A project-based learning approach has been introduced in the Materials Design and Reestyling course of the Mechanical Engineering degree at the Universitat Politècnica de València (UPV) to enhance student learning. Previously, students worked on projects as a learning method, but the updated approach now requires them to build a physical prototype of their design. This change makes the learning experience more practical, ensuring that students not only create theoretical designs but also develop solutions that can actually be manufactured. As part of this process, students must redesign an existing component to improve its properties by switching from its original manufacturing method to forged carbon fiber. One important requirement set by the instructors is that the redesigned component must be possible to manufacture using this material, which requires a mold.

To create this mold, additive manufacturing, commonly known as 3D printing, is introduced as the main technique. Using 3D printing for mold production is a modern prototyping method that is becoming more common in industry. This method allows students to design and produce the mold themselves, giving them hands-on experience with advanced manufacturing techniques. By following this approach, students go through a process similar to what they would experience in a real industrial setting, covering design, material selection, and production.

The project follows a structured process. First, in the design phase, students improve their selected components while considering important factors such as strength, ease of manufacturing, and environmental impact. After finalizing their design, they use 3D printing to produce the mold, allowing them to quickly test and refine their ideas before moving forward. Finally, they manufacture the carbon fiber parts through a forming process, following procedures used in industry and gaining valuable practical skills. This learning method helps students develop key engineering skills, such as problem-solving, critical thinking, and clear communication. Additionally, by working with modern technologies like 3D printing and composite materials, students gain knowledge that better prepares them for careers in engineering. The effectiveness of this teaching method is evaluated through student feedback and academic results, which show increased motivation and better learning outcomes.

Keywords: Project-based learning, Additive manufacturing, Carbon fiber, Computer-aided design and manufacturing.