PTC workshops are certainly the right way to get started! After writing several training courses as part of my normal job as well as for mentoring FIRST teams, I have to say that I'm really impressed with PTC's curriculum.
I'm working on a new model for training local teams. Since I'm about the only one doing Pro/Engineer training for local teams, I have to be more efficient.
I currently have one student that holds CAD training sessions over the summer using the PTC curriculum. They spend a couple hours a week going over the curriculum as well as setting up new CAD team members. The goal is to have a CAD leader for each school who will run the training. I support those training sessions answering any questions as well as providing additional training for those who are more advanced.
1. As far as supplemental training, I've always found that the best training is to start doing real work and have a good support network for questions. Often I will challenge students by asking them to do things like edit references to move a feature to a different location. If it's a part that moves, I'll have them create a mechanism that moves the way it should.
2. I try to make sure new students start off with instructor-led courses, at least several initial hours. It's too easy for them to get frustrated at the beginning and quit.
3. I've been fortunate in having some really talented students and I don't think I've really had much problem with visualization...except when it comes to sketching. I usually have students do some 3-D sketching for practice. It's really a necessary part of design and they need to know how to communicate with their teammates without running to Pro/E.
4. Ratio of students to teacher/mentors related to success is a difficult one. I've had groups of 20 where maybe 5 students really participated. I've had groups of 6 where 5 students participated. Almost every season, I end up with 3-5 students who design the robot in Pro/E.
Perhaps the #1 thing I've learned is that the training really has to be more than an hour to be effective. I would prefer to do an 4 or 8 hour training and then perhaps meet weekly to answer questions.
Finally...thankyou for your questions! I am really hopeful that the entire group interacts, comparing notes and learning from each other. If you have more questions, please ask. Please share your experiences as well.
Thanks and look forward to hearing from you again.
Josh