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DT (Electronics, Mechanics and Manufacturing, Materials, Identifying…
DT
Electronics, Mechanics and Manufacturing
Injection moulding
Blow moulding
Compression moulding
Extrusion moulding
Rotational moulding
Vacuum Forming Process
Electronics
System
Input
The Stimulus
Button
Switch
LDR
Thermistor
Sensor
Process
Embedding
Customising a micro-controller to be permanently placed in a product
Programmable micro-controller
Output
The Result
Light
Screen
Piezo (multiple tones)
Buzzer (one tone)
LED
Advantages
Lower energy consumption
Longer lifetime
Come in a huge variety
Anode - the positive connection on a component
Cathode - the negative connection on a component
Polarised - A component that must be connected the correct way round in a circuit
Speaker
Motor
Sensor
Digital
Latching Switches
A switch that stays on/off after the button is released
Toggle switch
Slide switch
Rocker switch
Key switch
Time delay switch
Time switch
Tilt switch
Reed switch
Float switch
Opto switch
Momentary Switches
A switch that stays on only when pressed
Tactile switch
Rotary switch
Micro switch
Push switch
A sensor that detects only 2 states: yes/no
Analogue
LDR
A type of resistor whose resistance varies with change in light level
High resistance when dark
Thermistor
A type of resistor whose resistance varies with temperature
High resistance when cold
IR Sensors
Passive IR
sensors can detect a
moving warm object
IR Distance
sensors that measure the
distance
to a nearby object
IR Receivers
pick up data signals from an
IR transmitter
Physical Quantity
Something that can be measured
Temperature
Mechanics
Mechanisms
A series of parts that work together to control forces and motion
Used to change
Direction of movement
Type of movement
Speed of movement
Force or torque
Types of movement
Rotational/Rotary
Gears
Spur gears
Pinion
Simple Gear train
Gear ratio
Complex Gear Train
Pulleys
Cam & Followers
Pear
Eccentric
Snail/Drop cam
Linear
Reciprocating
Oscillating
Linkages
Fixed joints through the use of pivots and sliders can alter the size of the force/distance moved, direction and type of movement
Parallel motion
Reverse parallel
Bell Crank
Bevel gears
Changes the direction of the drive shaft by 90*
Materials
Papers and Boards
200 grams per square metre
Anything less than this is classed as paper, anything more than this is classed as board.
Paper
Bleed-proof paper
Smooth
Thick to prevent ink from bleeding
Used for art or sketchbooks
Cartridge paper
Smooth
Generally white
Thin
Used for drawings and pencil or charcoal paintings
Grid paper
White
Printed grids of isometric lines/squares
Used for maths and technical drawings
Layout paper
Thin
Relatively transparent
Used for technical and architectural drawings
Tracing paper
Transparent
Used for copying and tracing
Quite thick and durable
Board
Corrugated card
3 Layers
Fluted middle layer to provide structural integrity
Used for packaging to protect from damage
Duplex board
Smooth matte side
High shine finish on one side
Used for food packaging that requires printing on one side
Foil-lined board
Card
Lined with aluminium foil to provide insulation
Used for food containers and milk cartons
Inkjet card
Gloss finish on one side
Matte finish on one side
Used for high quality photographs
Solid white board
Strong
High quality
Bleached card for printing
Used for boxes and storage
Timbers
Hardwoods
Come from
broad-leafed deciduous
trees that
lose their leaves
over winter
Oak
Maple
Beech
Birch
Softwoods
Come from
Conifers and evergreen
trees that
keep their needles
all year round
Pine
Fir
Cedar
Spruce
Manufactured boards
Sheets of timber made by
gluing wood fibres/wood layers together
MDF - Medium Density Fibreboard
Blockboard
Plywood
Metals & Alloys
How metals are converted from raw materials to finished products
Ferrous metals
Contain Iron, almost all are
magnetic
Carbon steel
Cast iron
Wrought iron
Non-ferrous metals
Do not contain Iron, they are
not magnetic
Aluminium
Copper
Tin
Alloys
Metals are mixed with other metal to
improve their physical properties
Brass
Stainless Steel
High-speed steel
Polymers
Thermoforming polymers
Polymers contain
no cross-linking
molecules
Not resistant to heat
Can be easily melted, moulded and re-formed
Recyclable
Acrylic
ABS - 3D Printing
HIPS - Plastic forming
HDPE - Water bottles
PVC - Window frames
Thermosetting polymers
Polymers undergo a chemical change when formed that makes them permanently rigid. They
have cross-linkage
They are resistant to heat and fire
They cannot be reformed
They are not recyclable
Epoxy resin
Melamine formaldehyde
Polyester resin
Urea formaldehyde - sockets
Specialisation: Polymers
Textiles
Fibres
Tiny hair-like structures that are spun (twisted) together to make yarns. These yarns are then woven together to create fabric.
