This module aims to highlight the importance of sustainability and digital manufacturing to innovate solutions, optimise and minimise environmental impact. Digital tools will be utilised to support this process.

The following topics will be covered:

Life cycle assessment (LCA): To evaluate and measure the use of materials in the overall process of environmental management.
Materials selection: To understand and use materials selection with reference to digital databases.
Additive Manufacturing: Explore ways in which prototype models can be optimised to take advantage of the opportunities such processes offer.
Reverse Engineering: Using Digital Scanning to collect 3D data to support the development of parts.
Generative Design: Using appropriate digital tools to support the development of functional design solutions
Lean Manufacturing: Integrate lean principles to reduce waste and improve quality.

1. A team portfolio to cover research, analysis and design for the set brief. Meeting AHEP 4 Outcomes: M5, M7, M13, M15, M16 & M17
(Wordcount may be offset by Design work and includes a peer assessment element)

2. A 15-minutes Team Presentation followed by questions. Meeting AHEP 4 Outcomes: M17

Formative assessment and feedback will be undertaken during the module to assess and develop your learning. Teaching staff will check-in on a regular basis to evaluate progress and direct.

Professional Body requirements mean that a minimum overall score of 50% is required to pass the module with a minimum mark of 40% on a component unless otherwise stated.

Whole group lectures will be used to deliver material relating to manufacturing and sustainability strategies. Group tutorials, with activities designed to support team activities and develop software skills which will then be used to apply the skills and knowledge learned. Formative opportunities for informal assessment and feedback will take place throughout the module to help to assess your learning and support development and to ensure that teams are functioning as expected.

1. Design a prototype following research-based concept development to meet industry standard requirements in terms of product lifecycles, sustainability and health & safety. (AHEP 4: M5, M7)

Application & Problem-solving

2. Demonstrate how digital manufacturing could be used within the development and quality management of a prototype product. (AHEP 4: M13, M15)

Digital Literacy

3. Critically reflect on team performance, planning and collaboration in complex design projects. (AHEP 4: M16)

Critical Reasoning & Collaboration
Reflection

4. Effectively communicate ideas to a diverse audience using a range of visual and written presentation techniques. (AHEP 4: M17)

Communication

Standard engineering software including CAD Software / LCA software

You will be expected to engage with independent reading, which should include texts, journals, websites that are pertinent to the learning outcomes and the issues or areas that form the focus of the module.

The digital industry provides a framework for examining the challenges of future production technologies and the various factors that can influence future manufacturing. Manufacturing in digital industries includes case studies that offer practical solutions:

Davim, J.P. ed., (2020). Manufacturing in Digital Industries: Prospects for Industry 4.0 (Vol. 6). Walter de Gruyter GmbH & Co KG.

Digitalization and Sustainable Manufacturing is an essential reference for professionals and researchers in manufacturing, production, and operations, especially those interested in technology and sustainability. It explores interactions within innovative and sustainable organisations, as well as developments in materials, products, processes, digital twins, and AI-supported automated manufacturing systems:

Gulbrandsen-Dahl, S. (2025) Digitalization and Sustainable Manufacturing: twin transition in Norway. London: Taylor & Francis.

Sustainable Products provides insights into the identification and assessment of environmental footprints, sustainability practices in manufacturing companies, stakeholder management, and communication strategies. It also includes case studies and practical examples that enable analysis of current conditions and emerging trends:

Has, M. (2022) Sustainable Products: Life Cycle Assessment, Risk Management, Supply Chains, Eco-Design, De Gruyter. ISBN 3110767295

Making It uses contemporary design as a platform to explain more than 120 production processes. Each process is also assessed for its sustainability and environmental impact:

Lefteri, C. (2019) Making It: Manufacturing Technologies for Product Design, 3rd Ed., Laurence King. ISBN: ż9781786273277

Product Design and Development focuses on industrial practice and the complex roles of the various members involved in product development teams. For industry practitioners, it offers a range of product development methods that can be applied to project work:

Ulrich, K.T. and Eppinger, S.D. (2016) Product Design and Development. 6th ed. New York: McGraw-Hill Education. ISBN: 9780078029066

Studying this Sustainable Product Design and Digital Manufacture module, you will have the opportunity to work in a team, having been introduced to team formation strategies to prepare you for working on a set brief. You will have the opportunity to analyse, test, measure through a Lifecycle assessment in order to support and justify the develop of a new product. You will use a variety of design simulation tools to develop a prototype solution that will be documented in your design portfolio. You will have the opportunity to present your work as a team.