This module provides a critical stepping stone in empowering students to make informed decisions in relation to engineering design. Building on previous modules, students will further develop their understanding of materials, with a specific focus on the properties and manufacture of a range of polymers. The exploration of advanced machining and joining processes through skills building activities will give students an opportunity to refine their skills and evaluate the effectiveness of these using objective measures and self-critique. A contemporary engineering problem will be given to students and they will be expected to synthesise their knowledge of material properties, understanding of a wide range of processing skills and engineering specification in generating a concept. Students will be expected to use skills and knowledge from previous graphics, design and technology, and process modules in developing a design solution through ideation sketches, development of prototypes and culminating in a virtual animation of their final design with appropriate specifications, calculations and environmental impact considerations.

Outline of the sources, physical structure, manufacture, classification and main forms of supply plastics, Methods of waste disposal, Properties and use of the common thermoplastics including polyethylene, polypropylene, PVC, polystyrene, acrylics, PTFE, cellulose acetate and nylon. Properties and use of the common thermosetting plastics including; phenolic resin, polyester resin, epoxy resin and polyurethanes. Processing of plastics including; injection moulding, extrusion, vacuum forming, blow moulding, compression moulding, calendaring, spreading and laminating. Casting Processes - Casting terminology, Design considerations in casting, Expendable mould casting, Cores and core making, Multiple-use-mould casting processes, Thermal joining processes, Classification of welding and thermal cutting processes, Welding basics and common concerns, Types of fusion welds and types of joints, Design considerations, Heat effects, Weldability and Joinability, Oxyfuel Gas Welding, Consumable and non-consumable arc welding processes, Resistance welding and other advanced welding processes, Soldering and Brazing, Destructive and non-destructive testing, Engine Design - Internal and external combustion engines, Environmental impact evaluations, Basic load calculations and design considerations (direct, shear, strain, Young's Modulus, torque), Frameworks, Dynamics - linear motion angular motion, relative motion, Work, Energy, Newton's law of impact

On successful completion of this module, students will be able to... • Understand fundamental properties of polymers and the processes utilised in their manufacture. • Describe the differences between thermosetting plastics and thermoplastics. Understand the principles associated with casting processes and discuss the importance of design considerations when casting components. • Describe a range of joining processes and discuss the advantages and limitations of these in various contexts. • Understand the principle operation of internal and external combustion engines, evaluate environmental impact compared to alternative propulsion systems. • Demonstrate an in-depth understanding of systematic material selection. • Understand the principle associated with tool design with particular reference to ISO standards. • Calculate the deflection of machine elements subjected to loads in simple cases. Apply equations for Newton's Laws in analysing a variety of motions in engineering design.

On successful completion of this module, students will be able to... • Develop an appreciation for the complexities associated with material selection and advanced processes utilised in the manufacturing of engineering components. • Display strong interpersonal and communication skills in generating design solutions for applied engineering/technology problems. • Consider environmental impact and cost in generating conceptual designs

On successful completion of this module, students will be able to... • Demonstrate an ability to communicate a solution to a complex engineering problem using a range of media including freehand sketches, prototypes and animated digital model. • Demonstrate an ability to carry out a range of advanced machining processes through specific, skills building activities. • Evaluate the quality of skills and processes through a variety destructive and non-destructive testing techniques.

This module will incorporate a conceptual project requiring students to work collaboratively as part of a team in bringing the concept from initial idea through to a final fully animated virtual solution. Laboratory sessions will facilitate students in exploring and refining a range of skills and processes with particular focus on thermal joining processes and mechanical design. Students will be expected to self-critique and evaluate their performance using a range of objective measures including relevant destructive and non-destructive testing methods. Lectures will focus on further developing students understanding of materials, advanced joining and machining processes, engineering specifications and fundamental engineering science.