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| Section | Objectives |
|---|---|
| Topic 1: Manufacturing Process - Joining | - Creating the Gearwheel - Adhesives and Gluing - Brazing and Soldering - Introduction to Joining - Mechanical Joining - Welding |
| Topic 2: Design and Designing | - Introduction to Design - Design as Model-Making - Design, Creativity, Invention and Innovation - Design and Needs - What is Good Design? - Problems and Solutions - Designing as Heuristic Problem-Solving |
| Topic 3: Manufacturing Process - Casting | - Casting Metals and Plastics - Liquefying the Material - Viscosity and Fluidity - Introduction to Casting - Types of Casting - Casting the Food Mixer Gearwheel - Casting Microstructure and Defects |
| Topic 4: Models of the Design Process | - Building a Simple Model of Design - Introduction to Models - Pahl and Beitz's Model of Design - March's Model of Design - French Model of Design - Usefulness of Design Models - BS 7000 Model of Design |
| Topic 5: Manufacturing Processes Overview | - Product Shapes - Basic Manufacturing Processes - Gears and Gearing - Scales of Material Structure |
| Topic 6: Manufacturing Process - Cutting | - Machining the Gearwheel - Cutting Processes - Machine Cutting - Types of Tool Material - Mechanics of Machining - Hardness - Introduction to Cutting |
| Topic 7: Manufacturing Process - Forming | - Working Temperatures - Forming the Gearwheel - Forces Applied during Forming - Forming Processes - Forming versus Casting - Introduction to Forming |
| Topic 8: Introduction to Manufacturing Processes | - The Manufacturing Process - Component Parts - Foundation - What is Manufacturing? |
| Topic 9: Product Design | - Engineering or Industrial Design - Product Function or Form - The Four Ps - Introduction to Product Design - Marketing the Product |
| Topic 10: Case Study in Design and Innovation | - Case Study: Brompton Folding Bicycle - Concept to Prototype to Production - Prototyping and Improving - Production |
| Topic 11: Surface Engineering | - Case Study: The Kitchen Knife - Stainless Steel - Applying Surface Coating Material - Introduction to Surface Engineering - Surface Wear |
| Topic 12: Product Design Specification | - Introduction to Product Design Specification - PDS Checklist - PDS Development |
| Topic 13: Conceptual Design | - The Importance of Concept - Establishing the Design Space - Concept to Prototype Case Study - Jet Engine - Concept to Prototype - Conceptual Design Case Study - Human-Powered Flight |
| Topic 14: Optical Materials Engineering | - Optical Materials Selection - Optical Properties of Light - Anti-reflective Coatings - Scratch-resistant Coatings |
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