Engineering Β· Define, Develop & Optimize

Detroit is mid-build: bridges, batteries, and blocks.

The Gordie Howe International Bridge, Factory ZERO's EV lines, and neighborhood-by-neighborhood housing retrofits are all live engineering projects happening in Detroit right now. This unit runs the full NGSS engineering design cycle β€” define, develop, optimize β€” on real local problems.

NGSS Standards Addressed High School

  • HS-ETS1-1 Analyze a major global challenge to specify criteria and constraints for solutions that account for societal needs and wants.
  • HS-ETS1-2 Design a solution to a complex real-world problem by breaking it down into smaller, more manageable problems.
  • HS-ETS1-3 Evaluate a solution to a complex real-world problem based on prioritized criteria and trade-offs that account for a range of constraints.
  • HS-ETS1-4 Use a computer simulation to model the impact of proposed solutions to a complex real-world problem with numerous criteria and constraints.

NGSS Standards Addressed Middle School

  • MS-ETS1-1 Define the criteria and constraints of a design problem with sufficient precision to ensure a successful solution.
  • MS-ETS1-2 Evaluate competing design solutions using a systematic process to determine how well they meet the criteria and constraints.
  • MS-ETS1-3 Analyze data from tests to determine similarities and differences among several design solutions to identify features that can be improved.
  • MS-ETS1-4 Develop a model to generate data for iterative testing and modification of a proposed solution.
Warm-Up

Bell-Ringers

Project one at the start of class. Each has a click-to-reveal discussion note. More formats (Notice and Wonder, CER, Fact or Fiction, and more) are in the Bell-Ringer Bank.

πŸŒ‰ Transportation

The Gordie Howe International Bridge, connecting Detroit and Windsor, is a cable-stayed bridge instead of a simple beam bridge. Given that it needs to span a wide shipping channel without support piers in the water, why might engineers choose a cable-stayed design?

Discussion notes
Cable-stayed designs transfer deck loads through cables directly to tall towers, allowing very long spans without mid-channel piers that would obstruct shipping lanes β€” a constraint (keep the channel clear) that directly shapes the design solution, which is exactly the kind of criteria-and-constraints reasoning HS-ETS1-1 asks for.
🏠 Housing

A Detroit homeowner wants to lower winter heating bills in a century-old house. Insulation costs money upfront but saves money over time. What criteria and constraints would an engineer need to weigh before recommending a retrofit?

Discussion notes
Criteria might include: reduce heat loss, stay within budget, avoid disrupting the home's structure or historic character. Constraints could include wall cavity size, moisture control, and payback period. A good design balances upfront cost against long-term energy savings β€” a real trade-off analysis (HS-ETS1-3).
πŸš— Technology

Detroit automakers converting factories from gas engines to EV production have to redesign the entire assembly line, not just swap one part. Why can't they just replace the engine-building station and leave everything else the same?

Discussion notes
EVs use a fundamentally different power system (battery packs and electric motors instead of engines and fuel systems), which changes material flows, worker training, safety systems (high-voltage handling), and even the shape of the vehicle chassis β€” illustrating how engineering problems are systems, not single components (HS-ETS1-2).
πŸŒ‰ Transportation

Engineers weren't allowed to put a support tower in the middle of the river while building the Gordie Howe International Bridge. What's one reason a bridge builder might not be allowed to put a support piece in the middle of a busy river?

Discussion notes
Large cargo ships need clear open water to pass through the shipping channel β€” a support tower in the middle would block traffic. This is a constraint (a rule the design must follow) that shaped the whole bridge design.
🏠 Housing

A homeowner wants to keep their house warmer in winter without spending too much money. What are two things (criteria) they'd need to balance when picking an insulation upgrade?

Discussion notes
Cost (how much the upgrade costs upfront) and performance (how much heat loss it actually reduces) are the two main criteria to balance β€” the cheapest option isn't always the best value if it barely helps, and the best-performing option isn't worth it if it's unaffordable.
πŸš— Technology

Building electric cars needs different parts than gas cars β€” big batteries instead of gas tanks and engines. Why would a car factory need to change more than just one machine on the assembly line to build EVs instead of gas cars?

Discussion notes
A car is a system of connected parts. Changing the power source changes the parts, tools, and worker skills needed at many other stations too β€” not just one. Engineers have to think about how every part of a system affects the others.
Hands-On

Labs

Build the Bridge: Engineering a Model Span

⏱️ 60 minπŸ‘₯ Teams of 3–4πŸ“Ž Design, test, optimize

Teams design and build a model bridge from limited materials (craft sticks, string, tape) to span a fixed gap and hold as much load as possible without a mid-span support β€” mirroring the real constraint faced by Gordie Howe International Bridge engineers over the shipping channel β€” then test, measure failure points, and redesign.

Retrofit Detroit: Insulation Design Challenge

⏱️ 45 minπŸ‘₯ Teams of 3–4πŸ“Ž Heat transfer, cost vs. performance

Teams model heat loss through different wall assemblies using a small temperature-controlled or ice-cube test box, then compare insulation materials on cost vs. performance to recommend a retrofit package for an aging Detroit home.

