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Topic 04 - Final Production, 1) Natural is clean and twist 2) Melted,…

- - - - A measure of how much matter is in the object and is independant from gravity
    - - The pull of gravity on the mass of the object
    - - How much mass is in one cubic cm (how tightly all the atoms are packed)
    - - A materials ability to conduct electricity
        
        High Resistance
        
        Good Insulator
        
        Low Resistance
        
        Good Conductor
    - - How well a material conducts temperature
    - - The degree of increase in dimmensions when an object is heated
    - - Resistance to penetration or scatching
  - - - The ability of withstand tension (pulling force)
      - Good
        
        Ropes or steel cable
    - - Resist compression/crushing (concrete)
    - - Young's Modulus (rise over run)
      - Resistance to elasticity
      - Low YM means gradient is lower and it can withstand more stress
      - Stress & Strain
    - - Resistance to the formation of cracks
    - - The ability to be extruded in terms of length (wire)
    - - The ability of a material to be formed into a new shape. When the material is bent or deformed beyond its yield it does not return to its original shape.
  - - - Use of difference ingredients in ratios to determine essential characteristics like taste, storage/shelf life.
    - - Physio-pleasure, infers material use (leather) or state of the product (Car Showroom Smell)
    - - the visual conditions (impacts sale-ability)
    - - The feel - may be essential to its function (arm-chair)
    - - NOT SMART - but they way we use them is
      - They react to their local environment
- - - - Extract from ore by mining
      - Shiny, Hard, Electrical Conductor, Thermal Conductors/Insulators
      - Pure metals are soft, brittle or chemically reactive so we treat them
      - Ferrous (iron-based) or Non-Ferrous (no iron)
      - Ferrous metals rust when the react with oxygen in the atmosphere (forming oxides)
      - Ferromagnetic means it has iron and is magnetic
    - - Have positively charged nuclei
      - Electrons in the outer shell are free - allows it to pass electrical charge
      - Also allows for ions and chemical bonding
    - - Metals are naturally appear as crystals (ore) and are heated to the form we have.
      - Fine Grain size = tightly packed = strong bonds = hard metals
      - Larger Grain Size = weak bonds = soft and pliable metals
    - - A mixture - not chemically bonded
      - To change physical and mechanical properties
      - Steel is Iron and Carbon / Stainless Steel is Iron, Chromium, Nickel
    - - Based on Iron, Nickel or Cobalt
      - Perform in extreme environments at high performance
      - Aircraft Engines, Rocket Engines, Chemical Plants
      - Nickel-based are super resistant to temperature change
    - - All about GRAIN SIZE
      - Heating loosens the bonds
      - Hitting/Crushing heated metal pacts the grains , making it stronger / denser
      - Heating and rapid cooling by dropping in waters will tighten the bonds = stronger
    - - In scrapyards
      - Old, recycled metal is always mixed with new metal ore to ensure quality
  - - - Matures in 30-40 years
    - - Matures in 100+ years
      - More expensive, stronger and have better decorative qualities
    - - Mixing wooden chips/dust/particles with adhesives
      - Extruded in flat sheets
      - Chipboard (ikea shelves)
      - MDF (Medium Density Fibreboard) (DT Table)
    - - Softwood (planks)
      - Hardwoods (long lasting)
      - Composite (laminate, cheap but has cosmetic qualities of hardwood, lasts longer than soft wood)
  - - - Brittle
      - Transparent
      - Hard
      - Unreactive
    - - Use in windows (cars)
      - Thermally Treated so the outside in under compression and inside is under tension - means it doesn't shatter in shards
    - - Layered so it doesn't smash only cracks (spider web cracking)
  - - - Remoulded many times
    - - Molded Once
      - Heat has no effect and extreme heat will destroy the bonds and turn it to dust
      - Electrical & Thermal Insulator
    - - Polyproplyene
        
        Large thin sheets in DT
        
        Use in polymer notes, packaging, bottle tops, crisp packets
      - Polyethylene
        
        PET (Polyethylene Terephthalate)
        
        Moisture Barrier
        
        Plastic Bottles
        
        Very Flexible
        
        HDPE (High-Density Polyethylene)
        
        LDPE (Low-Density Polyethylene)
        
        Food wrap, Fuel Tanks, Shopping Bags
      - HIPS (High Impact Polystyrene)
        
        Rigid
        
        Toys, Road Signs
        
        Can be cut easily
        
        Found in sheets (like Acrylic)
      - ABS (acrylonitrile-butadiene-styrene)
        
