Product Design Revision:
Plastics
There are 3 types of plastic:
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Thermoplastics- can be reheated and reshaped as they have loose monomer chains, can be recycled
and coloured pigments can be added to make it more aesthetically pleasing.
Thermosets – undergo a chemical change so permanently rigid, cannot be reheated or reshaped as it
forms rigid cross links, e.g. spoons
Elastomers – can be distorted under pressure but will return to their original shape
The properties of plast6ics are:
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Electrical and thermal insulators
Good strength to weight ratio
Good atmospheric and chemical corrosion resistance
They are lightweight
Fairly low melting points (thermoplastics)
They can be self-coloured, opaque, translucent or transparent
Common
name
Working name
ABS
PC
polycarbonate
PP 5
Polypropylene
HIPS
High impact
polystyrene
acrylic
PMMA 7
HDPE 2
LDPE 4
PET 1
High density
polyethylene
Low density
polyethylene
Polyethylene
terephthalate
PS 6
polystyrene
PVC 3
Polyvinyl
chloride
Epoxy
resins
Polyester
resin
Melamine
formaldehy
de
Characteristics
Common uses
Manufacturing
process
Thermoplastics
High impact strength, giving good
Kitchen products, mobile phone
Injection
toughness and strength, scratchcases, safety helmets, toys, car parts moulded
resistant, li9ghtweight durable
Good chemical resistance, expensive, Protective shields, safety hats and
Injection
very tough, high melting point
glasses, hairdryer bodies, telephones moulded
Lightweight, food safe, good impact
Food containers, medical
Injection
and chemical resistance
equipment, string and rope
moulded
Good impact resistance, good
Toys and refrigerator linings
Vacuumed
strength and stiffness, lightweight
formed
Food safe, tough, hard, durable,
Light units, illuminated signs, lenses
Hand/CAM cut
easily machined
for car lights
Good stiffness, good chemical
Crates, bottles, buckets, bowls
Injection
resistance
moulded
Lightweight, low stiffness and
Detergents bottles, toys, carrier bags Blow moulded
rigidity, good chemical resistance
Moderate chemical
Clothing, blow moulded bottles for beer and
Blow moulded
resistance
soft drinks, electrical sockets, video tapes,
insulation tapes
Lightweight, rigid, colourless, low
Packaging, disposable cups, sound
Vacuum formed
impact strength
and heat insulation, yoghurt pots
Good chemical and weathering
Hose pipes, cable insulation, drain
extruded
resistance, hard, rigid, tough,
pipes packaging
lightweight, can be coloured
thermosets
Good chemical and wear resistance
. Adhesive for bonding wood to metal, plastic to
metal..
Good chemical and wear resistance
Used for casting (pouring into a mould) mixed with
glass fibres to make fibreglass
Rigid, good strength and hardness,
Plastic coating for Tableware,
scratch-resistance, can be coloured.
decorative laminates for work
surfaces.
Elastomers: common ones are thermoplastic elastomer (TPE), thermoplastic rubber (TPR) and liquid silicon
rubber (LSR). Used for car bumpers and trims, and product grips (over mouldings)
Joining plastics:
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Plastic weld – a multipurpose adhesive that joins most plastics (not foamed plastic)
Tensol 12 – is good for acrylic, it is quick and easy to use, if spilt marks the work, not very strong
Rivets, nuts, bolts and machine screws can be used to join plastic
Additives:
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Fillers – used to reduce bulk of plastic so cheaper e.g. sawdust (increases strength and hardness)
Flame retardants – used to reduce risk of combustion, releases agents that stifle it.
Ant-static agents – reduce effect of static charges that could build up
Plasticiser – added to improve the flow properties of plastics when being moulded by reducing
softening temperature and brittleness.
Stabilisers – used to reduce the effect of ultraviolet light by making plastic more resistant to being
broken down by sunlight.
