COURSE SYLLABUS

On completion of the course the student shall:

• display knowledge of the relationship between the product requirements, the product design and the selection of materials and manufacturing methods
• show familiarity with key concepts of circular economy and sustainability, as well as standard testing methods for surface technology selection
• demonstrate comprehension of the economic and sustainability impacts of materials and manufacturing processes

• demonstrate the ability to apply structured selection strategies to identify suitable materials and manufacturing methods in product design, ensuring alignment with performance, sustainability, and production feasibility requirements
• demonstrate the ability to evaluate the environmental footprint of a product throughout its life cycle and understand the purpose and application of life cycle assessment (LCA)

• demonstrate an understanding of the economic and sustainability impacts of product design, materials, and manufacturing processes
• demonstrate the ability to critically analyse and select materials and manufacturing processes, including surface treatment technologies, to fulfil the requirements and specifications of products
• demonstrate the ability to understand the product life cycle in all its aspects

The course deals with the systematic selection of materials and production processes for product design. The concept of Design for X (DfX) is introduced as a foundation for future courses. Different case studies will support understanding the relationship between a product's function and the design requirements based on the performance.

These requirements will be translated into materials' properties and manufacturing methods to select valid solutions. Surface treatment technologies will be reviewed as an essential part of product adaptation, together with relevant testing standards. The concepts of technology readiness levels (TRL) and manufacturing readiness levels (MRL) are part of the technology evaluations. Sustainability aspects are the focus of eco-design strategies, and the methods used to assess the environmental impact of a product's life cycle, like life cycle assessment (LCA) and materials flow analysis (MFA), for example. The project deals with the materials and process selection for a real-life product and its practical realisation to understand the challenges with materials and manufacturing methods.

The course includes the following elements:

• Overview of properties of different material groups and manufacturing processes
• Analysis of case studies to understand the product's characteristics and requirements, with an introduction to user perception
• Overview of the characteristics of different surface treatment techniques and related test standards.
• The relationship between product design, material properties and manufacturing methods
• Sustainability perspective in material selection by eco-design and related strategies
• Introduction to Life Cycle Assessment (LCA) of products and their environmental impact

Lectures, assignments and a project.

Language of instruction is in English.

Michael F. Ashby, Materials Selection in Mechanical Design, Publisher: Butterworth-Heinemann, ISBN: 9780443160288 (6TH EDITION)

Michael F. Ashby, Materials and the Environment, Publisher: Butterworth-Heinemann, ISBN: 9780128215210 (3TH EDITION)