Engineering Institute of Technology


Unit Name


Unit Code



Unit Duration



Bachelor of Science (Engineering)


Duration 3 years

Year Level


Unit Creator/Reviewer





BME204S, BME207S

Credit Points



Total Program Credit Points 81 (27 x 3)

Mode of Delivery

Online or on-campus.

Unit Workload

(Total student workload including “contact hours” = 10 hours per week)

Lecture : 1.5 hours

Guided labs / Group work / Assessments : 2 hours Tutorial : 1.5 hours

Personal Study : 5 hours

The objective in presenting this unit is to provide students with an in-depth knowledge of modern manufacturing processes and technologies, as required by the competitive industrial environment.


The subject matter covered in this unit will include: an overview of manufacturing fundamentals and the economic and technological considerations involved; a detailed examination of manufacturing processes such as forming, casting, welding, and joining; specifying cutting tool requirements, and identification and selection of the appropriate machine tool techniques; and, the selection of jigs and fixtures for a particular application, including an understanding of the economics involved.


Students will also have an opportunity to evaluate and understand the principles of metrology, where the focus will be on the most up-to-date information and best practices; and, they will be instructed on the principles, functions, applications, and programming aspects of CNC machines, and their importance in manufacturing.


Project work involving the different aspects of manufacturing technology and processes will also be a component of the unit requirements.


At the conclusion of this unit, students will have been imparted with the requisite knowledge to comprehend and utilise modern manufacturing processes and technologies.


Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

  1. Evaluate the fundamentals of manufacturing along with the economic and technological considerations involved.

  2. Examine in-depth the principles and process characteristics of the metal forming, metal casting, and welding processes.

  3. Explain the concepts related to powder metallurgy.

  4. Evaluate the design aspects of cutting tools and the economics of machining.

  5. Describe the science of metrology and its underpinning principles and methods.

  6. Distinguish between traditional and non-traditional machining processes.

  7. Detail CNC machining concepts, operational principles, and applications.

    Completing this unit may add to students professional development/competencies by:

    1. Fostering personal and professional skills and attributes in order to:

      1. Conduct work in a professionally diligent, accountable and ethical manner.

      2. Effectively use oral and written communication in personal and professional domains.

      3. Foster applicable creative thinking, critical thinking and problem solving skills.

      4. Develop initiative and engagement in lifelong learning and professional development.

      5. Enhance collaboration outcomes and performance in dynamic team roles.

      6. Effectively plan, organise, self-manage and manage others.

      7. Professionally utilise and manage information.

      8. Enhance technologist literacy and apply contextualised technologist skills.

    2. Enhance investigatory and research capabilities in order to:

      1. Develop an understanding of systematic, fundamental scientific, mathematic principles, numerical analysis techniques and statistics applicable to technologists.

      2. Access, evaluate and analyse information on technologist processes, procedures, investigations and the discernment of technologist knowledge development.

      3. Foster an in-depth understanding of specialist bodies of knowledge, computer science, engineering design practice and contextual factors applicable to technologists.

      4. Solve basic and open-ended engineering technologist problems.

      5. Understand the scope, principles, norms, accountabilities and bounds associated with sustainable engineering practice.

    3. Develop engineering application abilities in order to:

      1. Apply established engineering methods to broadly-defined technologist problem solving.

      2. Apply engineering technologist techniques, tool and resources.

      3. Apply systematic technologist synthesis and design processes.

      4. Systematically conduct and manage technologist projects, work assignments, testing and experimentation.

The Australian Engineering Stage 1 Competency Standards for Engineering Technologists, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.


Stage 1 Competencies and Elements of Competency


Knowledge and Skill Base


Systematic, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the technology domain.


Conceptual understanding of the, mathematics, numerical analysis, statistics, and computer and information sciences which underpin the technology domain.


In-depth understanding of specialist bodies of knowledge within the technology domain.


Discernment of knowledge development within the technology domain.


Knowledge of engineering design practice and contextual factors impacting the technology domain.


Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the technology domain.


Engineering Application Ability


Application of established engineering methods to broadly-defined problem solving within the technology domain.


Application of engineering techniques, tools and resources within the technology domain.


Application of systematic synthesis and design processes within the technology domain.


Application of systematic approaches to the conduct and management of projects within the technology domain.


Professional and Personal Attributes


Ethical conduct and professional accountability.


Effective oral and written communication in professional and lay domains.


Creative, innovative and pro-active demeanour.


Professional use and management of information.


Orderly management of self and professional conduct.


