The design of effective learning experiences is critical in equipping future engineers with the skills to address real-world challenges. This study presents the development and implementation of a practical learning experience integrated into the Theory and Design of Machines (TDM) course, a core component of the Mechanical Engineering Degree at the Polytechnic School of Alcoy, Universitat Politècnica de València. The initiative focuses on a self-constructed mockup of a rotating machine equipped with interchangeable bearings and a vibration monitoring system.

The primary aim is to enhance students’ understanding of machine condition analysis through hands-on experimentation while reinforcing theoretical principles related to bearing performance and maintenance. The learning experience was developed following active and experiential learning methodologies, combining simulation tools (KISSsoft and KISSsys) with physical interaction with the mockup. Over two sessions, 112 students, divided in 4 groups, participated in the initiative, adjusting motor speeds, acquiring vibration data using accessible measurement tools, and analyzing patterns to evaluate the system's health.

The results of a post-activity survey showed that 78% of the students saw improvements on their understanding of vibration analysis. 67% of the students are confident that they are able to tackle real-world vibration analysis cases. Qualitative feedback highlighted the mockup's accessibility and the ease of integrating simulation and experimental components.

The design emphasizes accessibility by using open-source tools and low-cost technologies, enabling its replication in other educational contexts with minimal resources. This study demonstrates how integrating theoretical, simulated, and practical components fosters a deeper understanding of mechanical design and predictive maintenance. The proposed methodology not only aligns with contemporary pedagogical approaches in STEM education but also provides a transferable framework for designing similar practical experiences in engineering disciplines.

Keywords: Predictive maintenance, active learning, mechanical engineering, STEM education.