ENT260 - Advanced Solid Modeling for Mechatronics
Why This Course Is Structured This Way
Many students entering mechatronics and engineering technology programs learn CAD as a standalone skill, focusing primarily on modeling tools and drawing production. While these skills are important, real engineering work requires using CAD as part of a larger system development process.
ENT260 was redesigned to treat CAD not just as a drafting tool, but as a core component of multidisciplinary engineering. The course emphasizes how mechanical design connects to electronics integration, manufacturability, and system architecture.
Rather than teaching isolated modeling techniques, the course focuses on:
- designing parts that interact with real hardware
- thinking about assemblies and interfaces early in the design process
- documenting design intent clearly
- building models that support iteration and modification
By the end of the course, students are not only able to use SolidWorks effectively, but also understand how mechanical design fits into the broader workflow of modern mechatronics and product development.
This structure reflects how mechanical design is used in real engineering environments, where CAD models must support electronics integration, manufacturing constraints, and system-level design decisions.
Course Mission: This redesigned SolidWorks course uses project-driven engineering challenges to build advanced 3D modeling, assembly, documentation, and design-for-manufacturing skills for mechatronics students. The curriculum is also structured to prepare students for the Certified SolidWorks Associate (CSWA) exam.
Course Overview
ENT260 was rewritten as an immersive studio-style CAD course built around realistic engineering scenarios instead of isolated software exercises. Each week places students in a client-style design context, asks them to balance technical constraints with manufacturability, and requires them to communicate their work through models, assemblies, drawings, and short design rationales.
The curriculum progresses from parametric modeling and design intent into assemblies, documentation, additive manufacturing, electronics enclosure design, and a multi-week team capstone. Throughout the course, students practice the same workflow expected in industry: define the problem, model the system, validate design decisions, and present a complete handoff package.
By the end of the course, students are expected to:
- Model, assemble, and analyze complex mechanical systems in SolidWorks.
- Apply design thinking and DFM/DFA principles to real engineering problems.
- Produce complete drawing packages and supporting manufacturing documentation.
- Integrate mechanical design with electronics packaging and system-level constraints.
- Complete CSWA-aligned modeling work under timed conditions.
Curriculum Structure
Module 1: Foundations and Design Thinking
Week 1: Ergonomic Redesign Challenge - “The Fatigue Factor”
Students redesign a handheld tool or multimeter probe to improve comfort and usability for technicians working in constrained spaces.
Deliverables: Three concept models, a one-page design rationale, and a basic dimensioned drawing of the final design.
Skills practiced: Sketching, constraints, extrudes, revolves, fillets, and annotation.
Week 2: Parametric Design Challenge - Universal Motor Mount
Students create a single SolidWorks model that adapts across NEMA 17, 23, and 34 motor sizes while fitting a standard 80/20 frame.
Deliverables: Parameter-driven model configurations, design equations table, compatibility assemblies, and a short explanation of the parameter and DFM strategy.
Skills practiced: Global variables, equations, configurations, and parametric design logic.
Week 3: Feature-Based Design Challenge - Modular Sensor Housing
Students design a modular enclosure system for coastal environmental sensors with interchangeable sensor modules and IP54 protection goals.
Deliverables: Base housing model, two sensor module variants, exploded view assembly, and design intent notes covering sealing and assembly strategy.
Skills practiced: Lofts, sweeps, shelling, feature patterns, and assembly mate strategy.
Module 2: Mechanical Systems and Assemblies
Week 4: Articulating Mount Challenge - “Vision Under Vibration”
Students model a rugged three-degree-of-freedom camera mount for industrial machine vision applications.
Deliverables: Full assembly, motion study, strength analysis of critical parts, and a short animated demonstration.
Skills practiced: Assembly mates, motion study, exploded views, and structural design.
Week 5: DFM/DFA Optimization Challenge - “Manufacturing on a Budget”
Students redesign a motor controller enclosure to reduce tooling complexity, part count, and manufacturing cost.
Deliverables: Original versus optimized model comparison, revised design with snap fits and fewer parts, draft analysis, and a brief cost-saving rationale.
Skills practiced: DFM/DFA review, manufacturability analysis, simplification, and fastener reduction.
Week 6: Engineering Drawing and Documentation Challenge - “Ready for Production”
Students produce a complete documentation package for a linear actuator design intended for fabrication.
Deliverables: Fully dimensioned drawings, a ballooned assembly drawing with BOM, exploded view assembly steps, and a simplified user-facing diagram.
Skills practiced: Orthographic views, GD&T, BOM creation, and exploded or section views.
Module 3: Applied Mechatronics Design
Week 7: Electronics Integration Challenge - IoT Enclosure
Students design a rugged Raspberry Pi 4 monitoring enclosure with cable routing, passive cooling, sensor mounting, and IP54 protection.
