Product Design and Manufacture BEng

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 

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.

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.

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.

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.

This module seeks to develop an understanding of materials in design across a wide range of engineering applications. The module is arranged in 4 blocks covering designing with light alloys, polymers, composites, and functional materials. This covers important functional ceramics as well as other 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 failure of the product/component. This module will explore:

• Material Attributes
• Engineering Context
• Manufacturing of Material
• Production Processes
• Environmental Impact

This is a project based module for Product Design and Manufacture students in their second year. Through practical design work the students will be faced with the problems of managing different constraints and producing cohesive design proposals. The students will become familiar with the process of receiving design briefs, managing time and resources and presenting design solutions. You’ll spend 12 hours in practicals and eight hours in further activity sessions each week when studying this module.

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

Building on Industrial Design and Professional practice from the 1st year of the programme, the second module continues to explore the field of Industrial design in more depth. The first half of the module focuses on topics such as branding and marketing; an understanding of these practises can impact how/what we design into products. We then build on the knowledge of ecology and sustainability established in the first module, to understand the impact that our designs have, and how we can minimise our environmental impact. The module also takes a more advanced look into Engineering Drawings and teaches students how to review drawings and make necessary alterations based on feedback.  

• Branding and Marketing
• Company Structures
• Product Design Industry
• Supply Chains
• Sustainability: the facts
• Sustainability Design Tools
• Engineering Drawings 

The aim of this module is to develop knowledge, understanding and practical skills in design for manufacturing and manufacturing and product development. It covers design for manufacturability, design for assembly, rapid prototyping and manufacturing, jigs and fixtures, process planning and group technology and design for cost. You’ll spend two hours in lectures and three hours in practicals each week when studying this module.

This is a project based module for Product Design and Manufacture students in their second year. The module comprises an individual and a group design project. Through practical design work the students will be faced with the problems of managing differing constraints, possibly conflicting views and workload management to produce a cohesive design proposal. You’ll spend ten hours in practicals and four hours in further activity sessions each week when studying this module.

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

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.

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