A Systematic Procedure for Design and Structural Mechanical Analysis: A Case Study for Construction of a Buggy

—Our research aims to develop an efficient framework for machine design in response to the growing industry demand for optimization. We utilize Design Thinking (DT) combined with Shigley’s Methodology (SM) to address ill-defined problems and promote human-centric problem-solving. SM’s iterative process consisting of six phases facilitates effective planning and innovation. We conducted a case study focusing on the design and analysis of a buggy-type vehicle with specific dimensions. Various analyses, including static, fatigue, structure resonance, thermal, aerodynamic, and impact analysis, were performed using MATLAB and Solid-work’s software. The structural analysis indicated values below the yielding stress, with a safety factor of approximately 3. The aerodynamic and impact studies were crucial in understanding the effects of airflow and assessing the structure’s resistance to impacts at different speeds. The obtained results validated the design in terms of safety coefficient, structure resonance, heat dissipation, impact resistance, and aerodynamic performance. Additionally, the cost of the designed prototype was found to be 48% lower compared to a similar model.