Module 1 - Design and Designing

• Introduction to Design
• Problems and Solutions
• What is Good Design?
• Design as Model-Making
• Design and Needs
• Designing as Heuristic Problem-Solving
• Design, Creativity, Invention and Innovation

Module 2 - Models of the Design Process

• Introduction to Models
• Building a Simple Model of Design
• March's Model of Design
• BS 7000 Model of Design
• French Model of Design
• Pahl and Beitz's Model of Design
• Usefulness of Design Models

Module 3 - Conceptual Design

• Establishing the Design Space
• Conceptual Design Case Study - Human-Powered Flight
• The Importance of Concept
• Concept to Prototype
• Concept to Prototype Case Study - Jet Engine

Module 4 - Case Study in Design and Innovation

• Concept to Prototype to Production
• Case Study: Brompton Folding Bicycle
• Brompton Folding Bicycle - Prototyping and Improving
• Brompton Folding Bicycle - Production

Module 5 - Product Design Specification

• Introduction to Product Design Specification
• PDS Checklist
• PDS Development

Module 6 - Product Design

• Introduction to Product Design
• Engineering or Industrial Design
• Product Function or Form
• Marketing the Product
• The Fours 'Ps'

Module 7 - Introduction to Manufacturing Processes

• Foundation
• What is Manufacturing?
• The Manufacturing Process
• The Fours 'Ps'
• Component Parts

Module 8 - Manufacturing Processes

• Introduction to Manufacturing Processes
• Gears and Gearing
• Basic Manufacturing Processes
• Scales of Material Structure
• Product Shape

Module 9 - Manufacturing Process - Casting

• Introduction to Casting
• Types of Casting
• Liquefying the Material
• Viscosity and Fluidity
• Casting Metals and Plastics
• Casting Microstructure and Defects
• Casting the Food Mixer Gearwheel

Module 10 - Manufacturing Process - Forming

• Introduction to Forming
• Forces Applied during Forming
• Working Temperatures
• Forming Processes
• Forming versus Casting
• Forming the Gearwheel

Module 11 - Manufacturing Process - Cutting

• Introduction to Cutting
• Cutting Processes
• Machine Cutting
• Mechanics of Machining
• Hardness
• Types of Tool Material
• Machining the Gearwheel

Module 12 - Manufacturing Process - Joining

• Introduction to Joining
• Mechanical Joining
• Brazing and Soldering
• Adhesives and Gluing
• Welding
• Creating the Gearwheel

Module 13 - Surface Engineering

• Introduction to Surface Engineering
• Stainless Steel
• Surface Wear
• Applying Surface Coating Material
• Case Study: The Kitchen Knife

Module 14 - Optical Materials Engineering

• Optical Properties of Light
• Optical Materials Selection
• Scratch-resistant Coatings
• Anti-reflective Coatings
• Optical Materials Engineering