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Product Development Using New Material Concepts

Module name (EN):
Name of module in study programme. It should be precise and clear.
Product Development Using New Material Concepts
Degree programme:
Study Programme with validity of corresponding study regulations containing this module.
Mechanical Engineering, Master, ASPO 01.10.2019
Module code: DFMME-2b3
The exam administration creates a SAP-Submodule-No for every exam type in every module. The SAP-Submodule-No is equal for the same module in different study programs.
Hours per semester week / Teaching method:
The count of hours per week is a combination of lecture (V for German Vorlesung), exercise (U for Übung), practice (P) oder project (PA). For example a course of the form 2V+2U has 2 hours of lecture and 2 hours of exercise per week.
4V+2PA (6 hours per week)
ECTS credits:
European Credit Transfer System. Points for successful completion of a course. Each ECTS point represents a workload of 30 hours.
Semester: 2
Mandatory course: yes
Language of instruction:
Project with documentation and final presentation

[updated 04.11.2020]
Applicability / Curricular relevance:
All study programs (with year of the version of study regulations) containing the course.

DFMME-2b3 (P610-0452) Mechanical Engineering, Master, ASPO 01.10.2019 , semester 2, mandatory course, Specialization Product Development
MAM_19_PE_2.06.PEW (P241-0067) Engineering and Management, Master, ASPO 01.10.2019 , semester 2, mandatory course, Specialization Product Development
Workload of student for successfully completing the course. Each ECTS credit represents 30 working hours. These are the combined effort of face-to-face time, post-processing the subject of the lecture, exercises and preparation for the exam.

The total workload is distributed on the semester (01.04.-30.09. during the summer term, 01.10.-31.03. during the winter term).
90 class hours (= 67.5 clock hours) over a 15-week period.
The total student study time is 240 hours (equivalent to 8 ECTS credits).
There are therefore 172.5 hours available for class preparation and follow-up work and exam preparation.
Recommended prerequisites (modules):
Recommended as prerequisite for:
Module coordinator:
Prof. Dr. Bernd Heidemann
Lecturer: Prof. Dr. Bernd Heidemann

[updated 08.07.2019]
Learning outcomes:
After successfully completing this module, students will be familiar with new material concepts, their technological properties and development potential and will be able to develop and use them.
They will be able to implement product functions with these properties by applying specific design methods.
Students will be able to analyze and optimize their product in terms of safety.
They will be able to assess whether a product falls under the Machinery Directive and determine its hazards.
Students will be able to classify safety engineering terms in the overall context of the Machinery Directive.
They will be able to apply the Machinery Directive and know the scope of a conformity procedure.
They will be familiar with the 3-step method for reducing hazards and will be able to select or develop measures to reduce hazards.
Student will be able to carry out a risk assessment of simple machines and products using harmonized standards.
They will be familiar with the Sistema calculation and can interpret an existing calculation.

[updated 04.11.2020]
Module content:
Material concept - Plastics:
technological properties, design and production relevant properties, ecological properties, sustainability.
Selecting materials:
Integration of databases for plastics and metallic and ceramic materials in product development and calculation.
Material concepts created in additive manufacturing processes: technological properties, design and production relevant properties, ecological properties, sustainability.
Material concept - "Other materials"  (fibre composites, graphene, current developments in materials technology):
technological properties, design and production relevant properties, ecological properties, sustainability.
Product development and component design with regard to material-specific properties: The principles of integral design methods and the integration of functions versus differential design methods and the separation of functions.
Explanation of terms and delimitations pertaining to product safety and the Machinery Directive.
Legal foundation of the Machinery Directive
Types of hazards
The 3-step method of risk reduction
Risk assessment procedure (risk assessment, evaluation and risk reduction)
The importance of harmonized standards and their application
Documenting a risk assessment
Examples of inherently safe product design
Protective devices: mechanical, control, organizational
Basics of Sistema calculation

[updated 04.11.2020]
Teaching methods/Media:
Seminaristic, interactive instruction.
The project will be carried out according to an annually updated guideline (specification sheet), that will be available at the beginning of the course. The project will be monitored in regular meetings.
The project should be carried out in teams in order to use and master group dynamic processes and procedures.

[updated 04.11.2020]
Recommended or required reading:
Gunter Erhard: Konstruieren mit Kunststoffen. Hanser-Verlag.
Gottfried Wilhelm Ehrenstein Mit Kunststoffen konstruieren: Eine Einführung. Hanser-Verlag.
Schürmann, Helmut: Konstruieren mit Faser-Kunststoff-Verbunden. Springer-Verlag.
Kurt Moser: Faser-Kunststoff-Verbund. Entwurfs- und Berechnungsgrundlagen. Springer-Verlag.
Andreas Gebhardt: Generative Fertigungsverfahren: Additive Manufacturing und 3D Drucken für Prototyping - Tooling _ Produktion. Hanser-Verlag.
Ian Gibson, David Rosen, Brent Stucker: Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. Springer-Verlag.
John O. Milewski: Additive Manufacturing of Metals: From Fundamental Technology to Rocket Nozzles, Medical Implants, and Custom Jewelry. Springer-Verlag.
Tarek I. Zohdi: Modeling and Simulation of Functionalized Materials for Additive Manufacturing and 3D Printing: Continuous and Discrete Media. Springer-Verlag.
Gries, Thomas, Klopp, Kai (Hrsg.): Füge- und Oberflächentechnologien für Textilien - Verfahren und Anwendungen. Springer-Verlag.
Safety engineering:
Alfred Neudörfer: Konstruieren sicherheitsgerechter Produkte. Springer Berlin Heidelberg.
Marco Einhaus, Florian Lugauer, Christina Häußinger: Arbeitsschutz und Sicherheitstechnik. Hanser Verlag.
Maschinenrichtlinie Richtlinie 2006/42/EG
Volker Krey, Arun Kapoor: Praxisleitfaden Produktsicherheitsrecht. Hanser Verlag.
Bernd Bertsche, Gisbert Lechner: Zuverlässigkeit im Fahrzeug und Maschinenbau. Springer Verlag.

[updated 04.11.2020]
[Sat Jul 20 21:48:42 CEST 2024, CKEY=mpmnw, BKEY=dmm2, CID=DFMME-2b3, LANGUAGE=en, DATE=20.07.2024]