Definitive Module Record (DMR) for MATS 320: assessment is 0% examination and 100% coursework.
This module integrates the learning from the Composites Design and Manufacture ..and.. Quality Management II modules in a
  practical assignment to specify, design, manufacture, test and report on a prototype composite component.
The modules MATS 320, MATS 324 and MFRG 310 are the specific components of the Composite Materials Engineering pathway.
Subject Index to assist in finding specific resources.

• Design
• How to write a Product Design Specification
• Getting What You Want: How to Write a Product Specification, IHS Engineering website.
• How to write an IB Design Specification, British International School Virtual Learning Environment
• Paul Hudson, How to write a PDS, University of Hertfordshire Blueprint website for studying Design and Technology.
• DESIGN CHECKLIST based on KD Potter, Design of Composite Products - a personal viewpoint, Composites Manufacturing, 1992, 3(3), 173-182. UOP Library
• BS 7373-1:2001  Guide to the preparation of specifications. Guide to preparation.
• BS 7373-2:2001  Product specifications. Guide to identifying criteria for a product specification and to declaring product conformity
• BS 7373-3:2005  Product specifications. Guide to identifying criteria for specifying a service offering
• Safety factors
• Recommended reading for design
• Costs
• Indicative costs for the laboratory coursework assignment
• Recommended reading for costs

The components considered in this module (and in MATS304 Composite Applications until AY2000/2001) were:

1997/1998	mountain bike suspension arm
1998/1999	bicycle front forks
1999/2000	yacht winch handle
2000/2001	skaters trolley
2001/2002	launching trolley for a dinghy
2002/2003	man-portable bridge
2003/2004	in-situ repair of a welded T-joint in an oiltank
2004/2005	yacht mast spreader
2005/2006	a crutch for a disabled table-tennis player
2006/2007	(a) car spoiler, (b) cross bow limb (published in Composites Part B: Engineering)
2007/2008	legs for a bipedal robot
2008/2009	kite-surf board
2009/2010	(a/b) bicycle crank, (c) luge board
2010/2011	(a) gas turbine blade, (b) ice-axe handle, (c) recreational helmet.
2011/2012	bridge span of 584 mm with 100 mm square maximum cross-section.

Factlets:

• Alain Giocosa (Renault Guyancourt) in a Keynote Address (FPCM-8, Douai - France, 13 July 2006) suggested that each 100 kg saved in a passenger car translates to a fuel saving of 4 litres/1000 km.
• Costas Soutis (University of Sheffield) in Plastics, Rubber and Composites, 2009, 38(9/10), 359-366 states that "1 kg weight reduction saves over 2900L fuel per year" in the context of the Airbus A320.

HEALTH & SAFETY
It is important that all students are aware of the Health and Safety considerations for this module.  You will be required to attend the Health and Safety presentation and to sign to confirm that you have done so before you will be allowed to use the facilities in the ACMC laboratory (Brunel 007). This support material can be accessed online. 

SAFETY FACTORS

CONDITION	FACTOR	REFERENCE
Static short-term loads (construction industry)	2	1
Static long-term loads (construction industry)	4	1
Variable/changing loads (construction industry)	4	1
Repeated loads (construction industry)	6	1
Fatigue or load-reversal (construction industry)	6	1
Impact loads repeated (construction industry)	10	1
Composite manufacture by handwork	1.5	2
Composite manufacture by machine controlled spray application	1.5	2
Composite manufacture by hand-held spray application	3	2
Composite chemical pressure vessel with a thermoplastic liner	1.2	2
Composite chemical pressure vessel without a thermoplastic liner	up to 2	2
Composite operating temperature (dependent on HDT)	1.0-1.25	2
Composite post-cure to manufacturers specification	1.1	2
Composite for operation up to 45ºC	1.3	2
Composite for operation over 45ºC	1.3	2

1. SM Halliwell, Polymer composites in construction, Construction Research Communications Limited by permission of Building Research Establishment Limited, Watford/London, 2000. ISBN 1-86081-429-8.
2. BS 4994:1987 Design and construction of vessels and tanks in reinforced plastics

Recommended reading:

• MF Ashby, Materials Selection in Mechanical Design,
  Pergamon Press, Oxford, 1992. ISBN 0-08-041907-0. UoP Library
• Daniel C Smoot and A Brent Strong, Product and Process Innovation - a review
  Journal of Advanced Materials, April 2006, 38(2), 64-79.  UOP Library 
• A Brent Strong, Composites in Manufacturing - Case Studies,
  Society of Manufacturing Engineers, 1991.  ISBN 0-87263-406-x.  UoP Library
• JFV Vincent, OA Bogatyreva, NR Bogatyrev, A Bowyer and A-K Pahl, Biomimetics: its practice and theory
  Journal of the Royal Society - Interface (online).  Supplementary materials: Appendix 1: Altshuller’s 40 Inventive Principles with biological examples
  Appendix 2: Apportioning Altshuller’s conflict features and inventive principles to the PRIZM categories.
  Appendix 3: Examples of functions at various size scales in biology and technology.

Cost comparisons

• Michael G Bader, Selection of composite materials and manufacturing routes for cost-effective performance, Composites Part A: Applied Science and Manufacturing, July 2002, 33(7), 913-934.
• Mauricio Cabrera-Ríos and José M Castro, The balance between durability, reliability and affordability in structural composites manufacturing, Polymer Composites, 2007, 28(2), 233-240.
• L Dickinson, M Mohamed and B Lienhart, Cost modeling for 3D woven preforming process, International SAMPE Symposium "Bridging The Centuries", Long Beach CA, 21-25 May 2000, volume 45, pp 227-140.
• L Dickinson, M Salama and D Stobbe, Design approach for 3D woven composites: Cost vs. performance, International SAMPE Symposium "2001: A Materials and Processes Odyssey", Long Beach CA, 06-10 May 2001, volume 46, pp 765-778.
• Markus Kaufmann, Dan Zenkert and Christophe Mattei, Cost optimization of composite aircraft structures including variable laminate qualities, Composites Science and Technology, October 2008, 68(13), 2748-2754.
• Sanjay K Mazumdar, Cost Estimation, Chapter 11 in SK Mazumdar, Composites Manufacturing - materials, product and process engineering, CRC Press, Boca Raton FL, 2002.  ISBN 0-8493-0585-3.  UOP Library
• John D Russell, Composites Affordability Initiative: successes, failures - where do we go from here?, SAMPE Journal, March/April 2007, 43(2), 26-36.
• TA Turner, LT Harper, NA Warrior and CD Rudd, Low-cost carbon-fibre-based automotive body panel systems: a performance and manufacturing cost comparison,
  Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 2008, 222(1), 53-63.
• J Verrey, MD Wakeman, V Michaud, J-AE Månson, Manufacturing cost comparison of thermoplastic and thermoset RTM for an automotive floor pan Composites Part A: Applied Science and Manufacturing, January 2006, 37(1), 9-22.