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Product Design - Final Exams - Coggle Diagram
Product Design - Final Exams
Material Categories
Natural and Manufacturered Timbers
Softwood Examples
Cedar, douglas fir, yew, redwood, larch, cypress, pine.
Coniferous trees, evergreen, grows much quicker, considered to be more renewable.
Hardwood Examples
Ash, beech, birch, cherry, mahogany, oak and teak.
Hardwood comes from broad-leaf, deciduous trees.
Manufactured Board Examples
Blockboard, chipboard, hardboard, MDF, fibreboard, plywood.
Man-made with waste timber as their main constituent. Fibres are held together with an adhesive.
Using and Working
Plane: Moved back and forth to remove excess materials.
Chisel: Handheld tool for carving or gouging.
Sanding disk: Creates smooth finish.
Glass paper: Abrasive paper used to finish.
Saws:
Coping saw: Thin and narrow blade, best for trim work.
Crosscut saw: Thick blade, beveled teeth. Good for cutting rough lumber.
Fret saw: Thin blade for making intricate cuts. Longer and wider frame.
Back saw: Short saw with a narrow blade, used for fine and straight cuts.
Scroll saw: Cut intricate cuts at high speeds.
Band saw: Clean and precise cut on heavier materials.
Circular saw: Heavy duty saw.
Jigsaw: Handheld tool for precise curves and complex shapes.
Joints and Fixings
Mitre: Two 45 degree angles.
Dovetail joint: Interlocking pins and tails.
Lap joint: Thickness halved at location of joint.
Finger joint: Dovetail but stronger.
Butt joint: Fixing two pieces together at a right angle.
Stock Forms
Rectangular section board
Dowel
Square section board
Sheet
Mould
Scales of Production
Prototype: Identify errors before quantity production.
One-off production: labour and material costs are high.
Batch production.
Mass production.
Continuous production.
Just in time production.
Specialist Techniques and Processes
Steam bending - Use of steam to make a piece of timber more malleable.
Laminating - Placing a wood veneer onto a surface using an adhesive.
Inlays - Removing a section of a wooden surface and placing a different wood type within the cavity, making it flush with the surface.
Veneer - Cutting thin slices of a wooden surface.
Vacuum bag press - Use of a vacuum bag and former to bend wood into a particular shape.
Surface Treatments and Finishes
Paint - Used to alter colour, protect wood and cover the grain.
Varnish - Coloured or clear: can seal the wood and make it waterproof.
Oil - Used to enhance the colour of the wood and offer protection against weather.
Stain - Used to saturate the wood and protect from weather.
Metals and Alloys
Ferrous Examples
Cast Iron: Hard, brittle, easy to cast. Used for kitchen pots, utensils and post boxes.
Wrought Iron: Soft, ductile magnetic and good tensile strength. Used for gates, fences and heavy duty chains.
Mild Steel: Strong, tough and durable. Used for construction and car bodies.
Tool Steel: Hard, strong, low ductility. Used for garden equipment, blades and scissors.
Stainless Steel: Hard, very smooth, shiny, hard to weld. Used for cutlery, kitchenware or surgical equipment.
Non-Ferrous Examples
Copper: Flexible, ductile, malleable, electrical conductor. Used in cabling, plumbing and pipes.
Aluminium: Excellent strength to weight ratio, light, ductile. Used for bike frames, cans and foil.
Silver: Best thermal and electrical conductor, very malleable and ductile. Uses include jewelry.
Zinc: Malleable, ductile, good electrical conductor. Used for galvanisation.
Tin: Malleable, ductile, soft and good electrical insulator. Used in cans, soldering, food storage and foil.
Bronze: Tough, hardwearing, corrosion resistant. Used in bearings, coins, air/water/steam valves.
Gold: Very malleable, ductile and highly resistant to corrosion. Used in jewelry, ornaments and bullion.
Alloys Examples
Brass: Copper (65%) and zinc (35%). Malleable and easy to cast. Easy to machine and polishes well. Used in instruments, plumbing, ornaments, fixtures and fittings.
Pewter: Tin (90%), Copper (5%), Antimony (5%). Low melting point, malleable, easy to cast, polishes well. Uses include jewelry and plates.
Sources and Origins
Blast furnaces are often used to extract iron from iron ore, the pure metal liquid falls to the bottom of the furnace with a layer of waste metal forming on top (slag). The waste runs off in a different direction to prevent contamination.
Using and Working
Pillar Drill: Allows for the drilling of holes in metals. A pilot hole is often drilled first. Pillar drills are accurate and powerful, they allow for a drill depth to be set as a quality control measure.
