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Product design and manufacturing

Research at the nexus of creative design and engineering for production
  • https://www.sydney.edu.au/engineering/industry-community/partner-with-us.html Partner with us
  • https://www.sydney.edu.au/engineering/about/our-people.html Our people

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This theme looks at how we conceive, develop and fabricate innovative products that meet societal needs and sustainability goals. Our researchers explore design for sustainability, ensuring products have minimal environmental footprint throughout their lifecycle.

We also champion human-centred design, crafting technologies around users for better functionality and adoption. From concept to prototype to mass production, we develop tools and methodologies to accelerate product innovation.

By uniting expertise in mechanical design, biomedical engineering and computing, along with insights from project management, this theme delivers greener, smarter products – and smooth pathways to manufacture them at scale.

Sub themes

Our research spans three strengths across multidisciplinary research

Design for sustainability and lifecycle engineering

Our research in Design for Sustainability and Lifecycle Engineering embeds environmental responsibility into every stage of product development. From selecting low-impact, recyclable or biodegradable materials to designing for efficient manufacturing, disassembly, reuse, and end-of-life recycling, we ensure sustainability is not an afterthought but a foundation.

By integrating mechanical and chemical engineering with lifecycle management, we develop innovative methods that reduce environmental impact while maintaining high performance. This work supports our strategy to lead in sustainable innovation and circular economy solutions.

Our researchers are advancing tools and frameworks that help industries design products with minimal waste, lower emissions, and longer usable lives, delivering real-world impact across sectors from consumer goods to infrastructure.

Research Impact

Our research helps industries design products that are easier to recycle, reuse, or safely dispose of—reducing waste and environmental harm. From biodegradable packaging to modular electronics, we’re enabling a circular economy were sustainability drives innovation.

Our researchers

Professor Ali Abbas

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Human-centred product design and prototyping

Our research places people at the heart of engineering innovation. By involving end-users early in the design process, we ensure technologies are intuitive, safe, and tailored to real-world needs. This approach spans applications from medical devices to consumer electronics, integrating biomedical insights to enhance health and well-being. We use rapid prototyping tools, including 3D printing and virtual reality simulations, to quickly iterate and refine designs.

Combining mechanical design creativity, biomedical engineering, and computer science, our researchers produce functional prototypes and proof-of-concepts ready for testing and further development. This work aligns with our commitment to impactful, user-focused innovation that improves lives and drives industry-ready solutions.

Research Impact

We design products that work for people, whether it’s a safer medical device or a more intuitive wearable. By prototyping with real users in mind, we help bring better, smarter technologies to life faster.

Our researchers

Professor Ali Abbas, Professor Judy Kay, Professor Eduardo Velloso

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Scale-up and advanced manufacturing integration

Our research in scale-up and advanced manufacturing integration focuses on bridging the gap between prototype development and full-scale production. We tackle the complexities of scaling up by integrating advanced manufacturing technologies, such as automation, machine vision, and sensor-based quality control, into existing production environments.

This includes optimizing supply chain logistics and developing robust systems for high-volume manufacturing. By combining engineering innovation with project management strategies, we ensure new products and processes can be efficiently and reliably ramped up.

Our work supports the strategic goal of accelerating technology adoption and delivering industry-ready solutions. Our researchers enable companies to bring advanced products to market faster, at lower cost, and with consistent quality, driving competitiveness and innovation across sectors.

Research impact

We help companies move from lab-scale breakthroughs to full-scale production, faster, cheaper, and with fewer risks. From automated assembly lines to smarter supply chains, our research makes advanced manufacturing more accessible and scalable.

Our researchers

Professor Ali Abbas

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Leading Schools

Title : School of Aerospace, Mechanical and Mechatronic Engineering

Description : Pioneering research and education for the next generation of aeronautical, mechanical, materials, robotics and space engineering solutions.

Link URL: https://www.sydney.edu.au/engineering/schools/school-aerospace-mechanical-mechatronic-engineering.html

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Title : School of Biomedical Engineering

Description : Advancing health through cutting-edge research, innovation, and transformative education to shape future biomedical leaders.

Link URL: https://www.sydney.edu.au/engineering/schools/school-biomedical-engineering.html

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Title : School of Chemical and Biomolecular Engineering

Description : Creating resources and technologies to transform industries and developing processes that reduce pollution and protect the world.

Link URL: https://www.sydney.edu.au/engineering/schools/school-of-chemical-and-biomolecular-engineering1.html

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Title : School of Computer Science

Description : Innovative research and education in information technology, computer science, digital health, data science, cybersecurity, artificial intelligence (AI).

Link URL: https://www.sydney.edu.au/engineering/schools/school-computer-science.html

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Title : School of Electrical and Computer Engineering

Description : Research across a broad range of fields with emphasis on future energy networks, wireless communications, computer engineering, software engineering, photonics and the Internet of Things.

Link URL: https://www.sydney.edu.au/engineering/schools/school-of-electrical-computer-engineering.html

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Title : School of Project Management

Description : Conducting teaching and research excellence across the areas of aerospace engineering, mechanical engineering and mechatronic engineering.

Link URL: https://www.sydney.edu.au/engineering/schools/school-of-project-management1.html

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Useful links

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