yet others may be purchased, and still others may be leftover blocks and cylinders (placeholders) for a motor or gearbox yet to be made or purchased. Your mid-fidelity prototype should

• Communicate the actual size (footprint and volume) using good dimensioning and tolerancing techniques,
• Communicate all required fits, materials and material properties, etc.
• Communicate the approved layout of subsystems and/or components (identify all purchased and manufactured components)
• Demonstrates 1 key functional requirement, as well as other basic/general functionality

Oral Presentation

20 minutes for Presentation, 3 minutes for Q&A

• Content (“What”)

  • Introduction
    • Team
    • Project
  • Background
    • Business
      • The target customers and their requirements are understood and reflected in the project objectives.
      • The full breadth of competition and/or benchmarks have been analyzed and the pros & cons explained against customer requirements.
      • The unit cost and sales price are accurately estimated.
      • The proposed solution will create value for the stakeholders.
    • Project Management
      • The project schedule is robust and will be achieved.
      • The project budget is robust and will be achieved.
      • Active Risk Management is in place and is effective and efficient
    • PDR
      • Multiple concepts have been generated, the pros & cons align to project objectives, and the selection rationale was logical.
      • The problem is worth solving and the solution will generate business and/or society value.
  • Design / Engineering
    • The conceptual design was taken into preliminary design and CAD modeling.
    • Engineering analysis has helped refine the size, shape, thickness, gaps, fits (allowance, clearance, tolerances, etc.), etc. making a more detailed design. The current problem & future aim are clearly defined.
    • The engineering analysis is thorough and robust providing confidence in the predicted functionality of the prototype.
    • The proposed solution is the optimal way to achieve the project objectives.
    • The final design is innovative
    • The test plan will accurately validate the design.
    • The key risks & safety concerns during the project and in production have been identified and effectively mitigated.
  • The Ask
    • Our final manufacturing drawing package will consist of:
      • What we propose to fabricate.
      • How we propose to test our prototype.
  • Q & A
    • Appendix slides that deal with your most predicted questions.
    • Video clips (in the event no questions are asked)
      • CAD Assembly
      • CAE Simulations
      • Etc.
• Presentation (“How”)
  • The presenters are wearing the appropriate attire, speak clearly, are confident and credible, and passionate about the project and their product.
  • While all of the “What” items listed above contribute to a successful project, remember, you are giving/making a Design Presentation, hoping to inspire approval to transition to the final prototyping and testing phase. The majority of your words and slides should be to persuade your sponsor(s) that the design being presented has the shape, topology, dimensions, structure, thermo, flow, controls, HMI, etc. characteristics and features to meet or exceed the requirements and specifications set forth by the sponsor(s).
  • The presentation is visually appealing, engaging, easy to follow, and easy to understand. Each slide has a well-defined & intuitive take-away that contributes to the overall message so that the full presentation communicates a clear and significant idea that energizes the sponsor to support the project.

Written Report

• Content (“What”)

  • The report should be informative, engaging, and quick for the sponsor to read.
  • The report should incorporate the following into its body;
    • (Not to exceed) 500 words (Requirement) of summary text woven in and through
      • Well-chosen, mentioned/referenced figures, images, tables, diagrams, lists, etc.
      • References to any and all Appendices
    • Provide a concise project statement
    • Discusses how the engineering design, and analyses have (are) shaping and sizing the components and assemblies. For example, highlight analyses that led to the size, shape, thickness, gaps, fits (allowance, clearance, tolerances, etc.), etc. of your most significant part and/or assembly. Then reference and discuss other CAD and CAE results in Appendices G & H.
    • It reinforces the Oral Presentation and key takeaways. It does not introduce new materials or results, but points to appropriate appendices for the material supporting your most important design, analysis, risk-mitigation, etc. claims and statements.
    • Provide a summary of the most important design, analysis, risk-mitigation, etc. elements accomplished thus far on the project (more in-depth discussion or background refer the reader to the appropriate appendix)
    • Requests approval to move to the next phase of the project
  • Appendices (e.g. Charter, WBS, ND, Budget, etc.) that were included in the written PD & CR report should be updated, changed, and made current with the status of the project (required), but have minimal reference in the body of the written CDR report. For example, Thus far the project has consumed 23% of its allocated budget, see Appendix C.
• Written Report Structure (“How”)
  • Title Page (Required)
    • Report Name
    • Project Name
    • Submitted to: Sponsor Name (if no sponsor, list your professor)
    • Submitted by: Team Names
    • Date
  • Body
    • Introduction - describing the project and disclosing the current project stage (state-of-affairs)
    • Background - discussing how you arrived at the CDR stage
    • CDR Design - discussing the nominal shape, size, aesthetics, function, etc. of components and system
    • CDR Analyses - discussing how analyses have refined your design
    • Proposed Prototype - sentences discussing what will be prototyped
    • Request to proceed to fabrication.
  • Appendices (Required, as applicable)
    • A: Team Members and Organization Structure
    • B: Charter
    • C: Business Case and Project Budget
    • D: Project Schedule, Network Diagrams, Work Breakdown Structures, etc.
    • E: Risk Mitigation
    • F: Sketches
    • G: Mechanical CAD
    • H: Mechanical CAE (FEA, CFD, motion path simulation, … depending on your project)
    • I: Electronic Schematics
    • J: Electronic Circuit Diagram/Wiring Diagram (if ready)
    • K: Electronic CAE
    • L: Flow Chart of Control/HMI Software/Operation and/or Skeleton Code (pseudo code)
    • M: Manufacturing Drawings
    • N: What was learned from mid-fidelty (and low-fidelity) prototype
    • O: List of Standards Referenced/Used/Applied to this project
    • P: ...other appendices as applicable