Biodegradable plastics – plastics do not break down easily normally and a lot is thrown away, biodegradable
plastics degrade in a biologically rich environment. Used for shopping bags, food trays, bottles, gardening,
medical and sanitary products. They can be produced from wheat, corn and potatoes. PHAs and PHBs are
made from bacteria and it is similar to polypropylene and used in packaging and medicine, it breaks down
completely when exposed to micro-organisms.
Oxo-degradable polymers – additive that causes a short degradation time (less than 5 years). Effects of heat,
oxygen, moisture break it down into a fine powder. Photo-degradable polymers breakdown when exposed to
UV light. Water soluble polymers are used for liquid detergent pouches and laundry bags in hospitals and
melts in contact with warm water, and used for slow release medicine. The cost of producing biodegradable
polymers remains more expensive than conventional polymers, also they cannot be recycled and products
made of this have a shelf life of several years.
Injection moulding
Stage 1 Granulated or powdered thermoplastic plastic is fed from a hopper into the Injection Moulding machine.
Stage 2 The Injection Moulding machine consists of a hollow steel barrel, containing a rotating screw
(Archemidial Screw). The screw carries the plastic along the barrel to the mould.
Heaters surround the barrel melt the plastic as it travels along the barrel.
Stage 3T he screw is forced back as the melted plastic collects at the end of the barrel.
Once enough plastic has collected a hydraulic ram pushes the screw forward injecting the plastic through
a sprue into a mould cavity.
The mould is warmed before injecting and the plastic is injected quickly to prevent it from hardening before the
mould is full.
Stage 4 Pressure is maintained for a short time (dwell time) to prevent the material creeping back
during setting (hardening). This prevents shrinkage and hollows, therefore giving a better quality product.
The moulding is left to cool before removing (ejected) from the mould. The moulding takes on the shape of the
mould cavity.
The image below shows an an Injection Moulding machine.
Advantages:
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produces very complex 3D shapes
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Large numbers can be produced with consistent
quality
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Metal inerts can be included
Disadvantages:
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Initial set up costs are high
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Moulds are expensive
Blow moulding
A tube of softened plastic called a parison is extruded into a mould.
Blow moulding
1. A tube of heated and softened polymer, a parison, is extruded vertically downwards
2. The mould halves close, trapping the upper end of the partisan, sealing it.
3. Hot air is blown into the parison, forcing it out and to follow the shape of the mould
4. The mould cools the polymer allowing it to be released
5. The mould halves are opened and the bottle is released
Blow moulding is used to shape plastics, mainly for making bottles, plastic buckets and similar shapes.
Rotational Mouling
1) Mould halves loaded with thermoplastic powder and clamped together
2) The moulds are rotated whilst heated until it melts ensuring it covers all the mould
3) The mould is then cooled
4) The mould halves are separated and the product removed
Vacuum forming
This process uses a wooden mould or form. A sheet of thermoplastic is heated, then shaped by creating
a vacuum underneath it. Air pressure then forces the plastic over the
mould.
1.
Plastic placed over mould.
2.
Plastic heated to softening point
3.
Air in mould removed to create vacuum
Vacuum forming is used to for food and confectionary packaging, trays, shop fittings and baths.
Advantages: low cost, good for smooth shapes with additional detail
Disadvantages: deep moulds result in thinning of wall thickness, only simple designs, trimming needed.
Bending
Thermoplastics cannot be bent when cold. They are bent
using a strip heater or line bender which will heat the plastic
in a straight line, so it can be bent by hand.
Press or compression moulding
A mould is made in two halves. Sheet plastic is placed between the
two halves, which are then heated and pressure applied, enabling
the plastics to assume the new shape.
Press moulding is used to make electrical fittings, handles, and
many other products. It can only be used with thermosetting plastics.
Extrusion
Extrusion moulding is used to produce long, but fairly thin products such as pipes or curtain tracks. Both plastics
and metal can be extruded. The material is forced through a die, which contains a hole which is the same shape as
the required product.
