Manufacturing Proposal to Produce a Component of the Deakin Ascend World Solar Challenge Car

Assessment Introduction

This assignment requires you to prepare a manufacturing proposal to produce a component of the Deakin Ascend World Solar Challenge Car. Students should apply the knowledge they have gained through the unit to develop the solutions required from a Mechanical Design Engineer in a manufacturing environment. The component should include a minimum of four mounting points that should be as realistic as possible (based on research of current technologies and designs). The panel should deflect less than 20 mm with a 20 kg load applied normal to the surface in the middle of the panel. The production run for the parts is extremely low (4-6) so minimal capital expenditure should occur and be justified.

Assessment Requirements

The aim of this assessment task is to provide an innovative solution that incorporates flexible advanced materials and advanced processes with consideration of the Circular Economy. The solution should be achievable and cost effective, with the goal of producing a report that would enable the manufacture of your components with minimal extra resources.

The report should include the following:

Selection of materials and processes with consideration of the Circular Economy and justification of material and process selection This must include a description of the internal structure of the material and a fundamental theory/mechanism based explanation of how the key material properties are suitable for this application. Design and virtual build of the mould tooling required to produce the component

Use what you learnt from Assessment 2 - Design Proposal here.

 A Process Flow chart for the proposed manufacturing processes with the realistic steps to manufacture the product

This must focus on the production of the component and clearly highlight the steps involved, capital equipment, tooling, labour and the approximate time taken for each step of the process. This flow chart should only include key steps that are required in turning the incoming goods into the finished product (i.e. don’t include steps such as shipping or design).

Criteria

The report must be written in the individuals own words. Do not copy and paste large paragraphs from literature straight into your paper, instead you are strongly encourage to paraphrase, i.e. re‐write the text in your own words. You must also clearly check the spelling and grammar of your own work. Any detected written work which has been poorly written, will be given a poor grade. 

Any references used should be cited using an approved style and avoiding plagiarism (see link below). This means you are expected to write the assignment in your words, and not use those of the references you find. Turnitin software will be used on all assignment submissions.

Step-by-Step Approach by the Academic Mentor

The academic mentor guided the student systematically through the assessment by breaking the task into manageable stages:

1. Understanding the Task Requirements

   • The mentor first clarified the scope: focus on a single component of the solar car.
   • Highlighted assessment objectives: innovation, sustainability, feasibility, and cost-effectiveness.

   • Explained the importance of addressing performance criteria (load deflection, realistic mounting points) alongside manufacturing practicality.

2. Material and Process Selection

   • The student was guided to research advanced lightweight materials such as composites and alloys.
   • Mentor explained how to connect internal structure and properties (e.g., stiffness, strength-to-weight ratio) to application requirements.

   • Circular Economy principles were introduced—prioritising recyclability, low waste, and minimal environmental impact.

3. Tooling and Design Development

   • Building on previous learning (from Assessment 2), the student was instructed to virtually design mould tooling using CAD.
   • Mentor emphasised incorporating low-cost tooling options due to the limited production run.

   • Discussions included trade-offs between cost, durability, and ease of manufacturing.

4. Process Flow Chart Creation

   • Mentor explained how to draft a clear, practical flow chart outlining manufacturing steps.
   • Guidance included identifying only the essential production processes (material preparation, moulding, finishing, inspection).

   • The student was coached to specify resources, time, and equipment realistically for each step.

5. Structuring and Writing the Report

   • Mentor stressed the importance of clarity, originality, and academic integrity.
   • Student was guided to paraphrase research insights, integrate references, and avoid plagiarism.
   • Attention was given to logical flow, professional formatting, and grammatical accuracy.

Outcome and Learning Achievements

By following this guided process, the student successfully:

• Produced a feasible manufacturing proposal for the solar car component.
• Justified material and process selection with scientific reasoning and sustainability considerations.
• Created a virtual tooling design suitable for low-volume production.
• Developed a detailed process flow chart mapping realistic production steps.
• Delivered a report that was well-structured, plagiarism-free, and academically sound.

Learning Objectives Covered

• Application of mechanical design knowledge to real-world manufacturing.
• Understanding the role of advanced materials and processes in sustainable engineering.
• Integration of Circular Economy principles into design decisions.
• Development of practical skills in tooling design and process planning.
• Enhancement of academic writing, referencing, and critical thinking abilities.

Get Your Assignment Support the Right Way

Looking for guidance on how to approach your assignment? You can download our sample solution file to understand the structure, depth of analysis, and writing style expected in academic work. This sample is designed to give you valuable reference material and a clear idea of how to present your ideas effectively.

Important Disclaimer: The sample solution is for reference and learning purposes only. Submitting it as your own work may lead to plagiarism issues and academic penalties. Always use it responsibly to guide your research and writing.

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