535.721.81 - Advanced Composite Materials & Manufacturing Processes

Course Structure

The course materials are divided into modules which can be accessed by clicking Course Modules on the course menu. A module will have several sections including the overview, content, readings, discussions, and assignments. You are encouraged to preview all sections of the module before starting. Most modules run for a period of seven (7) days, exceptions are noted in the Course Outline. You should regularly check the Calendar and Announcements for assignment due dates.

Course Topics

• Introduction to Composites
• Fiber Reinforcement 
• Polymer Matrices
• Fiber Reinforcement Forms
• Open Mold Manufacturing Processes
  
• Closed Mold Manufacturing Processes
• Tooling
  
• Composite Design 
• Sandwich Panels
• Adhesive Bonded Joints
• Repair
• Quality
• Material Testing
  

Course Goals

Provide students with a comprehensive understanding of composite materials, including the properties and behavior of fiber and matrix constituents and equip students with in-depth knowledge of modern manufacturing techniques, tooling methods, and design principles used in composite structure fabrication. Emphasis is placed on process optimization, quality control, and performance testing to ensure reliability in advanced applications. By the end of the course, students will be prepared to apply this knowledge to solve real-world engineering challenges in industries such as aerospace, automotive, and renewable energy.

Course Learning Outcomes (CLOs)

• Compare the differences between fiber reinforcements and matrices available for manufacturing.
• Evaluate composite processing methods and tooling approaches to satisfy part requirements.
• Compare the layup processes for solid and sandwich laminates and considerations for vacuum bagging and cure.
• Identify key material properties that influence the design, performance, and manufacturing of composites.
• Explain destructive and non-destructive testing techniques to inform design, manufacturing, and quality.
• Create a design, manufacturing, assembly, and test plan for a composite structure.

Textbooks

Strong, A. B. (2008). Fundamentals of Composites Manufacturing: Materials, methods and applications (2nd ed.). Society of Manufacturing Engineers.

ISBN-10: 0872638545; ISBN-13: 978-0872638549

Textbook information for this course is available online through the MBS website.

Required Software

In this class, some computer literacy skills you are expected to have include creating and submitting files in a word processing program, downloading and installing software, using spreadsheets, using presentation software, and using web conferencing tools and software. Additionally,  you will be expected to use online search tools for academic purposes, properly cite information sources, and prepare a presentation of such findings.

Student Coursework Requirements

It is expected that each module will take approximately 7–10 hours per week to complete. Here is an approximate breakdown: reading the assigned sections of the texts (approximately 3–4 hours per week) as well as some outside reading, listening to the audio annotated slide presentations (approximately 2–3 hours per week), and writing assignments (approximately 2–3 hours per week).

This course will consist of the following basic student requirements:

Discussions 

Discussions will be graded using a rubric.

Student response to the discussion post is 75% of the total discussion grade. The student reply is 25% of the grade. 

Assignments

All assignments are due according to the dates in the Calendar.

If, after submitting a written assignment you are not satisfied with the grade received, you are encouraged to redo the assignment and resubmit it. If the resubmission results in a better grade, that grade will be substituted for the previous grade.

Assignments will be graded using a rubric.

Course Project 

A course project will be assigned several weeks into the course. The next-to-the-last week will be devoted to the course project.

The course project will be graded using a rubric.

Exams

The midterm exam will be available in Module 4 during the summer course and in Module 5 during the spring course. The final exam will be available in the Module 10 during the summer course and Module 12 during the spring course. You will have two weeks to complete the exams and they will be due by 11:59pm on the last day of their respective Modules. You may use the course text to complete the exams.

Late Submission Policy (without prior coordination with Instructor) 

This policy applies to all discussions, assignments, exams, and project submissions. 

Coursework submitted up to one day late will receive no grade penalty. After the first day, a 2-point deduction will be applied for each additional day late. Coursework submitted one week late will receive a full letter-grade deduction. 

Grading Policy

Assignments are due according to the dates posted in your Canvas course site. You may check these due dates in the Course Calendar or the Assignments in the corresponding modules. I will post grades one week after assignment due dates.

I generally do not directly grade spelling and grammar. However, egregious violations of the rules of the English language will be noted without comment. Consistently poor performance in either spelling or grammar is taken as an indication of poor written communication ability that may detract from your grade.

A grade of A indicates achievement of consistent excellence and distinction throughout the course—that is, conspicuous excellence in all aspects of assignments and discussion in every week.

A grade of B indicates work that meets all course requirements on a level appropriate for graduate academic work. These criteria apply to both undergraduates and graduate students taking the course.

EP uses a +/- grading system (see “Grading System”, Graduate Programs catalog, p. 10).

