Background: Design and science inquiry are intertwined during engineering practice. In this study, we examined the relationship between design behaviors and scientific explanations. Data on student design processes were collected as students engaged in a project on designing energy-efficient buildings on a blank square city block surrounded by existing buildings using a computer-aided design program, Energy3D, with built-in solar energy simulation capabilities. We used criterion sampling to select two highly reflective students among 63 high school students. Results: The main data sources were design replays (automatic playback of student design sequences within the CAD software) and electronic notes taken by the students. We identified evidence of informed design such as problem framing, idea fluency, and balancing benefits and trade-offs. Opportunities for meaningful science learning through engineering design occurred when students attempted to balance design benefits and trade-offs. Conclusions: The results suggest that design projects used in classrooms should emphasize trade-off analysis and include time and resources for supporting trade-off decisions through experimentation and reflection. Future research should explore ways to visualize patterns of design behavior based on large samples of students.

This paper provides a theoretical perspective of how modeling and simulation on a CAD platform can be used to teach science concepts and inform design decisions. The paper discusses the educational implications of three recent advancements in CAD technologies: system integration, machine learning, and computational design. The challenges to design energy‐efficient buildings that harness solar energy are used as the engineering examples to illustrate the learning and teaching opportunities created by the modeling, simulation, and data mining capabilities of the Energy3D software, which is a CAD tool developed from scratch along the directions of the three advancements to support engineering research and education. Preliminary results from students in a physics classroom and an online course shed light on the effects of these features on guiding student to design cost‐effective rooftop solar power systems for their own home buildings.

Many pedagogical innovations aim to integrate engineering design and science learning. However, students frequently show little attempt or have difficulties in connecting their design projects with the underlying science. Drawing upon the Cultural‐Historical Activity Theory, we argue that the design tools available in a learning environment implicitly shape knowledge development as they mediate students’ design actions. To explore the roles of tools in design‐science integrated learning environments, this study investigated how secondary students’ tool‐mediated design actions were linked with their science learning in a tool‐rich design environment with minimal explicit guidance. Eighty‐three ninth‐grade students completed an energy‐efficient home design challenge in a simulated environment for engineering design supported by rich design tools. Results showed that students substantially improved their knowledge as a result of designing with the tools. Further, their learning gains were positively associated with three types of design actions—representation, analysis, and reflection—measured by the cumulative counts of relevant computer logs. In addition, these design actions were linked with learning gains in ways that were consistent with their theoretical impacts on knowledge development. These findings suggest that, instead of being passive components in a learning environment, tools considerably shape design processes, and learning paths. As such, tools offer possibilities to help bridge the design‐science gap. © 2017 The Authors. Journal of Research in Science Teaching Published by Wiley Periodicals, Inc. J Res Sci Teach 9999:1049–1096, 2017

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