OCR A-Level Product Design

what is six sigma?

- method to identify and reduce defects to a minimum possible level

-production is constantly assessed and improved

-means less wastage and more money is made.

what is scrum?

-long project is split up into short sprints

- constant feedback gave in meetings and progress constantly made, meaning morale is kept high

- meeting types: stand-up, sprint plan, review, retrospective

what is kanban?

- uses same ideology as scrum,. but not in sprints and done as continuous production flow.

- new tasks are given as old ones are completed, small wins but not in a sprint block

what are the seven areas covered by lean manufacturing?

- transport

- inventory

- motion

- waste

- over production

- over engineering

- defects

what is just-in-time manufacturing?

- lean manufacturing technique that only orders in parts and materials as they are needed in response to demands

- means no money is tied up in stock and less storage and staff are needed

- however can be bad if demands suddenly increase

what is kaizen?

-method of continuously improving a production system through employee feedback

- means employees are happy and become more efficient

what are the main stages of a product's lifecyle?

- introduction - introduced and market penetration achieved

- growth - advertising makes people more aware of the product and sales begin to increase

- maturity - sales begin to level off as more people have the product

- decline - market becomes saturated and sales begin to fall. product can be relaunched or withdrawn here.

how can demand be created for a product?

- idea of scarcity and FOMO

- promotional offers

- redesigning and rebranding of a product

- new advertising campaigns to new people

- endorsements and virality.

what are early adopters?

- people who are first to buy a new product

- they help spread the word about a new product to increase sale

- also more expensive to buy here, so more money can be made back by the company.

- eg beta testers and sending free products to influencers

what are venture capitalists?

- people who invest money into a product or company in return for a share of profits and company

- better than a loan as you get expertise and don't need collateral for it.

what is crowdfunding?

- when a project is funded by small donations from many people, who usually get a small reward in return

- eg Kickstarter, GoFundMe

what is inbound marketing?

- market research that is done to see if a gap in the market exists for a product to exist in.

what is outbound marketing?

- marketing done to raise awareness of a product and engage target market to actually buy a product

what are the 4P's of the marketing mix?

- price - depends on demands and costs and covered by 4 pricing Ps

- Product - must have a USP and fulfil the user wants and needs

- Place - must be suitable for how to user wants to buy the product

- Promotion - must engage target market and make the want to buy a product.

what are the main methods of advertising?

- TV - good for nationwide products and larger companies as it is very expensive

- Online - cheap and easy and can be targeting to specific people who are likely to buy the product

- Billboards/posters - can be locally targeted, but don't have as much exposure

what is market pull?

- when a consumer driven demand influences a designer to create a product to fulfil the demands

- means people will want to buy the product.

what is a technology push?

- when a new technology is implemented into a design that consumers didn't know about

- creates more functionality attracting new consumers

what are the advantages and disadvantages of fossil fuels?

- advantages: readily available, reliable, efficient at creating heat

- disadvantages: greenhouse and polluting gases, non renewable and we are quickly running out

what are the seven types of renewable energy?

- hydroelectric

- wind

- solar

- tidal barrage

- wave

- geothermal

- biomass

what are the advantages and disadvantages of renewable energy?

- advantages: low cost to run, no greenhouse emissions, biomass is easy to source

- disadvantages: high initial costs, unreliable, can spoil landscapes, habitat loss, lots of land needed

what is designing for disassembly?

- way of designing so products can be easily taken apart so parts can be recycled and reused more easily.

- eg, using fewer parts, using fewer fastenings, less finishes and adhesives.

what is a linear economy?

- when materials are extracted, product made and product is disposed of

- means parts are thrown away and put into landfill

- feeding into the depletion of resources

what is a circular economy?

- products are made using biological and technical nutrients which can be constantly reused during production, rather than ending up in landfill

- design also facilitates repair to extend a products lifespan

what is planned obsolescence?