Effective team membership and team leadership.

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 7 criteria, Engineers Australia Stage 1 Competency Standards for Engineering Technologists and the Sydney Accord:


Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Learning Outcomes

A. Knowledge of Science and Engineering Fundamentals

A1. Breadth of knowledge of engineering and systematic, theory-based understanding of underlying principles, and depth of knowledge across one or more engineering sub- disciplines


1.1, 1.3


2, 3, 4, 5, 6, 7

A2. Knowledge of mathematical, statistical and computer sciences appropriate for engineering technology




4, 5, 6, 7

A3. Discernment of knowledge development within the technology domain


2, 3, 4, 5, 6, 7

A4. Knowledge of engineering design practice and contextual factors impacting the technology domain




B. Problem Solving, Critical Analysis and Judgement

B1. Ability to research, synthesise, evaluate and innovatively apply theoretical concepts, knowledge and approaches across diverse engineering technology contexts to effectively solve engineering problems


1.4, 2.1, 2.3


4, 5, 6, 7

B2. Technical and project management skills to design complex systems and solutions in line with developments in engineering technology professional practice


2.1, 2.2, 2.3, 3.2


C. Effective Communication

C1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience




4, 5, 6, 7

C2. Ability to engage effectively and appropriately across a diverse range of cultures



D. Design and Project Management

D1. Apply systematic synthesis and design processes within the technology domain

2.1, 2.2, 2.3


D2. Apply systematic approaches to the conduct and management of projects within the technology domain




E. Accountability, Professional and Ethical Conduct

E1. Innovation in applying engineering technology, having regard to ethics and impacts including economic; social; environmental and sustainability


1.6, 3.1, 3.4



E2. Professional conduct, understanding and accountability in professional practice across diverse circumstances including team work, leadership and independent work


3.3, 3.4, 3.5, 3.6


Unit Competency and Learning Outcome Map

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Engineering Technologist.




Graduate Attributes














Engineers Australia Stage 1 Competency Standards for Engineering Technologist

























































































































































































Unit Learning Outcomes



































































Student assessment

Assessment Type

When assessed



(% of total unit marks)

Learning Outcomes Assessed


Assessment 1

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: Manufacturing basics, metal forming.

Students will complete a quiz with MCQ type answers to 30 questions to demonstrate relevant knowledge of the basics of manufacturing and metal forming processes.


Week 3




1, 2


Assessment 2

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: Casting, welding, joining, plastic manufacturing, powder metallurgy.

Students will answer descriptive questions on casting, welding, joining, and powder metallurgy operations, to demonstrate an understanding of the processes and procedures involved.


Week 6




2, 3


Assessment 3

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project

/ Report

Example Topic: Machine tool technology, tools, jigs/fixtures, metrology.

Students will solve simple problems on or simulate tool geometry and wear, to demonstrate their comprehension of machine tool technology, metal cutting theories, and the selection and application of appropriate machine tools for different manufacturing operation, or simple simulations using Solidworks for example.


Week 10




4, 5


Assessment 4

Type: Exam or project

Example Topic: Manufacturing technology and processes.

Students will execute a project work covering different aspects of manufacturing technology and processes. The assessor will specify the format in which the report will be prepared and the expected content.


Final Week




1 to 7


Attendance / Tutorial Participation

Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.






1 to 7

Prescribed and recommended readings



Rajput, RK 2007, A Text book of Manufacturing Technology (Manufacturing Processes), 1st edn, Firewall Media, ISBN: 9788131802441




DeGarmo, EP, Black, JT & Kohser, RA 2011, DeGarmo's Materials and Processes in Manufacturing, 11th edn, Wiley & Sons, ISBN: 9780470924679


Kalpakjian, S & Schmid, SR 2013, Manufacturing Technology, 7th edn, Prentice Hall, ISBN: 978-0133128741


Roy 1997, Processes and Materials of Manufacture, 4th edn, Prentice Hall, ISBN: 978- 813180244


Journal, website



Notes and Reference texts

Knovel library: IDC Technologies

Other material advised during the lectures


Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.


