Surface condition plays a critical role in the functional performance, durability, and aesthetics of engineering components. Manufacturing processes such as additive manufacturing, molding, machining, and polishing introduce distinct surface topographies that may further evolve under environmental or abrasive exposure. This paper presents the development and implementation of a comprehensive, hands-on laboratory module focused on surface roughness characterization within an undergraduate mechanical engineering curriculum. Students investigate polymeric and metallic materials produced through multiple manufacturing routes, including 3D printing, injection molding, and metallographic preparation. Surface roughness is quantified using stylus-based profilometry with carefully selected traverse lengths, while surface morphology is examined using optical microscopy. Students analyze how manufacturing method, surface condition, and measurement parameters influence roughness metrics such as Ra (average roughness), Rz (average peak-to-valley height), and Rmax (maximum peak-to-valley height). The laboratory is explicitly designed to support ABET Student Outcome 6 by engaging students in experimental design, data analysis, and engineering judgment. Representative results and assessment outcomes are presented to illustrate both the technical rigor and educational value of the laboratory.
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