- when products are specifically made by designers to have a shortened lifespan to products have to be replaced more quickly

- means more money can be made, but more products end in landfill

- can be either perceived or planned obsolescence.

what 3 main topics does product design cover?

- people

- planet

- profit

What are the five principles for sustainable design?

- cycle

- renewable

- safe

- efficient

- social

What stages of a product's life does a lifecycle assessment cover?

- raw material extraction

- transport to process

- product manufacturing

- distribution of product

- product usage

- end of life / disposal

What are the advantages of flat pack furniture?

- take up less space

- less packaging is needed

- made from recycled/off cut wood

What is a smart material?

Materials that change properties when exposed to an external stimulus and then return to original properties when input is removed

What the the main examples of smart material?

- polymorph

- ferrofluid

- photochromic pigment

- thermochromic pigment

- shape memory alloys

- ferrofluid

What is a modern material?

Material made using new technological advancements to perform specific functions and have improved properties

What is graphene?

- smart material

- super thin, strong, conductive, transparent, lightweight

- uses in nano technology and wearables

What is a technical textile?

Textiles developed specifically for functional performance in specific areas, not designed for aesthetics

What the four examples of technical textiles?

- Kevlar

- nomex

- cool max

- fastskin

What are two examples of fabric alternatives?

- mycelium - leather alternative made from fungus

- pinatex - leather made from pineapple leaf fibres.

What are the two types of non-woven fabric?

- bonded - fibres fused together using heat or chemicals

- felted - fibres matted together using heat ,friction and pressure

What are knitted fabrics?

- fabrics made from interlocking loops of yarn

- weaker, more stretchy but more insulating

What are woven fabrics?

- made from warp and weft running perpendicularly over and under each other

- have a selvedge where it cannot fray

- easiest way to make fabric, tough and doesn't warp

What are natural fibres?

- fibres from natural sources, plants or animals

- eg wool, cotton, silk, linen

What are synthetic fibres?

- fibres that are man-made usually from oil

- eg polyamide, polyester, elastane

What is a composite material?

- a material made up of 2 or more materials whose properties are combined to create a single material with enhanced properties

- eg alloys, manufactured boards, concrete

How is blow moulding done?

- parison of the product is extruded directly between the two mould halves

- mould closes around it and creates a seal around the parison

- hot air then blown into the parison to to take the shape of mould

- left to set and product removed and excess flash trimmed away

How is vacuum forming done on a commercial scale?

- roll of plastic passed through an oven to soften it

- this is then vacuum formed around the mould and blasted with cold air to cool it

- are is blown into mould to release pieces and guillotine separates form rest of the mould

How is vacuum forming done?

- tapered mould with air holes put on platen and lowered into machine

- pieces of hips clamped I n place making a seal, and heated until it sags slightly

- then platen is raised and air removed to form hips around mould

- heat removed, and air blown into mould to release it from the plastic

How is expanded polystyrene made?

- pellets are heated to around 100 degrees and mixed with steam to make them expand

- they are then put into the block moulding machine and the pieces are steam formed together to make a solid piece

- cooled by water and removed from mould

How is compression moulding done?

- used for thermosetting polymers as it is low temperature and slower

- charge of polymer put between moulds and hydraulic force presses it into shape of product

- heated to around 100 degrees to set the polymer

- can be removed from mould and excess flash trimmed away

How is rotation moulding done?

- powdered form of a pellet is poured into the mould of 2 halves

- mould closed and rotated in all directions to push powder to outer edge

- outside is heated in oven to melt polymer into an even outer layer to make a hollow product

What is extrusion?

- polymer pellets fed into hopper and move down Archimedean screw where they melt

- pressure builds up at end, forcing polymer through die to create a long continuous product with consistent cross section

What is injection moulding?

- polymer pellets fed into hopper and move down the Archimedean screw where it melts under heat

- hydraulic ram at end forces melted polymer through die into the mould

- mould is cooled by water and product can be removed by ejector pins

What are the advantages of plastic alternatives?

