Undergraduate Degree

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DR2012

DR2012 Materials and Manufacturing for Designers

[Contact Hours: 39 hours; Pre requisite: Nil; Academic Unit: 3.0]


Academic Unit: 3 AU

Pre-requisite: Nil


Learning Objectives

This course is designed to teach students the fundamentals of materials and manufacturing as part of the product design process. It covers the fundamentals and design principles for plastic parts design, in particular for plastic injection moulding parts. The course will also offer an introduction to different types of materials used in the manufacture of products.

 

Contents

In this course, students will acquire the basic knowledge of plastic part and injection mould design and material selection of different types of materials. With the acquired knowledge, students will embark on projects to design products using plastics and various other materials.

 

Course Outline

 Week

Lecture Topics

Hours

 

1

 

Introduction to Parts Design

Introduction of plastic, sheet metal and composite parts for products​

3

 

2 - 5

 

Plastic Part Design

Plastic materials and properties. Basic theory of plastic part design. Joining and assembly of plastics. Decorating plastics.

Introduction to plastic injection moulding and mould design.

Design for assembly.

12

 

6 - 8

 

Project 1 – Plastic Part Design

Design of plastic parts for a product, taking​ into account materials properties, decoration, joining, assembly and mould design.

9

 

9 - 11

 

Material Selection for Product Design

Metal materials.

Composite Materials.

Rubber and Elastomer Materials

Natural Materials and Natural Engineering Materials

9

12-13

Project 2- Materials Selection

Students to propose material selection for a range of products, e.g. consumer product, furniture, bicycle, etc.

6

Total

39

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Learning Outcome

Upon successful completion of the course, students will be able to:

1)      understand the design guidelines for cost-effective plastic part design

2)      learn the varied methods of fastening and joining plastic parts

3)      be familiar with the various types of decorating methods for plastic parts

4)      demonstrate the application of plastic for design and functional requirements

5)      be familiar with material selection for product designs

6)      demonstrate the application of various materials for design and functional requirements

 

Student Assessment

Continuous Assessment (100%)

a)    Class Project and Presentation 1 (45%): Design of plastic parts.

b)    Class Project and Presentation 2 (40%): Material selection for a range of products.

c)    Class Participation (15%): Students will be assessed on their participation in class discussions and showing of initiative in class activities.

 

 

References

​Malloy R.A., Plastic Part Design for Injection Molding: An Introduction, Hanser Gardner Publications, 2010 

Fuh J.Y.H., Zhang Y.F., Nee A.Y.C., Fu M.W., Computer-Aided Injection Molld Design and Manufacture, CRC Press, 2004. 

Anderson, DM, Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Cost, High-Quality Products for Lean Production, CRC Press, 2014. 

Ashby M., Johnson K., Materials and Design: The Art and Science of Materials Selection in Product Design, Elsevier, 2002 

Lesko J., Industrial Design Materials and Manufacturing, John Wiley & Sons, 2007
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