Cutting:
Hacksaw: Used to cut straight lines. Regular hacksaws are robust and appropriate for thicker materials while junior hacksaws can be used for thinner materials.
Coping saw: Used to cut curved lines in thinner materials, thin blade allows for detailed lines to be followed.
Mechanical hacksaw: Powered saw used for cutting thicker pieces of metal. Lubricant is added to the cut to cool the blade.
Abrading:
Filing: Used to smooth edges. Different profiles and grades are available for various tasks.
Wet and Dry Paper: Used to clean up or smooth surfaces.
Polishing mop: Used with fine abrasive to buff metals.
Fixings: Nut, nyloc nut, bolt, washer, pop rivet and grub screw.
Stock Forms
Sheet, rod, bar, tube.
Measuring and Marking
Steel rule: Used to measure lengths, measures from 0 mark.
Vernier calliper: Extremely accurate measuring device.
Centre punch: Mark dots on metal, used for drilling.
Spring divider: Used to mark very accurate arcs / circles.
Engineer's square: Used for marking out at right angles.
Micrometer: Measure lengths accurately.
Scriber: Thin and accurate marking implement.
Odd-leg callipers: Used to make parallel lines.
Specialist Techniques
Milling:
Cutting tool moves across the surface of the metal, can be used with CAD / CNC.
Turning:
Makes use of a lathe and rotation, traditional and CNC versions can be used.
Hot Forging:
Heating a metal until it is in a malleable state.
Die casting:
Molten metal is pushed into a mould and cooled rapidly.
Sand Casting:
Allows for complex shapes to be moulded using delft clay and parting powder.
Brazing and Welding:
Brazing: Flux added to prevent oxidation. Heated on Brazing hearth with spelter.
Welding: Materials are heated so that they bond.
Treatments
Powder coating: Electrostatic powder applied with heat.
Anodising: On aluminium.
Galvanising: Prevents rusting.
Hot Blackening: Dipped in oil and chemicals.
Sand blasting: Aesthetic.
Electroplating: Metal layer added with current.
Lacquer: Varnish
Polymers
Thermoset Examples
PP - Flexible, food-safe.
HIPS - Impact resistant.
HDPE - Lightweight, chem-res
LDPE - Flexible, S:W ratio
PET - Easily blow moulded
ABS - Rigid, good insulator
PVC - Tough, pipes
PMMA - Tough, brittle, car lights
Thermoplastic Examples
MF - Light, food-safe
ER - Heat resistant, seal
Urea Formaldehyde
Polyester Resin - Strong.
PF - Rigid, mechanical parts.
Using and Working
Drilling: Pillar drill
Cutting: Bandsaw, coping saw, vinyl cutter, laser cutter [consider kerf, speed, cleaning mirrors]
Abrading: Filing, wet and dry paper, abrading pads.
Stock Froms
Sheet
Rod
Tube
Granule / powder
Foam / film
Specialist Techniques and Processes
Line bending: Using a jig and a strip heater.
Vacuum forming: Clamped and heated above mould until droops. Sheet is pressed onto mould and air is removed. The mould must be tapered.
Blow moulding: Parison tube extruded into hollow mould and inflated. It is then cooled and trimmed.
Extrusion: Plastic continuously pushed through a die.
Injection moulding: Plastic granules pushed into a mould via an archimedes screw. This process is very accurate.
Surface Treatments and Finishes
Painting
Vinyl decals
Flocking
Embossing and Engraving
Heat transfer and hydrographic printing.
Electroplating.
Rubberising spray.
Papers and Boards
Paper Examples
Tissue Paper: Lightweight, soft, 10-35 GSM (means of measuring the weight of the paper). It is commonly used for gifts, arts and crafts and toilet / kitchen roll.
Newsprint Paper: Off white colour, lightweight, low cost, unfinished, mainly recycled, 45-55 GSM. Used in newspapers and low cost leaflets.
Layout Paper: Semi-translucent, some inks smear, good for pencil work, 40-60 GSM. Sketch and design work.
Bleed Proof Paper: Coated to stop markers bleeding through, 70 GSM. Uses include design pages when markers are being applied.
Tracing Paper: Translucent, works well with pencil, 40-120 GSM. Uses include tracing images, best when used with a light box.
Photocopy Paper: Lightweight, low cost, good for inkjet and laser printing. 70-150 GSM.
Cartridge paper: Opaque, fairly thick, 120-150 GSM, used for pencil and paper drawings + watercolour paintings.
