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SESG3024 Manufacturing and Materials

Module Overview

This module manufacturing and materials is intended to develop a deeper understanding of the relationship between design, manufacturing processing and materials properties. This module discusses various manufacturing methods including casting, forming, welding, cutting, 3D printing, composite/polymer manufacturing and micro and nano fabrication. For each manufacturing method, the aspects covered include: aesthetics, principles, choices of materials, choice of processes, properties of materials, advantages and disadvantages, process economics. Examples are drawn from manufacturing processes mainly used in aerospace, automotive and marine industries.

Aims and Objectives

Module Aims

• To teach students a deeper understanding of the relationship between design, processing and properties in metals, polymers, composites. • Give students an understanding of the manufacturing processes used to make products, and new processes including additive manufacturing. • To provide students with a sound understanding of manufacturing process selection in design.

Learning Outcomes

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:

  • Salient features of major manufacturing processes in metals, polymers, composites, including customer and user needs and the importance of considerations such as aesthetics
  • Advantages and disadvantages of each process as a method of producing a component or structure with appropriate properties for service, including awareness of quality issues.
  • Material behaviour in manufacturing processes.
  • The relation between manufacturing, material selection and sustainable engineering and development.
Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

  • Critically analyse alternative manufacturing processes.
  • Identify design features influencing manufacturing process choice.
  • Ensure fitness for purpose for all aspects of manufacturing with materials including production, operation, maintenance and disposal.
Transferable and Generic Skills

Having successfully completed this module you will be able to:

  • Interpret component/manufacturing processes in a wider context.
Subject Specific Practical Skills

Having successfully completed this module you will be able to:

  • Select a manufacturing process to make a given component.
  • Select a welding process to make a given joint in a given material.
  • Use CES to screen suitable materials and manufacturing process for designed products.


Introduction and Manufacturing process selection for design An introduction to the module, its teaching staff, its structure and assessment methods will be given. Manufacturing as a shape change operation will be introduced. A hierarchical classification for both manufacturing processes and the shape that they can produce is introduced. Performance factors related to manufacturing processes are then considered and the influence of the Product Design Specification on the selection of the manufacturing process outlined. Case studies are used to illustrate the concepts. The Cambridge Engineering Selector (CES) EduPack software is used to select materials and manufacturing processes and is introduced and used in a laboratory session scheduled midway through the module. Casting Processes The principles of component production by the liquid metal route are outlined. The major metal casting processes are considered in relation to design, structure, properties, quality and economics. Joining Processes An in-depth consideration of competing welding processes is provided. Joint design, quality, defects, service performance and cost in relation to the major classes of engineering materials are addressed. The properties of the weld are related to the microstructure. Metal forming Processes Component production using the bulk deformation processes of open and impression die forging, rolling, extrusion, and metal drawing are described. Sheet metal deformation processes such as shearing, bending, stretch forming and deep drawing are presented. Powder processing is also described. Emphasis is placed on the selection of production route in relation to the design, structure/property requirements and formability of the material. Machining and Cutting Processes Single and multiple point cutting processes are discussed and performance parameters established. Tool materials and the economics of tool wear are briefly considered. Manufacturing processes for polymers and composites A brief background to the types of resin systems and fibre architectures used in the production of polymer and fibre reinforced polymer is provided. Processes used for producing components from polymers and fibre-reinforce polymer are described. Polymer composite, metal matrix composite and ceramic matrix composite are compared. Adhesive bonding as a joining method for polymers and composites is described. Additive Manufacturing/3D printing The principles of additive manufacturing are introduced and a generalised processing sequence is described. Key forms of additive manufacturing are covered in terms of the associated physical processes and capabilities. Guidelines for process selection and design are developed. Applications, outlook, and technology developments are discussed. Revision lectures.

Learning and Teaching

Teaching and learning methods

Teaching methods include • Lectures on above material supported by question sheets on course material. • CES EduPack Computing lab. • Videos on manufacturing and joining processes. • Examples of components made by various manufacturing processes. • Blackboard tests on each section of the course. These tests have extensive feedback designed to help students understand the course material. • For distance learning, lecture notes and recorded lectures will be delivered through Blackboard. Learning activities include • Individual work on question sheets supported by informal surgery sessions.

Completion of assessment task25
Preparation for scheduled sessions25
Follow-up work30
Practical classes and workshops3
Total study time150

Resources & Reading list

S. Kalpakjian and S.R. Schmid,. Manufacturing Processes for Engineering. 


S. Kalpakjian and S.R. Schmid. Manufacturing Engineering and Technology. 

Ian Gibson, David Rosen, Brent Stucker,. Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. 

Sanjay Mazumdar. Composites Manufacturing: Materials, Product, and Process Engineering. 

L Edwards, M Endean. Manufacturing with Materials. 

M. P. Groover,. Fundamentals of Modern Manufacturing, Materials, Processes and Systems. 



MethodPercentage contribution
Coursework 10%
Examination  (120 minutes) 80%
Test 5%
Test 5%


MethodPercentage contribution
Examination 100%


MethodPercentage contribution
Examination 100%

Repeat Information

Repeat type: Internal & External

Linked modules

Pre-requisite: FEEG2005

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