Money
Mac £15
Ciaran £10
Chan £6
Alex £8
Will £3
Toby £12
David - £12
Logan £10
Evie £8
Stevie – paid
Luke morton - £6
Luke Murray - £10
Ben - £5
Connor £15
Jack £ 12
Charlie £14
Corey - £8
EXAM CONDITIONS – 30 minutes
In the space below develop a design for product for children aged between 3 and 6 based on one of the natural structures
images you can see here. You should show enough detail for somebody else to be able to make it.
The marks are for: (15 marks)
• How well your design reflects nature.
•Originality of ideas.
•Materials and construction techniques.
•How well you communicate your design.
Include 2 different views or a magnified view of a smaller part of your idea. Annotate to explain your idea in as much
detail as possible.
Which material is your
product made from?
How was it made?
Prohibited words
Wood plastic metal
Wood
Timber is the general name for wood materials. There are main types of timber, Hardwoods, Softwoods.
These are not descriptions of the woods, they just describe the type of tree it comes from.
Hardwoods – deciduous or broad-leafed trees
1)
Most hardwood trees are broadleaved and deciduous, meaning they shed their leaves annually.
2)
They tend to grow in warmer climates and are generally slower growing which tends to make them
harder.
3)
They can take around a hundred year to mature making them more expensive than softwoods.
Colours of common hardwoods:
-
Beech
creamy
-
reddish brown
Elm
Oak
-
-
light reddish
rich light brown
Softwoods – evergreen trees
1)
Most softwood trees are coniferous. They typically have thin needle like leaves and are evergreen.
2)
They grow in colder climates and are fast growing, mostly reaching maturity in around 30 years.
3)
This makes them easier to replace with new trees , so they are usually cheaper than hardwoods.
4)
They are normally softer and easier to machine than hardwoods.
Design & Technology
Mahogany
brown
There are several types of softwood commonly used, but they are all generally the same colour, pale yellow
with brown streaks.
Scots pine is fairly strong but knotty and is used for general building work.
Parana pine
is hard and usually
knot free making it harder and more expensive. It is usually used for
GCSE
Product
Design
interior joinery.
Plastics
Most plastics are produced by industry using water, oil (or coal or gas), are and salt. There are two families of
plastics – Thermoplastics and Thermosetting Plastics.
Thermoplastics – recyclable and bendy
1)
Thermoplastics are recyclable.
2)
They don’t resist heat very well and thus can be melted down and re-used.
3)
Thermoplastics are easily formed into shapes under moderate heat.
4)
A moulded shape can be reheated and softened without changing it’s properties.
5)
They can return to their original shape on reheating, this is known as plastic memory.
6) Some examples of thermoplastics are Acrylic, Polystyrene, polythene, polypropylene and ABS.
Thermosetting plastics – Non-recyclable and usually rigid
These types of plastic are non-recyclable.
2)
When formed they undergo a change in chemical properties, this creates strong links or cross chains in
their structure.
3)
This chemical change means that once set they are permanently formed and cannot be reshaped on
heating.
4)
Because they do not soften on heating they can be used in situations where temperatures reach in excess
of 400 degrees.
5)
Design & Technology
1)
Some examples of thermosetting plastics are, melamine-formaldehyde, polyester resin, epoxy resin
and urea formaldehyde.
Plastics come in a lot of different forms
1)
Plastics can be bought in many different forms – from powder, granules, pellets and liquids for processing
into finished products, through to films, sheets, rods, tubes and extruded mouldings.
2)
Plastics do not need any protective finishes due to high resistance to corrosion and decay.
3)
Plastics can be painted or polished for an alternative finish, but this is purely for aesthetic reasons.
GCSE Product Design
Metals
Some metals are pure and others are (alloys) mixtures of different metals. Both can be classified into two basic groups- Ferrous and
Non-Ferrous.
Metal
Properties
Uses
Ferrous metals contain Iron
Ferrous metals consist mostly of iron and
small quantities of other elements and
minerals. Ferrous metals are prone to
rusting if exposed to moisture and can be
picked up by a magnet. Both these
properties are due to the iron.
Mild Steel
High-Carbon Steel
Stainless Steel
Non-Ferrous metals don’t contain Iron
Metal
Aluminium
Non-Ferrous metals are metals that do not
contain Iron at all. These metals therefore
do not rust in the same way when exposed
to moisture and are not attracted to
magnets.
Brass
Copper
Quite strong and cheap but rusts easily
and can’t be hardened or tempered.
Car Bodies,
screws, nuts 7 bolts
Harder than mild steel and can be
hardened and tempered. Difficult to
work and rusts.
Drills, files, chisels
and saws
Hard and won’t rust like most ferrous
metals, is more expensive as a result
Medical equipment,
sinks, cutlery,
kitchen appliances
Properties
Uses
Lightweight and corrosion resistant.
Expensive and not nearly as strong as
steel.
Aeroplanes, cars,
ladders
Quite strong, corrosion resistant,
malleable, ductile and looks good.
Door furniture,
electrical parts
Relatively soft, malleable and ductile
and a very good conductor of electricity.