Sugar Paper: Range of colours, takes ink well, 80-150 GSM. Used for display work and contrast paintings.
Photo paper: High quality, bright images, gloss/satin/matte finishes, 120-160 GSM. Used in photographs, albums and cards.
Board Examples
(Boards are any paper based material over 200 GSM. Microns are used to measure board thickness = 1/1000 of a millimetre. Board is generally more rigid and durable).
Carton Board: Thick, easy to print on, 200-500 GSM. Used for food packaging.
Duplex Board: Cheaper than standard card, lightweight, stiff, easily coated, 200-500 GSM. Often used in packaging for food or drinks.
Card: Stiff, easily cut and creased, 200-500 GSM. Used for greeting cards, packaging and advertising.
Foil lined board: Stiff, good heat insulator, water and oil resistant, 200-400 GSM. Commonly used for takeaway packaging.
Mount Board: Thick, rigid, good finish, cuts well, 400-700 GSM. Used for frame borders and mounting images.
Foam Board: Lightweight, rigid, cracks and folds under pressure. Used in modelling, prototyping and mounting images.
Corrugated Cardboard: Strong, lightweight, rigid in one direction, good insulator, easy to print on. Commonly used for heavy duty boxes, packaging, storage boxes and pizza boxes.
Sources and Origins
Usually made form wood pulp but can be made from bamboo, straw and sugar cane.
To make paper:
Cellulose fibres are mixed with water to create a pulp.
Fibrous liquid is then bleached or coloured.
Water is drained using a mesh screen.
Felt fabrics are used to press out the water.
Heated rollers remove remaining water.
Finished paper is prepared in sheets or rolls.
(From 99.5% water to 0.5%)
Using and Working
Marking and Cutting:
Steel rule (measuring and drawing lines).
Safety rule (helps to safely cut with knife or scalpel).
Craft knife (cutting and scoring.
Scalpel (fine cutting and scoring).
Rotary cutting wheel (cuts curved lines).
Paper shears (used for cutting).
Creasing tool (crease thicker boards).
Cutting mat (anti-slip and protects surfaces.
Rotary cutter (used to cut paper and boards to correct sizes).
Creasing machine (used to make creased lines).
Common Fastens:
Split pin.
Bulldog clip.
Binder clip.
Rachet rivet.
Staples.
Paper clip.
Sealing Methods:
Self adhesive.
Tear strip.
Tamper-proof stickers.
Binding Methods:
Hard back binding.
Perfect binding.
Coil binding.
Adhesives:
Glue stick.
PVA.
Spray glue.
Superglue.
Double sided tape.
Glue gun.
Techniques
Offset Lithography:
Cost effective and time efficient.
Print goes through plate making, wetting and inking.
Ink sticks to the areas with images and the water repels them.
Prints one colour at a time (CMYK).
Digital Printing:
No need for plates, time efficient, high-quality so good for glossy magazines.
Editing is easy with the use of a computer.
Uses CMYK.
Screen Printing:
Used for art prints.
Fine mesh screen is fixed to a wooden frame.
Stencil is placed under the screen and ink is forced onto the material below.
Gravure:
High cost but capable of high quality prints.
Like digital printing but using plates.
Direct contact between photo-etched plates and the paper.
Flexography:
Uses photoetched plates which bring the ink right onto the page.
Can print on boards and plastics.
Die Cutting:
Used to cut multiple, identical shapes very quickly.
The material to be cut by the die is placed under it and the die is lowered.
Commonly used for manufacturing nets for packaging.
Quality Control:
Registration marks: If printed right, registration marks should overlap perfectly so the mark looks completely black.
Trim marks: Small marks that show exactly where the finished page will be cut.
Colour bars: Used for quality control, squares of the colour are printed on an area to be cut off, the printing press operator may use this to check colour density and consistency.
Finishes and Treatments
UV Varnish: Used for shiny finish and protective layer.
Foil Application: Used to create a metallic effect.
Laminating: Polymer film that protects from moisture and damage.
Embossing: Raises the surface by compressing to improve aesthetics.
Misc Points
Key Ideas
Origin in CAM is known as the datum.
CAM machines:
CNC routers
Laser cutters
3D printers
Products that are designed to become obsolete are known to have "planned obsolescence". Up-to-the-minute designs become obsolete when they become unfashionable.
Some products are built for maintenance.
6 Rs:
Repair
Re-use
Recycle
Rethink
Reduce
Refuse
Ethical Trading Initiative - initiative for better working conditions.