The authors describe their experiences creating a cornerstone engineering design course for mechanical and industrial engineering undergraduate students. Starting with a tabula rasa, we have been working to create a one-semester design experience that integrates Human Factors (HF) directly into every aspect of engineering design. In the last decade, we have identified three key issues with which we grapple: lack of integration of HF in design; lack of access to cohesive HF data; and dysfunctional student teams. Given the lack of available information upon which to draw for the design of this course, we adopted a CQI-like iterative, organic, and evolutionary approach. In this paper, we present many of the ways we have attempted to address these issues, relating to courseware development, course management, assessment and grading, and student and instructor support. We summarize by presenting our advice to others who are looking to fully embed HF or other non-design fields into a cogent design experience for their students. All our courseware and tools are available freely on the web.