Product Design and Manufacture including an Industrial Year BEng

Sketching; an essential skill for all Product Designers. This module will develop your sketching skills, taking you from the basics of drawing simple objects through to mastering drawing in perspective and constructing complex objects. We utilise modern and up to date technologies and as such the sketching which is taught and practised within this module will be digital and produced through the use of digital drawing devices! In this module you'll learn:

• Progressively learn to add detail to drawings.
• How to draw in 3-point perspective.
• How to draw quickly and neatly.
• To draw complex forms.
• How light and shade can explain complex forms. 
• Exercises to help develop an understanding and appreciation of form.

In this yearlong module you'll gain a deeper understanding of engineering design principles using practical project work. You'll learn CAD from the ground up, and by the end of the module you'll be well versed in the software.

Further you'll undertake practical workshops, where you'll learn how to use fundamental engineering machinery, which forms the basis of more advanced techniques you'll learn in higher level modules.

Topics covered include:

• Process of design supported by practical design activities
• Engineering drawing CAD solid modelling and drawing generation  
• Machine elements Group Design Project with Integrated Individual Element  
• Machine shop practical training 

Practising Product Designers are often referred to as a jack of all trades and a master of none; This module begins a series of modules which focus on the broader discipline of Industrial Design and many topics which influence the practice that Designers need to be well versed in to create appropriate solutions to problems! To support the learning of these topics, and to begin understanding the process of design in a little more depth, students who participate in this module will undertake a short design project.

Other topics covered include:

• History of Design.
• Impact on Popular Culture.
• Role of the Designer.
• Design Methodology.
• Ethical Responsibility.
• Graphical Skills.
• Photography.
• Portfolio Skills.
• Sustainability and Ecology.

A deep understanding of both materials and manufacturing techniques used to process these materials is essential for all product designers, to produce effective and commercially viable products. This year long module introduces students to the properties of materials, the main failure mechanisms which a designer will be concerned with (e.g overload, fracture, creep, fatigue) and core manufacturing methods used in engineering applications.

It includes the following topics:

• Role of materials and material properties in the design process.
• Selection and use of materials.
• Basic science underlying material properties Approaches to avoid failure of materials.
• Introduction to manufacturing in the UK.
• Casting, machining, moulding, forming, powder processing, heat treatment, surface finishing and assembly.
• Introduction into additive manufacturing an introduction to manufacturing metrology.

This module introduces a range of fundamental elementary mathematical techniques that can be applied to mechanical engineering, manufacturing and product design problems.

The aim of the module is to provide engineering students with a base in mathematical knowledge which can then be built on if required in subsequent years, however as a product design student this will be the only maths module you will undertake.

This module includes:

• The calculus of a single variable, extended to develop techniques used in analysing engineering problems
• Advanced differential and integral calculus of one variable
• First-order ordinary-differential equations
• Algebra of complex numbers
• Matrix algebra and its applications to systems of equations and eigenvalue problems
• Functions and their properties
• Vector spaces and their applications
• Vector calculus

The aim of this module is to introduce students to fundamental concepts and principles of solid mechanics and dynamics, and their applications to mechanical engineering systems. A wide range of engineering structures and mechanical components need to be designed to support static loads and as an engineer it is important to understand the way in which forces are transmitted through structures for efficient and safe design. This module includes:

• Static equilibrium: force and moment analysis in design; frictional forces.
• Stress, strain and elasticity.
• Bending stresses in beams.
• Relationship between angular and linear motion.
• Work, energy and power, including kinetic and potential energy.
• Geared systems.
• Static and dynamic balancing.

Designers need to be able to communicate their thoughts and design work to a broad range of individuals, not limited to, Clients, Customers, Specialist Engineers, Advertising specialists, other designers etc. To achieve effective communication a broad range of skill sets, and techniques need to be understood and employed. The module will develop CAD skills and include content on surface modelling so that students are able to model almost any object with the appropriate level of detailing. Following on from this the module will introduce Keyshot, a software that allows the production of high-end realistic computer-generated images and animations to communicate designs.

• Solidworks Parametric Modelling
• Solidworks Surface Modelling
• Digital Sketching & Rendering
• Keyshot Photo realistic Rendering

The aim of this module is to develop knowledge, understandingand practical skills in Design for Manufacturing (DFM) and CAD-CAM techniquesand tools for Manufacturing and Product Development. It covers design formanufacturability, design for assembly and knowledge of polymer, metal glassand timber production techniques.

This module will give students the experience of design principles associated with manufacturing processes. The lecture material will cover design for manufacture tools and techniques focusing on processes for high volume, low-value production. Key processes such as injection moulding will cover basic design constraints and tooling and assembly techniques. Re-assessment Students who fail this module overall and are required to complete a re-assessment will be re-assessed by exam. The re-assessment exam mark alone will be used to determine whether students satisfy progression requirements

Practising Product Designers are often referred to as a jack of all trades and a master of none; This module begins a series of modules which focus on the broader discipline of Industrial Design and many topics which influence the practice that Designers need to be well versed in to create appropriate solutions to problems! To support the learning of these topics, and to begin understanding the process of design in a little more depth, students who participate in this module will undertake a short design project.

Other topics covered include:

• History of Design.
• Impact on Popular Culture.
• Role of the Designer.
• Design Methodology.
• Ethical Responsibility.
• Graphical Skills.
• Photography.
• Portfolio Skills.
• Sustainability and Ecology.

The aim of this module is to develop an understanding of materials in design across a wide range of engineering applications, covering designing with polymers, designing with light alloys, designing with composites and designing with functional materials. This will be achieved through the design requirements of a case study, key material properties relevant to the engineering application, manipulation of the microstructure through processing and example calculation against the failure of the product/component. Consideration will be given to material attributes, engineering context, manufacturing processes and environmental impact. The students will be exposed to a portfolio of applications, materials properties, processing and principles that they can draw upon when tackling new designs.