Plastics degrade- Unless stabilized; almost all polymers (in particular thermoplastics) will deteriorate in
appearance. This seems to be mainly due to the combined effects of oxygen and ultraviolet light. Most polymers
absorb UV light causing the chemical bonds in the in the molecular chains to break, thus shortening them. To
counteract this process, a stabilising substance that will shield the material from UV radiation is added during
manufacture which makes it opaque. There is an extra cost to this application.
Finishes – plastics are generally self-finishing, meaning that once moulded into shape they require no further
work. Coloured pigments can be added when the plastic is made, before it is moulded. Screen printing is used on
vacuum forming.
Composite Materials: a mixture of two or more materials
Fibre-reinforced composites (GRP)
 A material made of resins and fibres
 They have a good strength to weight ratio (they are light in weight, with low density, and are strong for
their weight).
 They are resistant to corrosion.
 They have a good fatigue resistance.
 They possess a low thermal expansion.
 e.g. reinforced concrete where reinforcing rods (fibres) have been added
Particle-based composites (MDF)
 consists solely of particles of two or more different materials, e.g. cements and concrete
 They have a high strength in compression, as in the case of concretes, but less so in tension.
 They have good stability.
 They have a uniform structure ensuring consistent strength.
 They are generally free from surface defects.
Sheet-based composites (laminated boards)
 They have increased stability against warping.
 They have equal strength in all directions unlike natural timbers.
 E.g. man-made boards
material
Image
Common uses
Plywood
Backs of furniture e.g. cabinets, bottom of drawers,
panelling – can be flexible for producing curved shapes.
It is very strong due to the grain of each ply is positioned
at ninety degrees to each other. The plies are glued
together with synthetic resin. Plywood is less likely to
warp or split, due to this construction.
Block board
Generally used for table tops and furniture carcasses
Stirling board
Flooring for sheds and workshops, also for roofing and
shuttering for concrete
Chipboard
Knockdown furniture, kitchen cupboards and work tops,
usually veneered or laminated for furniture, also used for
flooring
MDF
Furniture sides acting as a base for veneers, pattern
making for casting
Hardboard
Backs of cupboards and drawer bottoms of kitchen units,
can be supplied pre-coated
Advantages of man-made board:
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Larger areas can be covered with one sheet as can be made on a larger scale than timber
The cost is reduced
They are stable, meaning they will not warp or twist like natural timber due to changes in
temperature, and free of defects (knots, splits)
They can be covered in a veneer or more expensive material to improve their aesthetic qualities,
chipboard is normally covered with a thermosetting plastic to give the impression of a higher quality.
More environmentally friendly as more sustainable as made of softwoods.
Joining man-made boards: Knock-Down fittings= designed for flat-pack or self-assembly furniture, which
don’t take ordinary wood screws as they are made from chipboard normally.
Glass fibre:
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This glass reinforced plastic – glass is spun to produce a fibre that is then coated to aid bonding to the
resin, it comes in a range of thicknesses
A mould is required, which can be made of woods, metals and polymers
“Laying up” is the process and inserts can be added
Can be used to manufacture vehicle bodies, sports equipment, canoes, boat hulls.
1) coat mould with releasing agent
2) apply gel-coat with brush, with thickness of 1mm
3) Cut glass fibre mat. Add colour and hardener to gel-coat
4) coat with catalysed resin then lay the first lamination of fibre glass, get the air out with a stiff brush, repeat
with other layers.
5) leave to dry an trim edges with a sharp knife
6) wait 3 hours to take out of mould then after 24 hours it reaches full hardness.
Carbon fibre matting:
 The long chains of carbon atoms needed are produced by heating up polyarcylonitrile filaments to
very high temperatures which evaporates other elements.
 Was very expensive but costs are coming down
 Carbon fibre is available in the form of a woven matt, which is cut to shape
 The material is placed into a mould half , where is it impregnated with resin and forced into the shape
of the mould.
 The mould halves are fixed together and placed into an oven on a high temperature for up to 8 hours.
