Modular Design Methods for Complex Systems

Modular design offers a systematic approach to decomposing complex systems into coherent, self-contained units, or modules, each fulfilling specific functions while interfacing predictably with others. By defining clear module boundaries and standardised interfaces, engineers can manage complexity, enhance maintainability and facilitate parallel development. Core techniques include dependency modelling via Design Structure Matrices (DSMs), interface decoupling through axiomatic design principles, and computational clustering algorithms that automate module partitioning. Recent advances have introduced data-driven workflows, leveraging large language models for rapid DSM generation, and multi-resolution modelling to tailor granularity across design stages. Together, these methods support scalability, reconfigurability and life-cycle adaptability in fields as varied as aerospace, automotive, consumer electronics and architectural systems.

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Research from all publishers

A novel workflow employs a large language model to generate a preliminary DSM for mechanical systems. The prototype reproduced over 75 per cent of expert-defined dependencies in a diesel engine case study, demonstrating that natural language processing can accelerate the module definition process without extensive manual input. A clustering approach for FDM 3D printers integrates DSM with the K-means algorithm, using the Jaccard similarity coefficient to segment functional modules. Evaluation via the elbow method and silhouette analysis yielded an optimal three-module architecture, offering a replicable methodology for consumer-orientated product modularisation. In the built-environment domain, a multi-resolution DSM framework models the modular building design process at varying levels of detail. Low- and high-resolution matrices enable schedule and cost simulations, with a proposed approximation method reducing modelling overhead. This quantifies trade-offs between granularity and predictability, informing decision-making in prefabricated construction.

Modular Design Methods for Complex Systems publication trend

The graph below shows the total number of articles in modular design methods for complex systems across all publications each year (not limited to Nature Index journals).

Technical terms

Design Structure Matrix (DSM): A square matrix representing dependencies among system elements to guide module partitioning.

Clustering Algorithm: A computational method that groups system components based on similarity metrics, such as functional or behavioural correlation.

Module Granularity: The level of detail at which modules are defined, balancing integration overhead against interface complexity.

Interface Coupling: The degree of interdependence between modules, where lower coupling enhances independence and reusability.

Large Language Model (LLM): A neural network-based model trained on extensive text corpora, here used to automate the construction of dependency matrices.

References

1. Auto-DSM: Using a Large Language Model to generate a Design Structure Matrix. Natural Language Processing Journal (2024).
2. Research on product innovation design of modularization based on theory of TRIZ and axiomatic design. Advances in Mechanical Engineering (2018).
3. K-Means Module Division Method of FDM3D Printer-Based Function–Behavior–Structure Mapping. Applied Sciences (2023).
4. Multiresolution Modeling of a Modular Building Design Process Based on Design Structure Matrix. Buildings (2023).