This paper builds on the introduction to engineering design taught in ENGEN180 and applies other material taught in years 1 and 2. The paper gives students an understanding of the fundamental principles and basic relationships underlying selected major manufacturing processes widely used in industry. Students undertake an engineering design project with a focus on design for manufacture which is taught through workshops. Engineering design methods are demonstrated through case studies. Knowledge on metrology and non-destructive testing techniques, which are critically important in modern manufacturing, will also be introduced. The paper also covers the practical aspects of selected major manufacturing processes via workshop and practical sessions where students have plenty of opportunities to build up their practical skills and apply their theoretical knowledge on manufacturing processes to solving practical problems. To pass the paper, students must achieve a minimum mark of 40% in both TESTS.

Please note that mask wearing while attending lectures and labs in B Trimester is required.

The learning outcomes for this paper are linked to Washington Accord graduate attributes WA1-WA11. Explanation of the graduate attributes can be found at: https://www.ieagreements.org/assets/Uploads/Documents/IEA-Graduate-Attributes-and-Professional-Competencies-2021.1-Sept-2021.pdf

The course is taught through a combination of lectures, practical design tutorials, and workshop sessions. The scheduled lecture and workshop session content are provided in this paper outline. Details of the workshop session will be provided at the beginning of the trimester.

Flipped learning and blended teaching could be used meaning that students need to read the lecture notes provided prior to any official lecture discussion/tutorial/review.

While design requires application of appropriate technical procedures, competency in technical communication will also be assessed in this paper. In practice it is largely accomplished by teamwork. Even in situations where (component design etc) it may be undertaken by one engineer, it needs to be checked by a peer. The presentation is as important as the technical analysis. Therefore, all assessed items must be presented in a way so that another student or an engineer will be able to follow the analysis and rationale for the design choices. Correct answers should be supported by clear reasoning. Any ambiguity in the reports or examination scripts may be heavily penalised. Late work will be penalised 5% of its mark for every working day after the hand in date.

2 x Tests on manufacturing processes (30%)

Manufacturing workshop sessions (20%)

CAD project (10%)

Design project (40%):

• Mechanical advantage report (5%)
• Concept generation and selection (5%)
• Drawings and manufacturing plan (5%)
• Engineering design report (10%)
• Design show demonstration of prototype (15%)

Samples of your work may be required as part of the Engineering New Zealand accreditation process for BE(Hons) degrees. Any samples taken will have the student name and ID redacted. If you do not want samples of your work collected then please email the engineering administrator, Natalie Shaw (natalie.shaw@waikato.ac.nz), to opt out.

This paper has a Moodle page (http://elearn.waikato.ac.nz) where you will be able to access lecture notes and assessment materials. There are also discussion forums where you can both ask and answer questions.

PLEASE NOTE: Moodle will be used for class notices etc and it is your responsibility to check the site regularly. Instructions provided on Moodle and in lectures are considered to be given to the class as a whole.

This 15pt paper emphasizes on the theories, fundamental principles, and workshop experience of manufacturing processes.

The paper has a total workload of approx. 160 hours as below:

Two 2-hour lecture per 12 weeks (24 hours), six 8-hour workshop sessions plus six 4-hour design project workshops (72 hours), 50 hours of design project (CAD, calculations, concept and presentation), and 14 hours of reading and revision for the tests.