Kevlar:
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Kevlar is long chain nylon like molecules held together by hydrogen bonds
Used for body protection, e.g. bullet proof vests as it is lightweight, comfortable and flexible
Used for sports equipment, e.g. skis, helmets and rackets as it is lightweight and strong.
Has high strength to weight ratio, low electrical conductivity, high chemical resistance, high
toughness, high cut-resistance, flame resistant and self-extinguishing.
Concrete:
 Can be moulded into complex shapes, it has properties similar to stone, it can be cast on site and is
good in compression
 However is it poor in tension, so it can be reinforced with steel rods to withstand heavier loads.
Metals:
Ferrous - contain iron, will corrode unless protected, attracted by a magnet.
Non-ferrous - don’t contain iron, aluminium, copper, tin and lead are all non-ferrous.
Pure metals – metals in their basic form
Alloys - A mixture of two or more metals, Brass is an alloy of 65% copper and 35% zinc, High tensile steel is an
alloy of low carbon steel and nickel, Stainless steel is an alloy of steel, chromium, nickel and magnesium. Alloys
can change the melting point, increase strength and hardness enhances resistant to corrosion and oxidation.
Aluminium
Lightweight, easy to machine, does not corrode easily, excellent conductor of electricity,
strong, used for kitchenware, overhead power cables
Mild steel
Strong. Can be welded, rusts unless protected, used for nuts, bolts, washers, car bodies,
panels for cookers.
Copper
Malleable, excellent electrical conductor, ductile (drawn knot wire), used for electrical
contacts, domestic pipe work for central heating and water, electrical cable, jewellery.
Pewter
Low melting point, can be cast into detailed shapes.
Inert: does not react to liquids or oxygen so does not corrode.
Stock forms of metals are: sheet, tube, bar.
Sand Casting:
1- A pattern is made out of
wood or plastic, can be
complex shapes.
2- Each half of the pattern is
placed on a baseboard, and a
mould half box placed over it.
3- Green sand is ‘tamped’
around the pattern forcing
itinto contact, this is followed
by the backing sand.
4- The pattern id removed form
the mould half and the runner
and riser gates are then cut
into the top half of the mould
5- The mould halves are fitted
together with locating pins
6- The molten metal is poured into the running gate, the riser is used to see when it is full
7- Once the metal has solidified, the mould is broken open, leaving the product with the rise and runner
gates still attached which need to be removed by a saw etc.
The advantages are:
 Complex 3D shapes can be made
 Cores can be used to produce hollow sections
 Automated processes are suitable for longer runs
Disadvantages:
 Due to poor surface finish, some machining is necessary
 Its not as accurate as die or investment casting
Die casting - is similar to sand casting, except the mould is made from alloy steel, gas rings arounf the outside
of the die (mould) keep it heated and fluxes are used to prevent oxidation of the metal. Moulds can aslo be
made out of foam cut on a laser cutter.
Joining metals:
 Bolts, nuts and washers used where a joint needs to be taken apart
 Pop rivets – enable you to complete the joint while only having access to one side of the work, they are
usually used for joining thin sheets together
 Soldering - for copper, brass and aluminium
 Brazing – works by running a filler rod over a hot metal which melts it, used on copper and low-carbon
steel.
 Oxy-acetylene welding – for low carbon steel, hotter flame than brazing, uses oxygen and acetylene.
 Electric arc welding – used on low carbon steel and stainless steel, strong ultraviolet light emitted need
mask, uses a current.
 MIG welding: metal inert gas, used to join thin sheet material use gas jet around filler wire to prevent
oxidation of material, different materials = different gas e.g. argon for aluminium
 Spot welding: uses electric current as heat source
 Self-tapping screws= cut a thread in thin steel as they are inserted
Metals corrode
o Ferrous metals- contain iron so it will corrode, they are magnetic, e.g. steel, iron
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Non-ferrous metals – doesn’t contain iron, wont corrode, are not magnetic
Alloy – a mixture of two or more metals e.g. brass, stainless steel
Finishes – paint, dip in plastic, dip in zinc
Finishes – a surface coat applied to a material to protect and enhance its aesthetic properties.