        3D Printing Materials (at school)
        
        High resistance
        
        camera bodies, power tool housing, casings
      - PVC (Polyvinyl Chloride)
        
        Non-toxic, chemically stable, biocomptabale, easily sterilized
        
        Used in Medical Equipment, Wiring, Cars, Toys
        
        Electrical Insulator
        
        Lightweight
        
        Coloured Easily
        
        Most practical
    - - Polyurethane
        
        Used in construction
        
        roller-coaster, automotive suspensions, elevators, hoses
        
        Used in Araldite
      - Urea-Formaldehyde
        
        A resin used in adhesives
        
        The vapour emitted whilst forming is cancerous
      - Melamine Resin
        
        Stiff and Hard that resists staining
        
        Used as a protective laminate
      - Epoxy Resin
        
        Electrical Insulator
        
        Adhesives (araldite)
        
        Resists chemicals well
  - - - Ductile material - pulled into long threads of a single strand then spun together
    - - carbon is bonded in a lattice structure = strong
      - Long thin Carbon Strands cross woven to form a fabric
      - mixed with epoxy to form shapes
    - - A composite that uses a metal.
      - When there are 3+ types of materials it is called a hybrid composite
  - - - Wool
        
        Low tensile strength
        
        high absorbency
        
        high elasticity
        
        chars when burnt
      - Cotton
        
        Medium tensile strength
        
        high absorbency
        
        medium elasticity
        
        burns intensely and rapidly
        
        chars when burnt
      - Silk
        
        High tensile strength
        
        medium absorbency
        
        low elasticity
        
        chars when burnt
        
        very heat resistant
    - - Conduct Electricity, incorporates electronics
    - - Nylon
        
        High tensile strength
        
        low absorbency
        
        low elasticity
        
        melts easily
        
        ignites easily
      - Polymer
        
        Low absorbency
        
        high tensile strength
        
        low elasticity
        
        melts at a low temperature
      - Lycra
        
        Very low absorbency
        
        medium tensile strength
        
        high elasticity
        
        burns and melts at low temperature
        
        Used in Sports Clothing
    - - Yarn
        
        Fabric
        
        Garmnets
  - - - When it is deformed (bent) it gives off a small electric charge
      - Used in Sebs' Glove to combat Parkinson's disease
      - Used in Airbag sensors
    - - Fluids
      - Change viscosity (from thick liquid to solid) when exposed to magnetic / electrical field
      - MR contain iron / ER contain corn starch or oil
    - - Metals
      - Happens with a temperature change
      - Nickel Titanium
- - - - Cuts Paper Sheets and Glues them together (using a water-based adhesive)
      - Limited Size
      - Paper is cheap
      - Quick Production Time
      - Paper Degrades = More Environmentally Friendly
    - - Same as Paper Based but uses Roll of Paper (bigger sizes)
    - - UV laser shone onto liquid resin/plastic which cures it
      - Cuts a CAD File into layers which it slowly builds
    - - What we use at school
      - Heating a thread of plastic and placing it - layer by layer
    - - Same principle as SLA but uses powder
  - - - Removing Materials by hand or specialised machine
      - Wood Lathes
      - Metal Lathes
      - Milling Machines
      - Router (hollows out)
  - - - Shaping Sheets
      - Press Moulding
      - Vacuum Moulding
    - - Liquefying a metal/plastic and pouring it into a hollow mould
      - Often uses a furnace to melt at high temperatures
    - - Creating a wax / clay model then creating a cast around it
      - Metal is poured in
      - Used to replicate shapes
    - - Adhering Layers Together
    - - Reshaped by knitting or weaving
  - - - Glueing
      - Welding
        
        Gas Welding
        
        Melting two sides of metal and fusing them together
        
        Electric/Arc Welding
        
        Acts as an electrode, heats the metal rapidly causing it to move and fuse with surrounding metal
      - Riveting
        
        A red hot bolt is placed in a hole, the other side of the rivet is placed and the rest of the bolt is cult off
    - - Screws
      - Velcro
      - Zips
- - - - Do one task, all the time, no sensors
    - - Operate autonomously, have sensors to react to the environment
    - - Operate autonomously (like healthcare robots), use AI
  - - - Several Heads that each do a separate task
      - Do a range of tasks
    - - A series of robots that work to coordinates with one-another
    - - Replacing a singular labourer