Students further their understanding of the engineering design process while combining mechanical engineering and bioengineering to create an automated medical device. During the activity, students are given a fictional client statement and are required to follow the steps of the design process to create medical devices that help reduce the workload for hospital workers and increase the quality of patient care.

Students design and build a mechanical arm that lifts and moves an empty 12-ounce soda can using hydraulics for power. Small design teams (1-2 students each) design and build a single axis for use in the completed mechanical arm. One team designs and builds the grasping hand, another team the lifting arm, and a third team the rotation base. The three groups must work to communicate effectively through written and verbal communication and sketches.

Student teams design, build and test small-sized gliders to maximize flight distance and an aerodynamic ratio, applying their knowledge of fluid dynamics to its role in flight. Students experience the entire engineering design process, from brainstorming to CAD (or by hand) drafting, including researching (physics of aerodynamics and glider components that take advantage of that science), creating materials lists, constructing, testing and evaluating—all within constraints (works with a launcher, budget limitation, maximizing flight distance to mass ratio), and concluding with a summary final report. Numerous handouts and rubrics are provided.

While building and testing model rockets fueled by antacid tablets, students are introduced to the basic physics concepts on how rockets work. Students revise and improve their initial designs. Note: This activity is similar to the elementary-level film canister rockets activity, but adapted for middle school students.

Acting as if they are biomedical engineers, students design and print 3D prototypes of pressure sensors that measure the pressure of the eyes of people diagnosed with glaucoma. After completing the tasks within the associated lesson, students conduct research on pressure gauges, apply their understanding of radio-frequency identification (RFID) technology and its components, iterate their designs to make improvements, and use 3D software to design and print 3D prototypes. After successful 3D printing, teams present their models to their peers. If a 3D printer is not available, use alternate fabrication materials such as modeling clay, or end the activity once the designs are complete.

Student teams are challenged to design models of Egyptian funerary barges for the purpose of transporting mummies through the underworld to the afterlife. Planning the boat designs requires an understanding of ancient culture and beliefs so the mummies are transported safely through the perils of the underworld. Students design and build prototypes using materials and tools like the ancient Egyptians had at their disposal. Then they do the same with modern materials and techniques, forming an awareness of the similarities and differences of the barge designs between the ancient materials and tools (technologies) and today's technologies, which are evolved from the earlier ways.

Using ordinary household materials, student “biomedical engineering” teams design prototype models that demonstrate semipermeability under the hypothetical scenario that they are creating a teaching tool for medical students. Working within material constraints, each model consists of two layers of a medium separated by material acting as the membrane. The competing groups must each demonstrate how water (or another substance) passes through the first layer of the medium, through the membrane, and into the second layer of the medium. After a few test/evaluate/redesign cycles, teams present their best prototypes to the rest of the class. Then student teams collaborate as a class to create one optimal design that reflects what they learned from the group design successes and failures. A pre/post-quiz, worksheet and rubric are provided.

In this activity, students design an innovative human shelter that is inspired and informed by an animal structure. Each group is assigned an animal class, and they gather information about shelters used by the animals in that class. After researching the topic and brainstorming ideas, students build small prototypes (models) of the structures. Finally, they present their products, explaining what attribute of the animal structure influenced their design.

Students learn about the unique challenges astronauts face while eating in outer space. They explore different food choices and food packaging. Students learn about the engineering design process, and then, as NASA engineering teams, they design and build original model devices to help astronauts eat in a microgravity environment --- their own creative devices for food storage and meal preparation.

Students apply high school-level differential calculus and physics to the design of two-dimensional roller coasters in which the friction force is considered, as explained in the associated lesson. In a challenge the mirrors real-world engineering, the designed roller coaster paths must be made from at least five differentiable functions that are put together such that the resulting piecewise curving path is differentiable at all points. Once designed mathematically, teams build and test small-sized prototype models of the exact designs using foam pipe wrap insulation as the roller coaster track channel with marbles as the ride carts.

Students investigate the ways in which ancient technologies six types of simple machines and combinations are used to construct modern buildings. As they work together to solve a design problem (designing and building a modern structure), they brainstorm ideas, decide on a design, and submit it to a design review before acquiring materials to create it (in this case, a mural depicting it). Emphasis is placed on cooperative, creative teamwork and the steps of the engineering design process.