 Galvanising – is the process of plating mild steel with zinc to prevent rusting, e.g. steel fences.
 Plastic dip coating – involves dipping a heated metal into thermoplastic powder, which melts to
provide an attractive coating, e.g. grips for hand tools
 Oil-based paint – provides a waterproof seal for ferrous metals an also an attractive finish, e.g. car
bodywork
 Anodizing – involves staining the oxide layer of aluminium with a pigment to introduce colour and
reduce corrosion, makes urface more durable so resistant to scratches e.g. mountain bike parts
Woods:
Hard woods: grows slowly, over many decades (50-60 years). They are close grained, strong and relatively
expensive used in high quality applications and for its aesthetic qualities. Examples are ash, oak, mahogany,
teak, birch. They last a long time, they are strong so they will withstand forces, durable, more value for money.
Soft woods: grows quickly (10-20 years) it is widely available and used in many applications including building
(timber frames), cheaper furniture and paper making. Examples are pine, Douglas fir and spruce.
Stock forms of wood: sheet, dowel, veneer
Permanent joints for wood:
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Mortise and tenon –
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Finger joint -
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Dovetail joint -
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Dowel joint -
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Mitre joint These joints are made stronger with nails and glue.
Woods decay
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Wet rot - where timber endures alternating wetness and dryness and begins to decompose
.Moisture is absorbed into the timber where it will partially dry out, followed by more moisture
absorption. This results in the resins and fibres breaking down. A protective barrier must be
applied to prevent this happening.
Dry rot - is a fungus that spreads its strands very quickly through woods, e.g. in a building. It is
called ‘dry rot’ because of the way it converts timber into a dry, soft, powdery state. The fungus
thrives in damp and unventilated conditions. Good ventilation is essential to prevent dry rot from
spreading in the first place.
Insect attack -The furniture beetle (woodworm) can be responsible for attacking woods in
floorboards, furniture and roof beams. If caught early, it can be eradicated by chemical spraying.
Shrinkage of woods occurs as it is dried out and loses moisture. Warping, bowing, twisting and cupping are
deformations due to uneven shrinkage.
Seasoning is the controlled drying of timber to increase its strength and stability, reduce moisture content
reduces the risk of the timber causing corrosion to the surrounding metal work. And it makes the timber less
prone to rot and decay.
Veneers: is a thin layer of wood that has been shaved off the trunk of a tree, usually hard woods because they
are more decorative and durable surface to inferior quality woods e.g. a veneer of yew could be applied to
chipboard
Laminates: made of up layers
 Melamine layer (touches floor)7
 MDF supporting material
 Printed layer or veneer, aesthetically pleasing
 Hard wearing thermosetting polymer
Finishes - a surface coat applied to a material to protect and enhance its aesthetic properties.
 Staining – involves applying a water-based pigment (colour) to improve the look of the wood.
 Polyurethane varnish – a tough, clear coating that seals the wood, but allows the grain to be seen,
e.g. used for outdoor furniture.
 Oil-based paint – provides a waterproof seal for exterior woodwork, e.g. external doors, window
frames.
Glass:
Blowing: used to manufacture hollow products such as bottles, mouth blowing is expensive glassware but
everyday products use an automated process is used where a ‘gob’ of glass is formed by a cycle of pressing
and blowing into a mould
Slumping: glass is heated until it becomes soft, allowing it to take the shape of a mould, e.g. windscreens
Toughened glass: heated to 400*C then rapidly cooled, for vehicle windows and glass doors.
Self-cleaning glass: a special coating is applied to the surface which is invisible, it prevents droplets settling on
the surface by forcing the water to spread out, it interacts with organic light to break down organic dirt.