Topic 1

Introduction to Manufacturing

  1. Importance of manufacturing

  2. Economic and technological considerations in manufacturing

  3. Classification of manufacturing processes

  4. Mechanization and automation

5. . Materials and manufacturing processes for common items

6. Computer aided manufacturing


Topic 2

Metal Forming

  1. Elastic and plastic deformation, yield criteria (Mises’ and Tresca’s)

  2. Principles and process characteristics

  3. Basic principles of hot and cold working

  4. Rolling, extrusion, forging, drawing, wire drawing, and spinning

  5. Sheet metal operations – measuring, layout marking, shearing, punching, blanking, piercing, forming, bending, and joining

  6. Design, lubrication, and defects in metal forming processes

  7. Unconventional metal forming/High Energy Rate Forming (HERF) processes – explosive forming, electromagnetic, electro-hydraulic forming


Topic 3

Metal Casting

  1. Fundamentals and principles of metal casting

  2. Casting processes

  3. Types of patterns and allowances

  4. Sand casting – sand properties, constituents, and preparation

  5. Mould and core making with assembly and its types

  6. Gating system

  7. Melting of metal, furnaces and cupola, metal pouring, fettling

  8. Casting types – sand, shell-mould, CO2 mould casting, cold and hot box, investment, vacuum, pressure, die, centrifugal, investment, continuous, stir casting

  9. Casting treatment, inspection, defects, and remedies


Topic 4

Welding and Joining

  1. Classification of welding processes

  2. Welding types – fusion welding, gas and arc welding, spot and seam welding, inert gas welding, TIG and MIG welding, submerged arc welding, resistance welding, thermit welding, CO2 shielded welding, pressure welding, solid phase welding, electro slag welding, electron beam welding, laser beam welding, forge welding, friction welding

  3. Welding equipment, weld joints – types, edge preparations

  4. Weldability – designs, process, and metallurgy

  5. Welding defects and remedies

  6. Mechanical fastening (riveting), adhesive bonding, soldering, and brazing


Topic 5

Manufacturing of Plastic, Glass, Powder Metallurgy

  1. Past, present, and future uses of plastics

  2. Injection moulding, compression moulding, transfer moulding, blow moulding, rotational moulding, thermoforming, extrusion of plastic section, welding of plastics

  3. Resins and adhesives

  4. Blow moulding and extrusion of glass

  5. Powder metallurgy manufacturing process and its application and advantages


Topics 6 and 7

Machine Tool Technology and Tools

  1. Cutting tool – types, requirements, specification, and application

  2. Tool life definition, tool wear, and measurement

  3. Factors influencing tool life – speed, feed, depth of cut, material, cutting fluids

  4. Geometry of Single Point Cutting Tool – tool angel, tool angle specification system, ASA, ORS, and NRS

  5. Theories of metal cutting, mechanism of chip formation, concept of shear plane, types of chips, chip breakers, orthogonal and oblique cutting, stress and strain in the chip, velocity relations, power and energy requirements in metal cutting

  6. Parameters affecting machining cost

  7. Classification, selection, and application of machine tools – lathe machines, milling machines, drilling machines, grinding machines, reaming machines, boring machines, broaching machines, lapping/honing machines, and shaping/slotting/planning machines

  8. Gear manufacturing – gear milling, standard cutters and limitations, gear hobbing, gear shaping, gear shaving, and gear grinding processes

  9. Surface finishing operations – honing, lapping, super finishing, polishing, buffing, process parameters and attainable grades of surface finish


Topic 8

Jigs and Fixtures

  1. Jigs and fixtures - locating and clamping devices and their principles

  2. Applications of jigs and fixtures

  3. Jigs bushes, drilling jigs, milling fixtures, turning fixtures, boring and broaching fixtures, welding fixtures

  4. Materials for jigs and fixtures

  5. Economics of jigs and fixtures


Topic 9


  1. Measurement, linear and angular measuring instruments

  2. Clampers, screw gauge, sine bar, auto-collimator, comparator – mechanical, electrical, optical, surface finish, and its measurements

  3. Micro and macro deviation

  4. Factors influencing surface finish and evaluation of surface finish

  5. Advances in metrology


Topic 10

Non-Traditional Machining Processes

  1. Need for non-traditional machining and principles

  2. Laser beam equipment and operation

  3. Detailed overview of non-traditional machining processes - plasma arc machining, electro-chemical machining, ultrasonic machining, abrasive jet machining, water jet machining, electron beam machining, electron discharge machining


Topic 11

CNC Machining

  1. CNC machines – introduction and principles of operation

  2. Major elements, functions, applications

  3. Controllers, open loop and closed loop systems

  4. Vertical machining centres and horizontal machining centres – constructional details, special features

  5. Coordinate measuring machines

  6. CNC machine maintenance

  7. G, M Codes, Basic CNC programming


Topic 12

Unit Review

(Distribute Case Study in Week 10). In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.