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Outline a suitable 3D laser scanning setup/process to extract data to facilitate remodelling.

Module Name: Design Principles

Module Number: MECH40635

Title of Assignment: Design Development and Modellin

Submission Deadline: Nominally 12 weeks from the start of the module.

See BLACKBOARD DATE

Module Learning Outcomes for This Assignment:

  1. APPLY BASIC DRAUGHTING/LAYOUT TECHNIQUES.

  2. USE A 3D CAD PACKAGE.

  3. DEMONSTRATE A KNOWLEDGE OF CONCEPT OF MANUFACTURING TECHNIQUES AND ASSEMBLIES

Knowledge & Understanding

  1. USE A RANGE OF VISUAL, ORAL AND WRITTEN PRESENTATION TECHNIQUES

Communication / Team Working

Assignment criteria

Introduction

One of the main challenges for Designers in today’s technological environment is that of communication. The task of generating and communicating design ideas can help develop a product or convey a solution to a problem. There are many methods to demonstrate your products or ideas; this assignment is designed to allow you to show these methods and understand the importance of design development. In order to produce feasible design solutions a designer must have an understanding of manufacturing processes, economic limitations, material finishing processes and assembly methods.

Assessment criteria

The three Questions required for your submission in one portfolio are as follows.

Question 1

A heritage motorcycle parts supplier specialises in and manufactures parts that are no longer available. There are no drawings and casting moulds are no longer in existence. They have asked you to investigate the possibility of remanufacturing replica Cylinder heads as new, using existing parts as reference material for size and form. 3D scanning and Reverse engineering in CAD software would be a starting point from which a decision could be made as to the most suitable manufacturing method. Parts would fit into a 250 x 250 mm cube and weigh between 1.5 and 2kg.

  • Outline a suitable 3D laser scanning setup/process to extract data to facilitate remodelling.
  • Present a range of manufacturing options that may suit both Ferrous and Non-Ferrous cylinder heads.

Use referenced sources for your information, feel free to include images to summarise processes with graphical data to support your justification. Suitability of process (and summary) to the material, Surface finish, additional operations, tolerances, time to manufacture and costs can also be included.

(Assume that the initial demand would be niche, so 50 units per annum. Would the process change if 2000 parts per annum were required? Support with data to show how batch costs vary.

A brief introduction to the whole assignment would be good, but no need for an Abstract. 25%

Question 2

Describe three methods of coating materials. Include details on the suitability for different materials, whether it is decorative or functional, advantages. Feel free to outline the application process, limitations, example products and alternatives. Use images and examples to support.

NB. This is not linked to part 1 above. (Guideline 2 pages) 15%

Question 3

Design: You are to choose a handheld product or device from the Table 2 below, or a similar product related to your job role. For the chosen item you are to carry out a design process with research with images and brief analysis of existing products with a view to improve through a modification and/or addition. You could include some user data in your research to support ergonomic design. You will develop possible solution sketches, a chosen concept and CAD model. The design you choose needs to be modelled with features linked to the design using sketching and 3D CAD representation. Creating a render view, engineering drawings will enhance your submission. Try to make separate parts to help convey how the product may function.

Multimeter

Audio visual controller

Data logger

This design section should include the following deliverables:

  • Evidence of research into existing products or design problem. Use images and analyse functionality, features including dimensions and materials (guideline 2 pages) 10%

  • Freehand annotated sketches showing development of your chosen product. This will include a final freehand isometric representation. Use colour to highlight features and dimensions. Communicate a range of different forms and functionality. (guideline 3-4 pages) 15% Continued

    • 3D CAD model demonstrating efficient use of CAD features and clear Design Intent. Annotate/describe your design intent and product features. (guideline 2 pages) You must insert screenshots of your design. You may also include 2D Orthographic Engineering Drawings from your 3D CAD model to enhance the communication. You must also submit your Final CAD data, or online share link for assessment. 35% 100%

Academic Dishonesty applied to all sections

All work submitted must be your own work and all sources must be properly referenced and cross referenced to the relevant parts in the report as per the university guidelines.

https://www.staffs.ac.uk/students/course-administration/academic-policies-and- regulations/types-of-academic-misconduct

We expect you to demonstrate learning by completing your assessments yourself in your own words.

Can I use AI tools at University? Answer

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Extenuating Circumstances.

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Short Solution

MECH40635 Design Principles

Design Development and Modelling Portfolio

Introduction

Design communication is one of the most important elements within modern engineering and product development. Designers are expected not only to generate innovative ideas but also to communicate them clearly through sketches, CAD models, technical drawings, prototypes, and manufacturing specifications. In today’s manufacturing environment, design development relies heavily on digital technologies such as 3D scanning, reverse engineering, and computer-aided design (CAD). These tools allow manufacturers to recreate obsolete components, improve existing products, and produce more accurate engineering solutions.

This portfolio explores three major areas linked to design principles and engineering communication. The first section investigates reverse engineering and manufacturing solutions for heritage motorcycle cylinder heads using 3D laser scanning and CAD remodelling techniques. The second section examines three material coating methods and evaluates their industrial applications, advantages, and limitations. The final section focuses on the design development of a handheld electronic product through research, concept sketching, ergonomic consideration, and CAD modelling.

The report demonstrates understanding of manufacturing processes, CAD development, visual communication, engineering analysis, and practical product development.

Question 1

Reverse Engineering and Manufacture of Heritage Motorcycle Cylinder Heads

Introduction to Reverse Engineering

Reverse engineering is widely used in industries where original drawings, tooling, or manufacturing data no longer exist. Heritage motorcycle restoration companies frequently face challenges sourcing obsolete components such as cylinder heads. Since original casting moulds and technical drawings may be unavailable, modern digital technologies provide an efficient solution.

3D laser scanning combined with CAD reverse engineering allows engineers to capture the geometry of an existing part and convert it into a digital model suitable for redesign and manufacture. This process reduces development time while improving dimensional accuracy.

The cylinder heads in this scenario are relatively small components fitting within a 250 mm cube and weighing approximately 1.5 to 2 kg. Production quantities are also limited initially at around 50 units annually, meaning manufacturing methods must balance tooling costs with part quality and production efficiency.

3D Laser Scanning Setup and Process

Preparation of the Existing Part

The original cylinder head would first require cleaning to remove oil, dirt, corrosion, and surface contaminants. Since reflective metal surfaces can interfere with laser scanning accuracy, a removable matte scanning spray may be applied.

The component would then be positioned securely on a rotary scanning table to allow multiple scanning angles without losing alignment.

Scanning Equipment

A structured light or laser scanning system would be suitable for this application. Examples include:

  • FARO Edge ScanArm
  • Creaform HandySCAN 3D
  • Artec Space Spider

These scanners provide high-resolution surface data with accuracy typically between 0.02 mm and 0.05 mm, which is sufficient for engineering remanufacture work.

Scanning Process

The scanner projects laser or structured light patterns onto the cylinder head surface while cameras capture reflected geometry data. Multiple scans are collected from different orientations to capture complex internal and external features such as:

  • Cooling fins
  • Combustion chamber geometry
  • Valve ports
  • Mounting holes
  • Gasket surfaces

Reference markers or alignment targets are often used to ensure accurate merging of scan data.

The resulting point cloud data is converted into a polygon mesh using software such as Geomagic Design X or PolyWorks.