Abstract:

The integration of active learning methodologies and emerging technologies in engineering education is essential to enhance the acquisition of technical and digital skills in higher education. This work presents a teaching experience developed in a fourth-year Mechanical Engineering course based on Project-Based Learning (PBL), where students design and manufacture molds for the production of forged carbon parts, a composite material consisting of a polymer matrix reinforced with carbon fibers.

The activity integrates Computer-Aided Design (CAD) design tools, mold manufacturing, and composite forming processes while incorporating Artificial Intelligence tools to support design decisions and process parameter optimization. Students complete the full product development cycle: part design, mold design, tooling manufacturing, and production of the final component through a forged carbon process. During these stages, dimensional metrology procedures are performed on both the tooling and the manufactured parts to verify tolerances and deviations from the original design model.

Based on the collected data, manufacturing parameters are analyzed, and artificial intelligence (AI) assisted data analysis tools are used to identify relationships between process variables and part quality. This analysis enables the proposal of optimization strategies related to material filling cycles within the mold, the amount of material required to ensure complete cavity filling, and the fiber–resin ratio of the composite material, together with the dimensional verification of both the tooling and the resulting parts.

Results indicate that integrating experimental manufacturing, dimensional control, and artificial intelligence promotes active learning, improves students' understanding of advanced manufacturing processes, and strengthens competencies related to digital engineering and process optimization. This approach enhances practical engineering education and prepares students for industrial environments associated with advanced manufacturing and Industry 4.0.

Keywords:

Artificial intelligence, Project-based learning (PBL), Engineering education, Mold design and manufacturing, Forged carbon composites, Advanced manufacturing, Industry 4.0.