Deliverables: Enclosure model with interfaces and vents, thermal or airflow strategy, cable routing diagram, and maintenance plan.
Skills practiced: Enclosure design, layout planning, surface modeling, and thermal consideration.
Week 8: Precision Mechanism Challenge - Linear Indexer
Students design a compact indexing mechanism that advances micro-sample trays in 10 mm increments with +/-0.1 mm repeatability.
Deliverables: Mechanism model, full assembly, motion simulation, force estimate, and component drawings with tolerance notes.
Skills practiced: Precision motion design, mate control, motion studies, and force estimation.
Week 9: Additive Manufacturing Challenge - Robotic End Effector
Students develop a lightweight robotic end effector optimized separately for FDM and SLA printing.
Deliverables: FDM and SLA model variants, STL files with slicing screenshots, additive manufacturing documentation, and a print-readiness comparison.
Skills practiced: Print orientation, lightweight design, material planning, and slicer optimization.
Module 4: Collaborative Design Project
Week 10: Capstone Kickoff - Concept Development
Teams begin a compact automated sorting system for small electronic components by defining requirements, generating concepts, and planning execution.
Deliverables: Client-style requirements document, three CAD-assisted concepts, a decision matrix, and a team task timeline.
Skills practiced: Concept generation, team planning, and early CAD prototyping.
Week 11: Capstone Detailed Design - “From Idea to Integration”
Teams fully develop the selected concept, including feeders, sorters, and control enclosures, while resolving integration issues.
Deliverables: Detailed subsystem models, integrated assembly, motion simulation, and BOM with interface resolution notes.
Skills practiced: Detailed modeling, system integration, and validation.
Week 12: Capstone Refinement and Documentation - “Handoff to the Client”
Teams finalize manufacturing drawings, maintenance documentation, exploded views, and a polished demonstration package.
Deliverables: Final CAD package, drawings, user and assembly manuals, slide deck, demo video, and project reflection.
Skills practiced: Documentation, communication, and presentation preparation.
Module 5: CSWA Certification and Final Presentation
Week 13: CSWA Intensive Prep - “Certification Sprint”
Students complete timed modeling problems under certification-style conditions and evaluate their own workflow efficiency.
Deliverables: Three timed part-modeling problems, a strategy reflection, and self-evaluation against provided solutions.
Skills practiced: Efficient modeling, time management, and exam preparation.
Week 14: Final Presentation and CSWA Exam - “Showcase and Certify”
Teams present their final capstone project to an engineering audience and then complete the CSWA exam or document their certification attempt.
Deliverables: Fifteen-minute professional presentation, portfolio submission, and CSWA completion or exam reflection.
Skills practiced: Design communication, professional presentation, and certification performance.
Assessment Strategy
The grading structure ties each weekly challenge to a specific engineering competency while preserving room for a larger collaborative design project and certification work.
- Week 1: Ergonomic Redesign - 5%
- Week 2: Parametric Motor Mount - 5%
- Week 3: Modular Sensor Housing - 5%
- Week 4: Articulating Mount - 5%
- Week 5: DFM/DFA Optimization - 5%
- Week 6: Drawing Documentation - 5%
- Week 7: IoT Enclosure Design - 5%
- Week 8: Linear Indexing Mechanism - 5%
- Week 9: Additive End Effector - 5%
- Weeks 10-12: Capstone Project - 25%
- Week 13: CSWA Prep - 10%
- Week 14: CSWA Exam and Final Presentation - 10%
| Component | Percent of grade | Notes |
|---|---|---|
| Weekly design challenges (9) | 45% | Practical, CSWA-aligned projects |
| Capstone project (Weeks 10-12) | 25% | Team design, documentation, and presentation |
| CSWA preparation and certification | 20% | Timed modeling, strategy, certification effort |
| Participation and peer reviews | 10% | Feedback, engagement, collaboration |
| Total | 100% |
Software and Tools
- SolidWorks 2024 as the primary design environment.
- Motion Study, FEA, Draft Analysis, and Thermal Simulation tools inside SolidWorks.
- Cura, PrusaSlicer, and Bambu Studio for additive manufacturing preparation.
- Canvas and Google Workspace for collaboration, planning, and project submission.
Instructional Design Notes
This course redesign emphasizes scenario-based learning, repeated design communication, and visible engineering tradeoffs. Students do not just practice commands; they work through human factors, packaging, manufacturability, documentation, and integration problems that mirror how CAD is used in actual product development.
The final capstone extends that approach into collaborative systems work. By the end of the term, students have not only a set of individual modeling exercises, but also a documented team design process, a production-style handoff package, and direct preparation for professional certification.
| Course Information: ENT260 - Advanced Solid Modeling for Mechatronics | Credit Hours: 3 | Format: Project-driven studio course | Primary Platform: SolidWorks 2024 |
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