As students learn more about the manufacturing process, they use the final prototypes created in the previous activity to evaluate, design and manufacture final products. Teams work with more advanced materials and tools, such as plywood, Plexiglas, metals, epoxies, welding materials and machining tools. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 6 in a series of six that guide students through the engineering design loop.)

Student teams design and create LEGO® structures to house and protect temperature sensors. They leave their structures in undisturbed locations for a week, and regularly check and chart the temperatures. This activity engages students in the design and analysis aspects of engineering.

Engineer and cartoonist Rube Goldberg is famous for his crazy machines that accomplish everyday tasks in overly complicated ways. Students use their new understanding of types of simple machines to design and build their own Rube Goldberg machines that perform simple tasks in no less than 10 steps.

Students are introduced to the biomechanical characteristics of helmets, and are challenged to incorporate them into designs for helmets used for various applications. By doing this, they come to understand the role of enginering associated with saftey products. The use of bicycle helmets helps to protect the brain and neck in the event of a crash. To do this effectively, helmets must have some sort of crushable material to absorb the collision forces and a strap system to make sure the protection stays in place. The exact design of a helmet depends on the needs and specifications of the user.

Students are given a biomedical engineering challenge, which they solve while following the steps of the engineering design process. In a design lab environment, student groups design, create and test prototype devices that help people using crutches carry things, such as books and school supplies. The assistive devices must meet a list of constraints, including a device weight limit and minimum load capacity. Students use various hand and power tools to fabricate the devices. They test the practicality of their designs by loading them with objects and then using the modified crutches in the school hallways and classrooms.

The purpose of this activity is for the students to draw a design for their own flying machine. They will apply their knowledge of aircraft design and the forces acting on them. The students will start with a brainstorming activity where they come up with creative uses for every day objects. They will then use their creativity and knowledge of airplanes to design their own flying machine.

Students create a concept design of their very own net-zero energy classroom by pasting renewable energy and energy-efficiency items into and around a pretend classroom on a sheet of paper. They learn how these items (such as solar panels, efficient lights, computers, energy meters, etc.) interact to create a learning environment that produces as much energy as it uses.

After a discussion about what a parachute is and how it works, students create parachutes using different materials that they think will work best. They test their designs, and then contribute to a class discussion (and possible journal writing) to report which paper materials worked best.

Students brainstorm ideas for board game formats. Then student teams design, create and test games in which players must think of alternative uses (recycling) for used products.

Students design and build a model city powered by the sun! They learn about the benefits of solar power, and how architectural and building engineers integrate photovoltaic panels into the design of buildings.

Student teams use their knowledge about ancient Egypt to design playgrounds for Egyptian children. This involves brainstorming ideas on paper, building models with LEGO® bricks or other materials, and explaining their ideas to the class in five-minute presentations.

In this two-part activity, students design and build Rube Goldberg machines. This open-ended challenge employs the engineering design process and may have a pre-determined purpose, such as rolling a marble into a cup from a distance, or let students decide the purposes.

Students learn how to use wind energy to combat gravity and create lift by creating their own tetrahedral kites capable of flying. They explore different tetrahedron kite designs, learning that the geometry of the tetrahedron shape lends itself well to kites and wings because of its advantageous strength-to-weight ratio. Then they design their own kites using drinking straws, string, lightweight paper/plastic and glue/tape. Student teams experience the full engineering design cycle as if they are aeronautical engineers—they determine the project constraints, research the problem, brainstorm ideas, select a promising design and build a prototype; then they test and redesign to achieve a successful flying kite. Pre/post quizzes and a worksheet are provided.

Students learn about the types of possible loads, how to calculate ultimate load combinations, and investigate the different sizes for the beams (girders) and columns (piers) of simple bridge design. Students learn the steps that engineers use to design bridges: understanding the problem, determining the potential bridge loads, calculating the highest possible load, and calculating the amount of material needed to resist the loads.

Students are introduced to engineering, specifically to biomedical engineering and the engineering design process, through a short lecture and an associated hands-on activity in which they design their own medical devices for retrieving foreign bodies from the ear canal. Through the lesson, they learn the basics of ear anatomy and how ear infections occur and are treated. Besides antibiotic treatment, the most common treatment for chronic ear infections is the insertion of ear tubes to drain fluid from the middle ear space to relieve pressure on the ear drum. Medical devices for this procedure, a very common children's surgery, are limited, sometimes resulting in unnecessary complications from a simple procedure. Thus, biomedical engineers must think creatively to develop new solutions (that is, new and improved medical devices/instruments) for inserting ear tubes into the ear drum. The class learns the engineering design process from this ear tube example of a medical device design problem. In the associated activity, students explore biomedical engineering on their own by designing prototype medical devices to solve another ear problem commonly experienced by children: the lodging of a foreign body (such as a pebble, bead or popcorn kernel) in the ear canal. The activity concludes by teams sharing and verbally analyzing their devices.

Students learn the engineering design process by following the steps, from problem identification to designing a device and evaluating its efficacy and areas for improvement. A quick story at the beginning of the activity sets up the challenge: A small child put a pebble in his ear and we don't know how to get it out! Acting as biomedical engineers, students are asked to design a device to remove it. Each student pair is provided with a model ear canal and a variety of classroom materials. A worksheet guides the design process as students create devices and attempt to extract pebbles from the ear canal.

Student teams act as engineers and brainstorm, design, create and test their ideas for packaging to protect a raw egg shipped in a 9 x 12-in envelope. They follow the steps of the engineering design process and aim for a successful solution with no breakage, low weight, minimal materials and recyled/reused materials. Students come to understand the multi-faceted engineering considerations associated with the packaging of items to preserve, market and safely transport goods.

Student teams create laparoscopic surgical robots designed to reduce the invasiveness of diagnosing endometriosis and investigate how the disease forms and spreads. Using a synthetic abdominal cavity simulator, students test and iterate their remotely controlled, camera-toting prototype devices, which must fit through small incisions, inspect the organs and tissue for disease, obtain biopsies, and monitor via ongoing wireless image-taking. Note: This activity is the core design project for a semester-long, three-credit high school engineering course. Refer to the associated curricular unit for preparatory lessons and activities.

Students find and calculate the angle that light is transmitted through a holographic diffraction grating using trigonometry. After finding this angle, student teams design and build their own spectrographs, researching and designing a ground- or space-based mission using their creation. At project end, teams present their findings to the class, as if they were making an engineering conference presentation. Student must have completed the associated Building a Fancy Spectrograph activity before attempting this activity.