This module seeks to develop an understanding of materials in design across a wide range of engineering applications. The module is arranged in blocks covering designing with polymers, designing with alloys, designing with ceramics, designing with composites and designing with functional materials. Each block will explore the design requirements in detail of a particular case study followed by other examples, key material properties relevant to the engineering application, manipulation of the microstructure through processing and example calculations against the failure of the product/component. Consideration will be given to materials attributes, engineering context, manufacturing processes and environmental impact. Taken as a whole the blocks build up a portfolio of applications, materials properties, processing and principles that the students can draw upon when tackling new designs.

Case studies are an increasingly popular form of teaching and have an important role in developing skills and knowledge. Student-centred activities are based around topics that demonstrate theoretical concepts in an applied setting.

This module will introduce ergonomics (human factors) encompassing different aspects of product design and other applications. The module will demonstrate why ergonomics input to design is important and will teach the practical application of user centred research methods, also covering research ethics and statistical methods to analyse results. Content covered includes:

• Task Analysis
• Anthropometric data and Understanding Humans
• Human Factors in Design
• Designing for Users
• User Based research methods
• Evaluation Methods
• Ethics in Design
• Emotional Design

The Major Project is the final and largest piece of work which students undertake during their studies on our programme.

Students conduct the design and engineering phase of the project over 16 weeks. The project requires students to utilise and demonstrate a variety of skills which have been learnt throughout the duration of their course and apply them to develop a fully detailed and complete design. At the end of the module students will present their final design, alongside documents such as engineering drawings which communicate all the required manufacturing detail to produce the product. These are as follows:

• Ideation phase
• Production of high-quality concepts
• Development Design Detailing
• Engineering detail
• Engineering Drawings
• High quality Renders
• Design Presentation Boards

Building on Industrial Design and Professional practice from the first 2 years of the programme, the third module continues to explore the field of Industrial design in more depth. Linked directly with the two projects within BEng 3rd Year Projects, the module provides an opportunity to practice implementing some of the theory learnt about sustainable design and Engineering analysis, to a real-world design problem.

• Topics within this module include:  
• Sustainable Design
• Bioplastics + Biodegradable plastics
• Commercial considerations of sustainability
• Young's modulus + stress and strain
• Finite Element Analysis (FEA) Theory
• FEA Drop Testing
• FEA Static Tests

The Major Project is the final and largest piece of work which students undertake during the final 16 weeks of their study. In this module a problem area/project title is selected, and students undertake a substantive body of research and investigation to understand the background and relevant requirements prior to entering the design phase of the project. A broad range of investigatory methods will be utilised in order to identify a profile of user requirements and desires for the product which will be designed. 

• User based Research
• Questionnaires
• Empathy Studies
• Identify Project opportunities
• Develop requirements for the Product
• Production of Brief

Within this module we build on the materials and manufacturing knowledge developed within the first two years of the programme, with a particular focus on Polymers and the Injection moulding process; a heavily utilised manufacturing process by Product Designers. Consideration of part/component design for this manufacturing technique shall be explored in depth, and this shall be practiced in a design project that runs alongside this module. Later in the module other material and manufacturing areas will be looked at such as timber selection and metal casting.  

• Component design and optimisation for injection moulding
• Advanced Polymer selection
• Mold Flow Analysis within Solidworks
• Part costings
• Understanding mold design - core and cavity design
• Timber selection, production and manufacturing methods
• Metal selection and casting techniques

The module comprises of two projects. In the first project, students will be able to use ‘People Centred Research’ to find creative approaches to difficult problems. In the second project, students will be able to detail a simple product for manufacture by injection moulding. You’ll spend 12 hours in practicals and four hours in further activity sessions each week when studying this module.

In this module you will start to develop one of the key skills for an engineer – that of being able to program. You will gain the skills required to analyse, design and implement solutions to practical engineering problems through the use of computer aided design tools and the development of software based solutions.

This module will provide you with a thorough understanding of cognitive ergonomics and the way in which the consideration of cognitive ergonomics can impact on human performance in the workplace. 

A broad-based module covering the chemistry, material properties and manufacturing methods relevant to polymers.

Topics include:

• Polymer chemistry and structure
• Routes to synthesis, polymerisation techniques, practical aspects of industrial production
• Viscoelasticity, time-temperature equivalence
• Rheology of polymer melts, heat transfer in melts, entanglements
• Properties of solid polymers, yield and fracture, crazing
• Manufacturing with polymers, extrusion, injection-moulding
• Design/ processing interactions for plastic products

For human factors/ergonomics work, simulation tools can enable designers, managers and end-users to experience products and systems in realistic, interactive environments. Such advancements have significant cost implications, enabling designs and their implications to be visualised early in the development life cycle. In addition, virtual/augmented reality and other advanced human-machine interfaces (HMIs) are being developed in many different industries to support different user needs.

This module will provide you with the knowledge and skills required to understand and utilise computers as human factors tools for understanding peoples’ interactions with new technology. Moreover, the module will consider HMIs that are increasingly common in modern life and frequently designed and evaluated using simulation techniques.

The module is a mix of practical and research-oriented content, and you will make extensive use of the simulation facilities and on-going research projects within the Human Factors Research Group and elsewhere in the University.

Topics include:

• virtual reality technologies/environments/interfaces
• augmented reality; fidelity and validity of simulators
• presence factors for simulation
• understanding and minimising simulator sickness
• multimodal interfaces including the use of natural language and gesture interfaces, computers and collaborative/social interfaces, accessibility, in-car interfaces 

Delivery

Assessment method