People Mover Route Optimization

⏱️ 40 minπŸ‘₯ PairsπŸ“Ž Optimization & trade-offs

Using a simplified map of downtown Detroit, students optimize a transit loop for a given set of stops, balancing total distance, ridership access, and cost constraints against competing route options.

Explore

Simulations

Original on The Lab

Bridge Truss Load Tester

Adjust span, truss depth, and member strength, then load the bridge until the first member fails.

Launch Simulation →

Energy Forms and Changes

PhET Interactive Simulations β€” model heat transfer and insulation, directly supporting the retrofit design challenge.

Open Simulation β†’

Forces and Motion: Basics

PhET Interactive Simulations β€” explore load, friction, and force before testing a bridge design.

Open Simulation β†’

Gordie Howe International Bridge Progress

Windsor–Detroit Bridge Authority's public project site β€” real engineering milestones, specs, and construction photos.

Visit Site β†’
Go Further

Project Ideas

Design challenge

Vacant Lot Redesign

Choose a real or hypothetical vacant Detroit lot and design a proposal β€” urban farm, pocket park, stormwater garden β€” that balances community need, cost, and environmental benefit.

Systems project

EV Charging Network Plan

Design a public EV charging station layout for a Detroit neighborhood, weighing grid capacity, walkability, and equity of access across income levels.

Case study

Stadium Engineering Teardown

Pick one feature of Ford Field or Little Caesars Arena (retractable roof, sightlines, acoustics) and explain the engineering trade-offs behind its design.

Build challenge

Mini Bridge Challenge

Using only paper and tape, build the lightest possible bridge that can still hold a toy car across a fixed gap, and explain your design choices.

Build challenge

Insulated Box Challenge

Build a small insulated box out of household materials that keeps an ice cube from melting the longest, and explain which material worked best and why.

Design sketch

Redesign a Bus Stop

Sketch a redesigned bus stop that adds shelter, seating, and accessibility features, listing the criteria and constraints (cost, space, weather) you considered.

Assess

Show What You Know: Exit Ticket

Three quick questions to close the lesson. Answers are hidden until you click. Use Project Mode to display them full-screen.

Question 1

Using the Gordie Howe International Bridge as an example, give one criterion and one constraint for the design problem.

Answer
A criterion is what the design must do, such as carry heavy truck traffic safely. A constraint is a limit, such as no support piers in the shipping channel or a limited budget and schedule.
Question 2

A truss bridge fails first at its bottom chord in tension. Name two design changes that could raise its load capacity.

Answer
Increase the truss depth, since chord force is about bending moment divided by height. Add stronger or doubled members in the bottom chord, or add panels to spread the load.
Question 3

Why do engineers test a design, change it, and test again instead of testing once?

Answer
Each test reveals failure modes and trade-offs. Iteration lets engineers improve the solution against the criteria while staying inside the constraints.
Question 1

You are redesigning a bus stop. List two criteria and two constraints.

Answer
Criteria might be shelter from rain and seating for riders. Constraints might be a small sidewalk space, a limited budget, and keeping a clear path for wheelchairs.
Question 2

Why is it useful to test a design more than once?

Answer
Testing shows what works and what fails. Changing one thing at a time and re-testing lets you improve the design.
Question 3

Describe a trade-off a homeowner faces when choosing wall insulation.

Answer
Better-performing insulation usually costs more up front. The homeowner balances cost against energy savings over time.

View project rubrics →

Why Does This Matter?

Engineering, built on Detroit

Transportation

The Gordie Howe International Bridge and the century-old Ambassador Bridge sit a few miles apart, giving students two real bridge designs to compare for load path, materials, and constraints.

Housing

Detroit's ongoing push to renovate and retrofit its housing stock β€” rather than only building new β€” makes constrained, real-world design trade-offs (cost vs. performance vs. preservation) part of everyday city life.

Technology

Detroit's EV manufacturing transition is a live, citywide systems-engineering project, with visible local stakes in jobs, training, and infrastructure.

Sports

Detroit's stadiums and arenas are full-scale case studies in structural, acoustic, and crowd-flow engineering that students can see and visit directly.

Careers

Who works on this in Detroit?

Real roles and organizations in and around the city where this science is part of the job.

Civil / structural engineer

Windsor-Detroit Bridge Authority, MDOT

Designs, builds, and inspects bridges and roads, such as the Gordie Howe International Bridge.

Manufacturing engineer

GM Factory ZERO, Stellantis Detroit plants

Redesigns assembly lines and processes to build electric and gas vehicles safely and efficiently.

Building energy / retrofit engineer

DTE energy efficiency programs, housing agencies

Models heat loss and recommends insulation and system upgrades that cut energy bills.

Mobility engineer

Michigan Central innovation district and automaker mobility teams

Develops connected, automated, and electric vehicle technologies and the infrastructure they need.

Transportation planner

SEMCOG, DDOT, City of Detroit

Optimizes routes, stops, and street designs using ridership data, cost limits, and safety criteria.