Student pairs experience the iterative engineering design process as they design, build, test and improve catching devices to prevent a "naked" egg from breaking when dropped from increasing heights. To support their design work, they learn about materials properties, energy types and conservation of energy. Acting as engineering teams, during the activity and competition they are responsible for design and construction planning within project constraints, including making engineering modifications for improvement. They carefully consider material choices to balance potentially competing requirements (such as impact-absorbing and low-cost) in the design of their prototypes. They also experience a real-world transfer of energy as the elevated egg's gravitational potential energy turns into kinetic energy as it falls and further dissipates into other forms upon impact. Pre- and post-activity assessments and a scoring rubric are provided. The activity scales up to district or regional egg drop competition scale. As an alternative to a ladder, detailed instructions are provided for creating a 10-foot-tall egg dropper rig.

Students act as structural engineers and learn about forces and load distributions as they follow the steps of the engineering design process to design and build small-scale bridges using wooden tongue depressors and glue. Teams brainstorm ideas that meet the size and material design constraints and create prototype bridges of the most promising solutions. They test their bridges to see how much weight they can hold until they break and then determine which have the highest strength-to-weight ratios. They examine the prototype failures to identify future improvements. This activity is part of a unit in which multiple activities are brought together for an all-day school/multi-school concluding “engineering field day” competition.

To gain a better understanding of the roles and functions of components of the human respiratory system and our need for clean air, students construct model lungs that include a diaphragm and chest cavity. They see how air moving in and out of the lungs coincides with diaphragm movement. Then student teams design and build a prototype face mask pollution filter. They use their model lungs to evaluate their prototypes to design requirements.

Students learn about the role engineers play in designing and building truss structures. Simulating a real-world civil engineering challenge, student teams are tasked to create strong and unique truss structures for a local bridge. They design to address project constraints, including the requirement to incorporate three different polygon shapes, and follow the steps of the engineering design process. They use hot glue and Popsicle sticks to create their small-size bridge prototypes. After compressive load tests, they evaluate their results and redesign for improvement. They collect, graph and analyze before/after measurements of interior angles to investigate shape deformation. A PowerPoint® presentation, design worksheet and data collection sheet are provided. This activity is the final step in a series on polygons and trusses.

Students follow the steps of the engineering design process while learning more about assistive devices and biomedical engineering applied to basic structural engineering concepts. Their engineering challenge is to design, build and test small-scale portable wheelchair ramp prototypes for fictional clients. They identify suitable materials and demonstrate two methods of representing design solutions (scale drawings and simple models or classroom prototypes). Students test the ramp prototypes using a weighted bucket; successful prototypes meet all the student-generated design requirements, including support of a predetermined weight.

Student teams investigate biomedical engineering and the technology of prosthetics. Students create a model prosthetic lower leg using various materials. Each team demonstrate its prosthesis' strength and consider its pros and cons, giving insight into the characteristics and materials biomedical engineers consider in designing artificial limbs.

Students design and build prototypes for protective eyewear. They choose different activities or sports that require protective eyewear and design a device for that particular use. Students learn about the many ways in which the eyes can be damaged and how engineers incorporate different features and materials into eyewear designs to best protect the eyes.

Students experience the steps of the engineering design process as they design solutions for a real-world problem that could affect their health. After a quick review of the treatment processes that municipal water goes through before it comes from the tap, they learn about the still-present measurable contamination of drinking water due to anthropogenic (human-made) chemicals. Substances such as prescription medication, pesticides and hormones are detected in the drinking water supplies of American and European metropolitan cities. Using chlorine as a proxy for estrogen and other drugs found in water, student groups design and test prototype devices that remove the contamination as efficiently and effectively as possible. They use plastic tubing and assorted materials such as activated carbon, cotton balls, felt and cloth to create filters with the capability to regulate water flow to optimize the cleaning effect. They use water quality test strips to assess their success and redesign for improvement. They conclude by writing comprehensive summary design reports.

Students design and build their own model levees. Acting as engineers for their city, teams create sturdy barriers to prevent water from flooding a city in the event of a hurricane.