Module manager: Professor Robert Kay
Email: R.W.Kay@leeds.ac.uk
Taught: Semesters 1 & 2 (Sep to Jun) View Timetable
Year running 2026/27
| MECH2636 | Design and Manufacture 2 |
This module is not approved as a discovery module
This module will introduce and develop the concepts of Additive Manufacturing (AM) and demonstrate the different AM techniques commercially available. It will also cover the latest developments in this rapidly evolving field including elements of research led teaching. This course will teach the various processes in relation to the seven joint ISO/TC 261 ASTM F42 standards in order to easily categorise the different processes and overcome issues with the technology classifications. The module will emphasise the strengths and weaknesses of the various technologies and highlight applications and case studies from the AM industry. The course will cover AM for use in production development, rapid tooling and Reverse Engineering (RE) with case examples from a range of industrial sectors including automotive, medical and electronics. The module will encompass various interactive lectures, hands on tutorials using 3D printing equipment and demonstrations using the various Additive Manufacturing equipment available at the University of Leeds.
The module aims to develop a comprehensive understanding of Additive Manufacturing (AM) processes defined by ASTM F42–ISO/TC 261 standards, including their fundamental principles, applications, capabilities, limitations, and associated data formats. Students will learn how AM supports product development, rapid tooling, and Reverse Engineering (RE), gaining insight into relevant scanning and imaging methods as well as the scientific principles that underpin both RE and AM.
The module further seeks to build competence in advanced design techniques tailored to AM, awareness of current industrial practice and emerging developments, and the ability to evaluate the economic and practical considerations of AM compared with traditional manufacturing.
Additionally, students will cultivate intellectual, practical, and transferable skills such as analysing and selecting appropriate AM and RE technologies, generating and processing relevant data, producing components from CAD through to finished parts, assessing complex AM‑specific designs, and determining when AM is the most suitable manufacturing method across various industrial contexts.
On successful completion of the module students will be able to:
1. Describe in detail a range of Additive Manufacturing processes and their advantages and disadvantages.
2. Identify suitable Additive Manufacturing processes for different applications / products based on specified production requirements.
3. Describe the complex design techniques specific to Reverse Engineering and Additive Manufacturing.
4. Demonstrate a comprehensive understanding of the scientific principles and current practice of Additive Manufacturing and Reverse Engineering, their limitations and likely new developments.
5. Demonstrate a good appreciation of the industrial application of Additive Manufacturing for a range of different fields.
6. Explain the economics of Additive Manufacturing and compare this with traditional tooling-based production methods.
7. Demonstrate product development in a practical sense by combining 3D CAD design, data manipulation and Additive Manufacturing.
These module learning outcomes contribute to the following AHEP4 learning outcomes:
- Apply knowledge of mathematics, statistics, natural science and engineering principles to the solution of complex problems. Some of the knowledge will be at the forefront of the particular subject of study. [C1]
- Analyse complex problems to reach substantiated conclusions using first principles of mathematics, statistics, natural science and engineering principles. [C2]
- Select and evaluate technical literature and other sources of information to address complex problems. [C4]
- Design solutions for complex problems that meet a combination of societal, user, business and customer needs as appropriate. This will involve consideration of applicable health and safety, diversity, inclusion, cultural, societal, environmental and commercial matters, codes of practice and industry standards. [C5]
- Apply an integrated or systems approach to the solution of complex problems. [C6]
- Use practical laboratory and workshop skills to investigate complex problems. [C12]
- Select and apply appropriate materials, equipment, engineering technologies and processes, recognising their limitations. [C13]
- Apply knowledge of engineering management principles, commercial context, project and change management, and relevant legal matters including intellectual property rights. [C15]
Skills learning outcomes:
On successful completion of the module students will be able to:
Students will have had the opportunity to develop the following skills through this module:
a. Interactive hands-on learning
b. Team working to collectively develop a new product produced in conduction with RE and AM
c. Self-direction and effective decision making;
d. Independent learning via self-guided research including conducting a literature review of the latest developments in AM and RE.
e. Application of various engineering methods including design, manufacture and analysis to develop an AM produced product.
f. Communication of information, arguments and analysis in a variety of forms, whilst demonstrating understanding of levels of ambiguity and uncertainty.
Semester 1 will focus on learning the principles of AM as per the joint ISO/TC 261-ASTM F42 standards and also the procedures and methods around design and build set-up considerations. In semester 2 the understanding around AM will be further developed with a particular emphasis on: RE for AM, data scanning techniques & applications areas; Design for RE and AM; RE and AM in medical engineering; Rapid tooling; Economics of AM (Costing and Business models); and AM research.
Interactive labs will support the taught curriculum over both semesters and allow the students to experience the full process from design to the production of a part. Initially students will learn how to create their own design concepts, manipulate the file format, choose print parameters and 3D print a component. Students will then start a group project (4-6 students) where a portable electronic device is reverse engineered, redesigned / enhanced and then additively manufactured. This group project will require the students to put all their design, manufacturing and also general engineering skills together to successfully complete this project. The labs will be split over several weeks consisting of: product assessment, design considerations, reverse engineering, 3D, manufacturing, post-processing and demonstrating the working new product. The curriculum will also be supported with tutorials that aim to test the application of the knowledge.
Methods of assessment
The assessment details for this module will be provided at the start of the academic year.
| Delivery type | Number | Length hours | Student hours |
|---|---|---|---|
| Lecture | 2 | 2 | 4 |
| Lecture | 20 | 1 | 20 |
| Practical | 11 | 2 | 22 |
| Tutorial | 4 | 1 | 4 |
| Private study hours | 150 | ||
| Total Contact hours | 50 | ||
| Total hours (100hr per 10 credits) | 200 | ||
Feedback given to students in response to assessed work:
- General feedback discussed as part of a tutorial
- Individual feedback on practical lab work.
- Developmental feedback generated through teaching activities.
- Laboratory interaction with tutors / academics including online practicals.
- Practical knowledge of commercial AM equipment for application in Industry.
- Students undergo process demonstrations, part handling and set up parts for manufacture.
- Students use tutorial based software training using industry leading software and have parts produced on table-top 3D printers.
Check the module area in Minerva for your reading list
Last updated: 30/04/2026
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