Provides a rationale for materials selection in the design of engineered components and commercial products, with a general aim towards structural optimization and sustainability. Defines concepts of life cycle analysis and embodied energy, reviews material recycling technologies and methods, and environmental issues associated with materials in manufactured products, and waste. Develops a rationale for advanced materials selection, using the Ansys Granta CES materials software (a database for thousands of materials), for component design, based on an identification of the functional requirements. Develops a method for 'eco-audit' estimation of the total embodied energy of products. Altogether, materials selection includes structural and material processing considerations, and a range of case studies provides examples of optimized and sustainable design. Hybrid (composite) materials design and options for sustainable bio-composites discussed, including basic composite mechanics and topology optimization for structural optimization. There are two main design projects associated with proposed products, involving materials selection and multiple component design, to demonstrate an optimization of material usage and overall product sustainability.

Course objectives: (1) Define the role that materials play in product design (properties, performance); (2) Define the embodied energy and sustainability of materials and products; (3) Establish a rationale for materials selection (a material index) by defining a design objective and constraints to optimize structural efficiency and sustainability; (4) Learn to apply software tools (Ansys CES) for materials selection; (5) Find compromise with multiple constraints; (6) Perform iteration in the optimization of product design, considering materials, shape and processing; (7) Design a device/product with multiple components, considering optimal performance, manufacturing and environmental sustainability.