Natural Fibres
Come from
biological
sources (plants and animals). They are renewable and biodegradable
Cotton
Soft
Warm
Clothes
Silk
Lightweight
Furnishings
Soft
Synthetic Fibres
Polymers manufactured from
chemical sources or fossil fuels
. Therefore, most are not sustainable or biodegradable
Polyester
Durable
Bedsheets
Clothes
Nylon
Non-absorbant
Sportswear
Blended and Mixed Fibres
Are made from spinning
two or more
fibres together to produce a yarn. Fabrics are blended to combine different fibres with
desirable properties
Polycotton
Durable
Bedsheets
Lightweight
Terrywool, Plywool
Elasticity
Blankets
Insulating
Fabrics
Woven fabrics
Made by interlocking two sets of yarn, 90* to each other. They tend to be very strong, so are used in clothes.
Non-woven fabrics
Made directly from fibres that are bonded by mechanical, chemical or thermal methods, so are used in disposable cloths.
Knitted fabrics
Made by interlocking loops of yarn together, so are used in clothes
Weft knit
Made by hand/machine using a yarn that
forms interlocking loops across the width of the fabric
Stretchy and warm
Can easily lose shape and unravel
Warp knit
Made by machine using yarn that forms
vertical interlocking loops
Less stretchy
Retains shape better and is less likely to unravel
Technical Textiles
Made specifically for their properties, not their aesthetic values
Nomex
Heat and flame resistant
Protective clothing for racing drivers, fire people, astronauts and oven gloves
Kevlar
Resistant to abrasion, damage to sharp and pointed objects
Stab and bullet resistant vests for police and armed officers
Car and motorcycle tyres
Coolmax
Wicks water away from body, improves breathability
Bedding, sportswear, uniforms, underwear
Fastskin
Mimics the skin of a shark, giving streamlining effect when underwater
Competitive sportswear and swimwear
New and improving materials
Modern Materials
Continually being developed through the invention of new or improved processes
Polymorph
Comes in the form of polymer granules
When heated to 60* in warm water, the granules melt and can be moulded into shape
Grips
Lenticular Plastic Sheet
Is smooth on one side, while the other side is made of small lenses
These lenses transform 2D images into a variety of visual illusions
3D Glasses
Flex ply
Is a form of plywood that is extremely flexible and can be easily bent into various shapes
Wiggle board, furniture
Teflon
Is mainly used as a non-stick coating on cookware, but is also used in paints, fabrics, carpets and clothing to repel
Non-stick pans
Precious metal clay
Is made from 99% silver or gold, and 1% clay.
Can be shaped at room temperature then heated in a kiln
Jewellery
Conductive polymers
Plastic products can conduct electricity
Gas sensors
Composite Materials
Produced by bonding different materials to produced new materials with improved properties. Composite materials are increasingly used in place of metals in machine tools
Glass reinforced plastic
Is polyester resin reinforced with glass fibre strands. Has all the properties of polymers, but is much stronger
Large structural items, like boats and car bodies
Kevlar
Similar to carbon fibre and has even stronger plastic woven into it
Even stronger and lighter than CF and is used for bulletproof vests
Smart Materials
Respond to difference in temperature or light and change in some way. Called smart because they sense conditions in their environment and respond
Shape memory alloy (SMA)
Remembers its original shape when deformed and returns to it when heated
Children's glasses
Shape memory polymers (SMP)
Can also be programmed to remember their original shape once heated
Stress balls
Thermochromics sheet
Printed with liquid crystal ink that changes colour above 27*C
Children's toys, jewellery, temperature indicators
Thermochromics pigments
Often used on novelty mugs that reveal a design when hot water is poured into the mug
Mug, mood rings
Photochromic material
React to light
Sunglasses that darken in bright sunlight use photochromic lenses
Self-healing materials
Have the ability to detect and repair damage done to them. Have embedded capsules that release adhesive when broken
Cutting mats
Identifying Requirements
Context
Who
Stakeholder
A person, group or organisation with an interest in a product/system (investment)
Primary User
The person or group who will use a product or system
Human Factors
The scientific discipline looking at the interaction between humans and elements of a product and/or system
Where
When
Why
How
The situation a design solution is intended for
Influences to product design
Social
Moral
Economic
Globalisation
Businesses and organisations operating globally and developing international influence
Sustainable Economic Growth
Development that aims to satisfy the economic needs of humans while sustaining natural resources (such as materials) and the environments for future generations
Cultural
Colours
Hand signals
Word meanings
Religious iconography
Symbols
Images of people
Usability in Prototypes
The impact of a solution on a user's lifestyle
The ease of use and inclusivity of design solutions
Ergonomic considerations and the use of anthropometric data in support
The importance of aesthetics
Production, marketing, materials & cost need to be considered; but the user's safety, comfort, characteristics and needs must be central to the design
How easy a product is to use, how clear and obvious its functions are
Inclusive design
Designing mainstream products for the widest possible audience without the need for special adaptation
Products should promote equal, confident and independent use for all groups and exclude as few as possible
Ergonomics
The study of how we use and interact with a product or system
These interactions include:
Objects
Work environments
A good fit means:
Comfort and improved efficiency
Ease of understanding
Anthropometrics
The study of the sizes of the human body
The measurements shown in tables of data
Finger lengths
Hand spans
Percentiles group the data
5th percentile (smallest 5%)
Aesthetics
Factors concerned with the appreciation of beauty
Sight, Hearing, Touch, Taste, Smell, Form, Texture, Scale, Colour, Symmetry
Beauty is
not
achieved through the addition of features that don't improve a product's function
Colour
Elicits an emotional response: positive & negative
Packaging needs to be
eye catching
and convey key information quickly
The colour wheel; colours next to each other are in harmony, colours opposite each other are complementary
Mathematics
Proportion
The relative size and scale of the various elements in a design
Symmetry
When elements are arranged in the same way on both sides of an axis or when rotated around a point
Asymmetry
The absence of symmetry of any kind
Golden ratio
A common mathematical ratio found in nature that can be used to create pleasing, natural-looking compositions in design. Also called the Golden Mean/Section, or the Fibonacci Sequence, or the Greek letter
Phi
It provides balance, harmony and order. Often seen in nature
Design Communication
Designers communicate their ideas by:
Using digital methods
CAM
CAD
Portfolio presentations
2D/3D technical drawings
Oblique
Exploded drawings
Isometric
Orthographic
Rendering
Perspective
Concept sketching
Sketching
Helps designers to develop ideas
Clear communication method
Physical models
Paper/card
Blue foam
Cardboard
Plastercine
Foamcore
Circuit/system diagrams
Control system
Inputs
Outputs
Use of labels/annotations
Manufacturing processes
Explanation of thought process
Dimensions
Digital annotations
Hand-drawn annotations
Sketching types
2D
A flat drawing that only shows 2 dimensions, x,y axis
Use?
To make manufacturing diagrams
3D
A drawing that shows 3 dimensions, x,y,z axis
Use?
To see multiple sides from one viewpoint
Modelling
The use of a variety of materials and computer animations to demonstrate a design
Use?
To present ideas to investor, stakeholder and primary uses.
To begin the initial testing process
Sketching / drawing styles
Oblique
A simple 3D sketch with one square face. Used by some designers but not as often as other graphical drawing techniques.
Examples
Isometric
A 3D techniques in which parallel lines at 30 degree angles are applied to the sides of a drawn object.
Examples
Crafting and ellipses
Ellipses are squashed circles, when drawing ellipses the curve touches the middle of each side of the rectangular shape.
Example
Orthographic
2D sketches that show different views (eg. plan, front, side and sectional views)
Example
Perspective
3D drawing that shows objects in proportions (used by architects / product designers)
Examples
Exploded drawings
These sketches are used to explain how the components of a product fit together and how they are assembled. This allows designers and engineers to spot possible construction issues.
Example
Sketch modelling
Quick model, often just parts of a design, made from easy to work and low cost materials such as cardboard or foam
Mathematical modelling
The representation of a real situation using mathematical concepts and language
Schematic diagrams
They are used to show the layout in electrical systems - circuit diagrams and mechanical systems.
Research and finding information
Designers use different methods to find information to avoid design fixation
First hand information
Questionaires
Focus groups
Organised discussion run by a moderator where they are asked about products, services and brands ect.
Observations
Market research
Looking at how others have solved the issue
Magazines/reference books
Anthropometric data
Material proporties
Biomimicry
Uses nature as inspiration for problem solving
Creating a user-centered design
Definition : A strategy with the aim of making products and systems usable, a particular focus on the interface and interaction.
Methods
Focus groups
Usability testing
Data is gathered as people try out a product
Participatory design
People are actively involved in design and decision process at every stage
Interviews
Usually 1-2-1
Questionaires
System thinking
Understanding of a product or component as a part of a larger system or product. Ensuring all levels are considered ensures the product is given the required attention to detail.
Designers need to consider all elements not just physical product
Packaging
Use of product
Updates and maintainence
Disposal
Collaboration
Working with others for mutual benefit
Learning from Existing Products
When exploring existing product you need to understand the choices of designers and manufacturers make to make a successful product
Function
Materials/components
How it's constructed
Ergonomics
Aesthetics
Environmental impact
Lifecyle/recyclability
Influence for the design
In product analysis understanding and analysing particular materials, components and process use can:
Help you understand
why
they have been chosen
Know which properties make it suitable
Establish more suitable materials or different processes you could use to develop an improved product
What to look for:
Standard components:
Clips
Fasteners
Bindings
Hinges
Brackets
Screws
Rivets
Caps
Bolts
Structural integrity:
Construction
Assembly
Reinforcement
Fabrication
Triangulation
Webbing
Beams
Shell
Weave
Folds
Scale of production:
Batch production
Mass production
Just-in-time
One-off
Bespoke
Design periods
Organic design (1930 - present)
Streamlining (1930 - 1950)
Art Deco (1925 - 1939)
Scandinavian (1935 - present)
Bauhaus (1919 - 1935)
Pop art (1960s)
De Stijl (1914 - 1931)
Minimalist (1960s - present)
Art nouveau (1890 - 1905)
Memphis (1980 - 1990)
Victorian (1830s - 1890s)