- biodegradable under the correct conditions

- source is renewable, so wont run out

- not oil-based

What are the disadvantages of plastic alternatives?

- not as easy to source

- not as many options as oil-based polymers

- have relatively low softening temperatures

- more expensive to produce than oil-based

What is a thermopolymer?

- can be reheated and reformed multiple times without weakening structure

- molecules all run in a single direction

- eg HIPs, ABS, HDPE, LDPE

What is a thermosetting polymer?

- polymers that cannot be reformed once set

- have molecules that run in multiple interlocking directions

- eg phenol ,urea, melamine formaldehyde, epoxy resin

How is electroplating done?

- metal is first cleaned in an acid bath and sand blasted to remove impurities

- then attached to conductive rack and put into tank with conductive acid and donor metal

- current flows and donor metal is attracted to metal and forms an even layer over it

How is anodising done?

- aluminium put on conductive rack and put into cleaning bath to remove impurities

- then put in acid bath the etch ridges for better adhesion

- then put into deoxidising bath to removed final impurities

- then put into sulphuric acid bath and current flows, forming oxide layer over aluminium

- put in water bath to seal it in.

How is powder coating carried out?

- object is sandblasted to remove grease and impurities

- put in oven for 30 mins to heat up

- the positively charged and negative powder fired at it

- attracted in an even layer and minimal waste

- the baked to set the powder and smoothen it out

How is spot and seam welding done?

- metal held between two electrodes

- current flows through creating heat by resistance fusing the metals together.

how is inertia friction welding done?

- metal aligning in machine, one on a spindle

- spindle spins the metal and pushed together

- creates heat by friction and melts the metals together

what are the two different types of welding

MIG and TIG

what is stick welding?

- consumable electrode cover in flux creates arc

- melts the filler and base metal together, and leaves layer of flux over it

what is soldering?

- solder iron heated to 300 degrees and used to melt solder onto piece

- used for copper pipes and circuit boards

what five things are considered when choosing a method of welding?

- strength of weld needed

- type of weld needed

- desired aesthetics

- how accessible it is to do

- how thick the metal sheet is.

how is lost wax casting done?

- a silicone mould is made and hot wax injected not it to make multiple copies

- these are attached to a runner and the tree is cast in investment

- the wax is burnt out in a kiln and molten metal can be poured into the die

how is sand casting done?

- parison of product is created and pressed into the green sand to take shape

- tubes then cut for pouring and gas escape

- molten metal then poured in and excess is cut away

what is forging?

- metal is heated until it is yellow

- then hit with a hammer into the desired shape

- means molecules form grain shape which is stronger than cast metals

how is metal lathing carried out?

- metal is clamped between the tailstock and spindle

- spun and tool moves into it by the piece

- roughing blade removed material and facing off tool removes it from the piece

what is laser cutting?

- laser used to cut or engrave from metal sheets depending how on the power

- CNC so very accurate and precise

how is spinning carried out?

- round metal sheet is clamped between spindle and rounded former

- piece is then spun and tool pressed into the piece, creating heat by friction, making it malleable and forms around rounder.

how is drawing done?

- metal is stretched as it is forced between the mould and die

- creates thin walled, hollow products

compare punching and blanking

- punching - using die to press hole out of thin sheet metal

- blanking - using the shape that has been cut out

what is milling?

- spinning drill bit used to cut away at a material along a plane

- used for making moulds for die casting

what four ways can steel be finished?

- cold rolling to make thinner

- tinning - thinned and layer of tin added

- annealing - to make softer and malleable

- tempering - to make harder

how is steel manufactured?

- iron and scrap steel put into oxygen furnace and super heated

- purified oxygen blown in making the steel

- cast into slabs, reheated and descaled

- then rolled n rolling mill to make thin, long sheets

-then run through acid bath to clean the surfaces

how is iron manufactured?

- ground exploded to reveal taconite and the rock is crushed into pellets

- magnets used to separate the iron ore out of this

- put into furnace and heated with limestone and coke to operate iron from impurities

what is a ferrous metal?

