Lessons Learned from Capstone: Tips For A Successful Product Design

In the fast-evolving world of product design and development, delivering solutions that truly satisfy customers is both an art and a science. At Brigham Young University’s Capstone Program, I’ve seen firsthand how thoughtful design can transform ideas into impactful realities.  Drawing from this experience and broader industry insights, here are 14 principles to guide designers in creating solutions that exceed expectations while remaining practical and purposeful. 

1: Look Beyond Words: Decode Customer Needs 

Customers often articulate what they think they want, but their true needs may lie beneath the surface. A customer might request a lightweight tool, yet their real priority could be durability under heavy use. To bridge this gap, create a requirements matrix—list their stated desires alongside observable behaviors and constraints. For example, shadowing a user might reveal that ease of maintenance trumps weight. By using your eyes, not just your ears, you uncover the unspoken priorities that shape a successful design.  

2: Think Holistically with Systems Thinking 

A component designed in isolation is a recipe for failure. Consider a pump system: optimizing the impeller alone won’t matter if the housing leaks or the motor overheats. Systems thinking demands that you map how each part interacts within the whole—ensuring the entire function, like reliable water flow, is achieved. Sketch the system’s architecture early using block diagrams identifying interfaces and dependencies, to avoid costly rework later. 

3: Pinpoint the Customer’s Goal 

Every design serves a purpose, but what’s the customer really aiming to improve? Are they cutting costs, boosting sales, or enhancing performance? A manufacturer might seek a cheaper widget, while a retailer prioritizes shelf appeal. Dig into their context—ask why they’re investing in this solution. Understanding their “improvement vector” keeps your design aligned with their bottom line, whether it’s profit or efficiency. 

4: Optimize the Right Characteristics 

Not every aspect of a design needs perfection. You could enhance every gear in a mechanism, but if speed is the customer’s priority, only the drivetrain might need refinement. Build your requirements matrix into a design equation—solve for “X,” the critical characteristic that exceeds expectations (design for maintainability, etc.). For instance, if a bike’s weight must drop below 15 pounds, focus on frame materials rather than over-engineering the brakes. Focusing on “X” beats overkill. 

5: Iterate Early and Often 

Early iteration catches flaws before they solidify. A sleek housing might look great on paper, but if it’s unmoldable, you’re back to square one. Prototype quickly—think 3D-printed mockups or cardboard models—and test manufacturability. In one student project, we iterated automated assembly machine release mechanisms several times in a week, ensuring it could be 3D printed or machined. Early loops save time and resources downstream. 

6: Guard Against Scope Creep 

Ambition can derail a project. A customer might love your base design, then ask for a built-in sensor “while you’re at it.” Beware: extra features inflate costs and timelines. Define the scope upfront in your matrix and treat add-ons as separate deliverables. Charge accordingly—turn scope creep into an opportunity rather than a burden. Clear boundaries keep everyone focused. 

7: Anticipate the Unexpected 

Surprises sink designs. Tools like Design Failure Mode and Effects Analysis (DFMEA) and Process FMEA (PFMEA) are your crystal ball. For a portable stove, DFMEA might flag a weak hinge; PFMEA could highlight an assembly snag. Run these analyses early, ranking risks by severity and likelihood, then tweak your design—like reinforcing that hinge with a thicker pin. Mistake-proofing upfront beats firefighting later. 

8: Leverage Commercial Off-the-Shelf (COTS) Components 

Why build from scratch when proven parts exist? COTS components—like standard bearings or microcontrollers—slash development time and cost. In a recent BYU project, integrating an off-the-shelf actuator cut our timeline by months. The trick is integration: ensure compatibility through spec sheets and mockups. Reinventing the wheel rarely pays off. 

9: Grok It! 

Complex designs often need code—say, for a sensor-driven prototype. Don’t hand-code every line; use tools like Grok or Claude to generate efficient scripts fast. For an autonomous drone project, AI helped us create a Python wrap around to connect two devices.  We spent weeks trying to manually code it, but until we uploaded the pages of the tech manual into AI, we couldn’t solve the problem. Test the output right in AI, refine it, and focus your energy on the physical design. Smart tools amplify your craftsmanship.  

10: Benchmark Best Practices 

Innovation doesn’t mean ignoring what works. Study current best practices—competitor products, industry standards, or academic papers. If designing a collapsible chair, benchmark how others handle hinges or weight distribution. A quick teardown or web search reveals what to emulate or surpass. Standing on giants’ shoulders accelerates progress without redundancy.  

11: Design for Manufacturability 

A brilliant concept flops if it’s unmakeable. Not everything should be 3D printed—complex geometries might demand milling or casting instead. Sketch your product and process: can this part be stamped in one step, or does it need multi-stage assembly? Design with the factory in mind. 

12: Plan for Supply Chain Realities 

Even the best designs falter if parts vanish. In 2020’s volatile market, we had to check component availability—lead times for actuators and sensors stretched to months. Cross-reference suppliers during design; if a motor’s scarce, spec an alternative. One team avoided delays by sourcing dual-compatible batteries early. Anticipating supply hiccups keeps your timeline intact.  

13: Craft Prototypes with Care 

A prototype isn’t just a test—it’s your design’s ambassador. Hand-assembled models should exude quality, from tight tolerances to polished finishes. Prototypes should emulate the digital design and can have the appearance of factory made. High craftsmanship signals competence and builds trust.  

14: Design changes the world 

These principles aren’t abstract—they’re a playbook for turning customer needs into tangible solutions. At BYU, we’ve applied them to projects with global reach, proving that disciplined design can change lives. Whether you’re sketching a gadget or a system, prioritize clarity, practicality, and purpose. The result? Designs that don’t just work—they inspire. 

To cite this article:
Cutler, Scott. “Lessons Learned from Capstone: Tips For A Successful Product Design.” The BYU Design Review, 16 June 2025, https://www.designreview.byu.edu/collections/lessons-learned-from-capstone-tips-for-a-successful-product-design.