This paper describes classroom experience with the shape optimization
of a lap joint. The project stressed the combination of optimization b
ased on analytical models and experimental improvement of the design o
btained based on analysis. Students used a variety of tools for optimi
zing the designs, ranging from exhaustive evaluation via spread sheet
programs to formal optimization. The project shows promise for introdu
cing students to all aspects of design optimization. Improvements in t
he basic project are suggested on the basis of classroom experience.