Advantages:
 More rigid than polymers
 Ore scratch resistant than most polymers
 More transparent
 Is not effected by heat
 Better sense of quality
Disadvantages:
 Glass is heavy
 High melting point
 More easily broken
Ceramics:
 Ability to withstand high temperatures without distortion
 Strength and rigidity at high temperatures
 Hardness and resistant to wear
Paper:
Stock forms – A2, A3, A4, A5
Gms thickness –
Bleed proof – like cartridge paper but has a protective layer applied
to the back to prevent marker ink transferring to the paper behind
Off set lithography printing;
 Most versatile and economic type of printing
 Uses four colours – cyan, magenta, yellow, black (CMYK)
this is four press printing a fifth could be varnish.
1 - Printing material is fed into the machine as a sheet. Cane produce 1000-12000per hour
2 – Printing plates are produced from aluminium, the image being etched o to the pate using lasers.
3 – The plate cylinder is wetted with a water roller, while the grease-based inks will only go into the regions
required. The plate cylinder rotates onto a blanket roller, which them becomes coated with the ink, which in
turn transfers it onto the paper.
blankete
yjfewg;w
Recycled unbleached card:
 Made from paper and pulp so can be moulded to shape
 Doesn’t need to be aesthetically pleasing
 Sustainable, made from softwoods which grow quickly
 Biodegradable – degrades safely so can be used for packaging which is thrown away.
Smart materials:
Thermochromic pigments: colour pigments that change colour in response to heat, normally combined with
polymers. Used for baby feeding products, kettles and hi-tech jewellery. Thermo chromic sheets are used for
thermal warning patches, battery condition indicators and jewellery.
Photochromic pigments: used for sunglasses, and sun-blocking products
Shape memory alloys: heat treatments give the metal a memory, when stress and strains are placed onto hem
they will bend then return to their original shape. Reacts to body temperature in braces to return to original
shape, non-toxic, inert
Liquid crystal display: used for displays on calculators, mobiles, laptops, computers etc. They are carbon based
compounds which when aligned in their natural form will allow light to pass through, however when a small
voltage is applied the crystals change direction, blocking light.
Polymorph: a thermoplastic that has a low melting point so it useful in prototyping, it softens at 60*C making
it possible to fuse grains together and can be manipulated to create the desired shape, can be reheated in hot
water. Similar outcome to injection moulding, can be painted, an alternative is modelling clay
Flexible MDF: grooves are cut into the material allowing it to bend slightly, meaning curved shapes can be
created. Can come in large sizes so large curved wood furniture can be created, stable, no defects.
Joining Processes:
Permanent= adhesives, pop riveting, soldering
 Temporary= nut and bolt, wood screws, self-tapping screws
 Standard components= already made, buy them, easy to use
 Adhesives – invisible, doesn’t damage or change shape of components
 Wood to wood – PVA
 Paper and cards – hot glue sticks
 Acrylics – Tensol (acrylic cement)
 Laminate to chipboard - contact adhesives (wood to plastic)
 MDF – PVA (wood to wood)
 Nylon to Aluminium – epoxy resin (plastic to metal)
 Fabrics – animal glue
Properties:
 Strength – the ability of a material to withstand force without breaking or permanently bending.
 Elasticity – the ability of a material to bend and flex when subjected to a force and then return to its
original shape when the force is removed, bridges and buildings require a degree or elasticity.
 Hardness – the ability to resist abrasive wear, indentation and deformation. An important property
for cutting surfaces such as drill bits and saw blades.
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Toughness – the ability to withstand sudden stress in the form of shocks or blows without fracturing
and to resist cracking when subject to bending forces.
Brittleness – the opposite of toughness. A brittle material will not withstand sudden forces or blows,
glass is a brittle material.
Durability – the ability to withstand wear, tear and deterioration over time. Durability refers to both
the mechanical properties and the appearance of the material. The term used to describe weathering
and chemical attack of a surface, particularly metals in corrosion. Plastic materials degrade, rather
than corrode, but generally take much longer to do so.