100-98 = A+ 97-94 = A 93-90 = A− 89-87 = B+ 86-83 = B 82-80 = B− 79-77 = C+ 76-73 = C 72-70 = C− 69-67 = D+ 66-63 = D <63 = F

Final grades will be determined by the following weighting:

Item	% of Grade
Discussions	15%
Assignments	30%
Course Project (Peer Review + MRR)	25% (10% + 15%)
Exams (Midterm + Final)	30% (15% + 15%)

Student Generative AI (GenAI) Use

Yellow: Moderate GenAI use is permitted, with restrictions. Students may use Generative AI tools in limited ways to support their learning, consistent with course policies and assignment instructions. Appropriate uses may include brainstorming, clarifying concepts, organizing ideas, improving writing mechanics, or receiving feedback on drafts; however, GenAI should serve as a learning aid, not as a substitute for the student’s own thinking, analysis, problem-solving, or original work. Students are responsible for the accuracy, integrity, and originality of all submitted work and should not rely on GenAI to produce complete answers, discussions, exams, projects, or other required submissions. Any use of GenAI on assignments, discussions, exams, or projects must be clearly disclosed, including the tool used and a brief description of how it was used. Failure to disclose GenAI use or using it in ways that violate course instructions may be treated as an academic integrity issue.

Academic Policies

Deadlines for Adding, Dropping, and Withdrawing from Courses

Students may add a course up to one week after the start of the term for that particular course. Students may drop courses according to the drop deadlines outlined in the EP academic calendar. Between the 6th week of the class and prior to the final withdrawal deadline, a student may withdraw from a course with a W on their academic record. A record of the course will remain on the academic record with a W appearing in the grade column to indicate that the student registered and withdrew from the course. 

Academic Misconduct Policy

All students are required to read, know, and comply with the Johns Hopkins University Krieger School of Arts and Sciences (KSAS) / Whiting School of Engineering (WSE) Procedures for Handling Allegations of Misconduct by Full-Time and Part-Time Graduate Students. This policy prohibits academic misconduct, including but not limited to the following: cheating or facilitating cheating; plagiarism; reuse of assignments; unauthorized collaboration; alteration of graded assignments; and unfair competition. Course materials (old assignments, texts, or examinations, etc.) should not be shared unless authorized by the course instructor. Any questions related to this policy should be directed to EP’s academic integrity officer at ep-academic-integrity@jhu.edu.

Students with Disabilities - Accommodations and Accessibility

Johns Hopkins University values diversity and inclusion. We are committed to providing welcoming, equitable, and accessible educational experiences for all students. Our courses are designed with a proactive approach to accessibility to minimize the need for disability disclosure and accommodation requests, but we recognize that you may need additional support. Students with disabilities (including those with psychological conditions, medical conditions, and temporary disabilities) can request accommodations for this course by providing an Accommodation Letter issued by Student Disability Services (SDS). Please request accommodations for this course as early as possible to provide time for effective communication and arrangements.  For further information or to start the process of requesting accommodations, please contact EP Student Disability Services at ep-disability-svcs@jhu.edu. 

Student Conduct Code

The fundamental purpose of the JHU regulation of student conduct is to promote and to protect the health, safety, welfare, property, and rights of all members of the University community as well as to promote the orderly operation of the University and to safeguard its property and facilities. As members of the University community, students accept certain responsibilities which support the educational mission and create an environment in which all students are afforded the same opportunity to succeed academically. For a full description of the code please visit the Student Conduct Code website.

Classroom Climate

JHU is committed to creating a classroom environment that values the diversity of experiences and perspectives that all students bring. Everyone has the right to be treated with dignity and respect. Fostering an inclusive climate is important. Research and experience show that students who interact with peers who are different from themselves learn new things and experience tangible educational outcomes. At no time in this learning process should someone be singled out or treated unequally on the basis of any seen or unseen part of their identity. If you have concerns in this course about harassment, discrimination, or any unequal treatment, or if you seek accommodations or resources, please reach out to the course instructor directly. Reporting will never impact your course grade. You may also share concerns with your program chair, the Assistant Dean for Diversity and Inclusion, or the Office of Institutional Equity. In handling reports, people will protect your privacy as much as possible, but faculty and staff are required to officially report information for some cases (e.g. sexual harassment).

Course Auditing

When a student enrolls in an EP course with “audit” status, the student must reach an understanding with the instructor as to what is required to earn the “audit.” If the student does not meet those expectations, the instructor must notify the EP Registration Team (EP-Registration@exchange.johnshopkins.edu) in order for the student to be retroactively dropped or withdrawn from the course (depending on when the "audit" was requested and in accordance with EP registration deadlines). All lecture content will remain accessible to auditing students, but access to all other course material is left to the discretion of the instructor.