- metal containing iron

- magnetic, so cheaper to make

- eg iron and steel

- rust

what is a non-ferrous metal?

- metal not containing iron, so most not magnetic

- oxidise instead of rust

- more expensive to produce

- aluminium, copper, tin, gold

what are alloys?

- mixture of 2 or more different metals to combine their properties

- eg brass, bronze, steel.

what is coke?

- coal that is crushed and baked at a high temperature in a seal

- makes pure carbon fuel, which burns hotter than normal coal.

what is a knock down fitting?

- fittings that can be assembled and disassembled multiple times without weakening the joint of material

- used mainly in flat pack furniture

what is a temporary fitting?

- fitting that can be removed without weakening the material or joint

- usually knock down fittings etc

what is a permanent fitting?

- joints that damage the material when they are removed

- eg welding

what needs to be considered when choosing a joint?

- temporary or permanent

- strength of joint needed

- stiffness of joint needed

- effect of joint of the material

- appearance of the joint

how is steam bending done?

- hardwood (usually ash) is put into a steam box for 1-2hrs to soften the lignin so fires can slide over each other

- then bent around former and clamped in place until the fibres set in place

how is lamination done in industry?

- veneers pass through machine where a thin layer of adhesive is spread over

- then pressed in a stack between male and female former until set

- excess then trimmed away

how is laminating done on a bespoke scale?

- pea is evenly spread across the veneers

- then put over mdd former and held in place using vacuum bag until it sets

what are the main methods of finishing woods?

- varnishes

- waxes

- paints

why and how is wood finished?

- first sanded to make a smooth surface

- then must be primed to stop them being too absorbent

how is wood turned?

- job is clamped between headstock and tailstock quill and spun on the spindle

- roughing blade moves into it via saddle and cuts away to create cylindrical product

- facing off tool then removes it from the lathe

what are the advantages of manufactured boards?

- available in large sizes

- dimensionally stable, don't shrink or warp

- consistent properties, no knots or grains etc

- can have laminate finishes

- environmentally friendly, made from recycled or offcut wood

what is plywood?

- manufactured boards made from veneers adhered at 90 degrees to each other

- means there is no grain weakness and doesn't snap along the grain

how is MDF manufactured?

- logs are first debarked and chipped into a very fine powder

- chips are then washed and steamed and resin adhesive is mixed in

- spread into mat and hot press applies pressure and heat to make a mat of continuous thickness

- then cut to size and sanded down.

how is chipboard manufactured?

- wood is first chipped into fine and coarse chips

- the resin adhesive mixed in and spread out into even layer

- pre pressed to thickness and cut to length

- hot press applies heat and pressure and sets adhesive in place.

- can then be sanded and trimmed down

what are laminated boards?

- manufactured boards made up of veneers adhered in an organised way

what are compressed boards?

- boards made from chip, strands or particles that are glued together using a resin

- compressive force used to set in shape

what is illegal logging?

- wood that is cut, processed, transported or exported against local laws

- done to clear land for farming, mainly cattle, or to sell the timber

- done because of demand for wood in the EU

what are the effects of illegal logging?

- habitat loss

- keeps countries in poverty, as cannot profit from sustainable logging

- carbon emissions from the burning of wood to clear land.

what are the uses of recycled wood?

- animal bedding

- equestrian surface

- manufactured board

- biofuel

what is cross sawn timber?

- method of cutting logs so the grain is parallel to the cut

- means the wood warps and cups as it dries

- but its cheaper, faster and less initial waste

what is quarter sawn timber?

- slabs of wood that are cut perpendicular to the grain

- means it cannot warp or cup as it dries

- more expensive, time consuming and more initial waste, but better in long term

how are logs converted into timber?

- trees are felled from the forest and soaked in water for 20 mins to soften bark and remove dirt

- they are then debarked by shaving

- wood is the cross or quarter sawn

- then seasoned in a kiln to reduce moisture content and prevent warping