Wires & piping
Remember
Iron
Iron (Ferrite) is converted from its Ore by heating. The resulting impurities (Slag) are removed
from the furnace leaving a soft greyish metal once it has cooled. Iron is rarely used without
combining it with carbon, thus giving it a greater strength. The result in this combination is steel.
Steel
A mixture of Iron and Carbon. The amount of Carbon present in the material determines the
materials initial strength. Alloying with other Metals enables specific properties to be enhanced.
I.e. Toughness and resistance to corrosion.
Carbon
Carbon is an element found in a range of materials. Organic Materials such as Coal and diamond
are made up purely of Carbon. The amount of carbon in Steel has the effect of increasing strength
and hardness, however added carbon can also cause brittleness to the material.
Iron & Carbon
Iron is generally soft and ductile, which does not make it very commercially useful. When Carbon is
added (a very hard, brittle element) and mixed with Iron the characteristics (properties) change and
therefore the resulting material can be used for specific properties.
The increased amount of Carbon will result in;
The material becomes harder
Toughness reduces, can become brittle
High Carbon Steel & Medium Carbon Steel can be heat treated to increase strength & Hardness.
Complete the tables on these slides.
An example is given for you.
Finishing techniques you could use are:
Self finish applied in mould
Hand painted
Transfer image applied
Embossed
Stain resistance coating applied
Oiled
Screen printed
Product
Material
Aluminium
Wax coating applied
Glazed Varnish dip coated
Zinc plated
Piped spray painted
Browned using high temperature
Source of material
Bauxite Ore
Renewable or nonrenewable
Non-Renewable
Finish applied
Screen printed
Complete the tables on these slides.
An example is given for you.
Finishing techniques you could use are:
Self finish applied in mould
Hand painted
Transfer image applied
Embossed
Stain resistance coating applied
Oiled
Screen printed
Product
Material
Wax coating applied
Glazed
Zinc plated
Piped
Browned using high temperature
Source of material
Renewable or nonrenewable
Finish applied
Complete the tables on these slides.
An example is given for you.
Finishing techniques you could use are:
Self finish applied in mould
Hand painted
Transfer image applied
Embossed
Stain resistance coating applied
Oiled
Screen printed
Product
Material
Wax coating applied
Glazed etched
Zinc plated
Piped Offset lithography
Browned using high temperature
Source of material
Renewable or nonrenewable
Finish applied
Complete the tables on these slides.
An example is given for you.
Finishing techniques you could use are:
Self finish applied in mould
Hand painted
Transfer image applied
Embossed
Stain resistance coating applied
Oiled
Screen printed
Product
Material
Wax coating applied
Glazed etched
Zinc plated
Piped Offset lithography
Browned using high temperature
Source of material
Renewable or nonrenewable
Finish applied
Task 1. 25 minutes
• From Core Programs Open CD ROM player and focus on wood joints.
• Make sketches and notes of the following joints:
• Rebate
• Lap
•Dowell
• Mitre
Name a product
where you would
use each of these
wood joints.
• Finger
•Through and stopped Mortise and tenon
• Corner Bridle
Task 2. 25 minutes
• From Core Programs Open CD ROM player and focus on plastics.
• Make sketches and notes of the following :
• Injection moulding
• Blow moulding
•Vacuum forming
• Rotational moulding
• Extrusion
Name a product
that would be
manufactured
using each of
these processes.
• Injection moulding
•PET ,PP, HIPS
•Hopper, granules
•Heated screw thread
•Nozzle
•2 part mould
•Cool
•Ejector pins
Polypropylene
• flexible
• Thermoplastic so can be moulded
• hygienic
• Available in a range of colours.
• It can be recycled
1 2 3 4
5 6 7 8
9 10 11 12
Question
Are the following materials renewable
or non renewable?
Mild steel, polyester, porcelain
Answer
Non – renewable. They all come from finite
sources
return
Question
What is the name given to
plastic materials which soften
with heat?
Answer
Thermoplastics
return
Question
Name the two materials
this famous chair is made
from
Answer
Polypropylene seat, mild steel legs
(which have been powder coated)
return
Question
What do the following materials have in
common?
Cartridge paper, MDF
Answer
All made from wood pulp
return
Question
Which of these materials is the
odd one out and why?
Brass, pewter, copper.
Answer
Copper, the other two are alloys
return
Question
Why is mahogany regarded as
environmentally unfriendly?
Answer
Taken from rain forests which are destroyed
in the process.
return
Question
What do the following materials have in
common?
Plywood, MDF, blockboard, chipboard
Answer
All manufactured timber boards
return
Question
Where do renewable
materials come from?
Answer
Plants or animals (can be grown)
return
Question
Where do non-renewable
materials come from?
Answer
They are dug out of the earth – oil,
ores, clays etc. or come from
resources which are being destroyed
such as rainforests.
return
Question
Why are standard components
often used on products?
Answer
Cheaper to purchase from specialist
manufacturer, easier to maintain
return
Question
Name three common
hardwoods
Answer
Ash, Beech, Birch, Mahogany, Oak, Teak,
Jelutong…….
return
Question
Name three natural fibres
Answer
Wool, cotton, silk, linen, mohair,
cashmere….
return