For several decades, Kettering University has taught an introductory course for first year engineering students to acquaint them with the manufacturing processes that they might encounter as part of their cooperative work experience. The revision of the curriculum in 2001 caused a redesign of the course and added some design experiences to further enhance the educational process. This paper discusses the development of the new course called Interdisciplinary Design and Manufacturing and discusses relationship of course coverage to the SME competency gaps. The manufacturing portion describes the lecture topics and laboratory experiments that were an integral part of the course. The mechanical and electrical design portions describe the use of commercial toys and a self-designed toy platform that formed the basis of the new design laboratory portion of the class. It will be demonstrated that it is possible to make a meaningful first year experience for all engineering students combining mechanical and electrical design with manufacturing theory and laboratory.

Massoud Tavakoli, Kettering UniversityMassoud Tavakoli serves as a Professor of Mechanical Engineering at Kettering University.

is a Professor of Mechanical Engineering at Kettering University. He teaches in the areas of thermal design, mechanical design, and automotive engineering. His research focuses on sustainable mobility technologies including alternative fuels, fuel cells and hybrid electric vehicles. He is actively involved in the Society of Automotive Engineers and is the faculty advisor for Kettering's Formula SAE race team. Dr. Hoff is a registered Professional Engineer in the State of Michigan.

College freshmen, though they may be registered in the engineering programs, do not always know what discipline best suits their interests. Regardless of their future majors, current technological advancements and global competitions have created a necessary industrial atmosphere of interdisciplinary design and manufacturing in the product development cycle. An introductory course combining mechanical design, electronic control and manufacturing processes provides a totality in the perspective of engineering for the future. At the same time, the students' views of engineering are broadened by the exposure to the different disciplines. As a result of the multi-discipline engineering exposure, they are in a better position to select a future career. In this paper, the developmental process for establishing such a course is described. The process starts from the very top of the managerial pole. Potential departmental barriers are discussed and possible ways of quenching faculty and departmental traditional cultures are introduced. The structure for the lecture and laboratory sessions, the timing, the logistics of shuffling students from one area to the next are ironed out. Common times for lecture and labs are established. Students also work in teams to perform projects. Students are evaluated in the separate disciplinary areas as well as on a final integrated project where they are asked to combine aspects of mechanical design with electronic control and manufacturing processes. The assessment process will also be described. Fun objects are used in the laboratories, such as; battery operated mechanically animated pig, electronically controlled hexapod ("6-legged insect"), thermoformed Mickey Mouse, and machined pencil holder. Students' comments included their excitement about learning the various aspects of engineering as well as being able to do hands-on designing, controlling and fabricating real products.

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