• This project is designed for a Junior Level general Manufacturing Processes course.
• The intent is to expose the students to a variety of existing manufacturing processes.
• Have the students consider long term sustainability for both the products and processes they may use.
• Try to re-use and re-purpose already collected recycled materials to replace existing product components.

1. If an Industrial Partner is available:

• Partner with an industrial manufacturer and help with long term sustainability goals.
• Select a product with components that fail and need replacing.
• Consider the long term impacts of the components that need replacing. How would the students start to make a replacement component plan? 
• Have the students develop a Revised Life Cycle plan for the selected components.
• Work through the Engineering Design Process.
• Create a Manufacturing Plan.
• Work to the plan.

2. If an Industrial Partner is not available:

• Select a product that has replaceable parts (i.e., automotive, home repair, etc. - basically anything that has replaceable plastic components).
• Consider the long term impacts of the components that need replacing. How would the students start to make a replacement component plan?  
• Have the students develop a Revised Life Cycle plan for the selected components.
• Work through the Engineering Design Process.
• Create a Manufacturing Plan.
• Work to the plan.

This semester-long project challenges Mechanical Engineering Technology students to reverse engineer a common, consumer-grade product with replaceable plastic components, focusing on its mechanical function and manufacturing process. The problem statement is introduced in class by the customer and in lab the students will begin by meticulously disassembling and documenting the chosen product, creating detailed CAD models of its components. They will then apply critical design thinking to analyze the product's design, identifying areas for improvement in functionality, manufacturability, and sustainability. Using finite element analysis (FEA), students will simulate the product's performance under various loads, validating their design modifications. The project culminates in the redesign and physical prototyping of key components, utilizing both 3D printing for rapid iteration and injection molding for a more representative final product.

Furthermore, students will deeply explore the product's material lifecycle, investigating its original material composition and its potential for recycling. They will research and propose alternative sustainable materials, considering factors like biodegradability and recyclability, and integrate these findings into their redesigned components. Design for manufacturing principles will be emphasized throughout, ensuring that the redesigned product is not only functional and sustainable but also optimized for efficient production. Students will present their findings in a comprehensive report and presentation, demonstrating their understanding of reverse engineering, design optimization, manufacturing processes, and the critical importance of incorporating recycling and sustainability into modern engineering design.