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This study compares engineering expert problem-solving on a highly constrained routine problem and an ill-defined complex problem. The participants (n=7) were recruited from two large public Research I institutions. Using a think aloud methodology, the experts solved both routine and non-routine problems. The protocols were transcribed and coded in Atlas ti. The first round of coding followed a grounded theory methodology. Additional rounds of coding were informed by previous problem solving studies in math and engineering. In general, this study confirmed the 5 Step Problem Solving Method used in previous challenged based instruction studies. These results are discussed in terms of their implications for improving undergraduate engineering education.