Stability – the ability to resist changes in shape or size over time. Wood is particularly unstable and
tends to warp and twist in changes in humidity. Metals and some plastics tend to gradually deform
when subjected to stress over long periods.
Compressive forces – e.g. tennis racket, how it flexes then springs back again, it is compressed then
pushes the object away.
Tensile force – when there is a force acting on both ends of a material, pulling it apart e.g. tow-rope
between cars when one is getting pulled.
Sheer force – e.g. scissors when force of something cuts through a material, the weight of something
pulling it down.
Testing properties:
Hardness – a file can be run over the material, if it cuts the it is softer than the file, if it does not then is it
harder than the file. It can also be tested by a dot punch which is used to create an indent in the material, can
use to compare hardness if effort used to create dot is the same for all materials.
Ductility and malleability – place a piece of the material in a vice then attempt to create a 90* bend, if
material shows cracking on the outside then not very ductile, if crack shows on the inside then not very
malleable.
Tensile strength – the amount of energy required to bend material, place same size of the materials in a vice
and apply same load to them, the one bent the least is the most tensile.
Toughness – materials ability to absorb shock, clamp materials in a vice then striking them with a hammer, if
brakes then brittle, if doesn’t change shape then tough.
Design, environment and ergonomics:
The 3 R’s:
 Reduce – the amount of materials and energy used in manufacturing and the amount it will use in its
life.
 Recycle – aim to ensure products can be recycled by enabling the parts to be separated, cleaned and
used again
 Reuse – aim to ensure that materials and components that have already been used can be used again
in a new product, e.g. reusable ink cartridges, filters in coffee machines and vacuum cleaners etc.
Design improvements strategies:
 Use low-impact materials - use recycled polymers and metals, do not use aluminium (uses energy in
production) use woods with the forest stewardship council logo on.
 Reduction of materials used – make product smaller
 Reduce impact of distribution – use recycled materials in packaging, make packaging smaller
 Reduce energy consumption in use  Optimisation of product life time – use classic design that will not go out of date, make product
reapirable
 Optimisation of end of life – make parts easy to disassemble
Ergonomics= The study of the interaction between the human body, products and the environment and use
this in equipment design intended to maximize productivity by reducing operator fatigue and discomfort.
Influences colour, lighting, sound, comfort of a product, system or a environment. When evaluating think of
weight, children, symbols – easy to understand.
Anthropometrics= study of the dimensions of the human body, including arm and leg reach. Based on averages
delivered from measurements of large numbers of people. Essential to the design and development of
products which fit to the body, e.g. chairs and airline seats.
Consumer safety:
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The kite mark is the world’s premier symbol of trust, integrity and quality.
Manufacturers having this associated with their product or service will reassure
customers and specifies that they have satisfied the most rigorous of quality
processes.
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The forest stewardship council ensure that wood is sourced from sustainable, managed
forests.
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carried by products made from recycled material.
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substance harmful or irritant – (tensol, contact adhesive, epoxy resin)
Access fm:
A - Aesthetics (meaning appearance)
C - Cost (meaning a price range)
C - Customer (meaning the person who wants to buy it)
E - Environment (meaning where it is used and how eco-friendly it is)
S - Safety (meaning how safe it is)
S - Size (meaning how big it is)
F - Function (meaning what job it does)
M - Materials (meaning what materials would you need to make it)
CAD/CAM:
CAD= Computer aided design, drawing up using a computer, 2D drafting and 3D modelling, like prodesktop
 Quicker and more accurate than by hand
 Can be emailed, copied and modify without redrawing
 Expensive to set up
 Need to train staff
 Virus, power cut or software problems could stop work
CAM= Computer aided manufacture, machines are used to cut components, e.g. laser cutting, routing, vinyl
cutting are examples
 Quick and accurate
 Machines don’t get bored like humans
 Can break and are expensive
 Require skilled operators
Safety in workshop:
 Protective clothing: goggles, apron
 Extractor for toxic gases
 Visors for electric arc welding
 Labels containing warnings and what do in an emergency