Paper 2 - Product Design DT - A level - AQA

What is the acceptable range of accuracy known as?

Tolerance

What is a datum?

A datum is a reference point or surface from which all other dimensions of a component are taken; these other dimensions are said to be referred to the datum.

What is used to provide reference points to facilitate improved accuracy?

Datum edges and surfaces, as well as vertical and horizontal lines a generated by laser levels, provide reference points to facilitate improved accuracy.

Methods of eliminating errors

• Dials on machine controls allow precise movement on tools
• Digital test gauges are very accurate and are often computer linked
• Profile inspectors measure fine details
• CNC machines use computer code to control their movement and ensure accuracy.
• Laser micrometers, materials thickness sensors and alignment systems are examples of non-contact testing devices.

What is a jig?

Jigs are guide for cutting tools.

What is jig used for?

They help tools such as drills, for repetitive machine operations without needing to mark out. This helps reduce the need for skilled workers and reduces the chance of human error.

What is a fixture? (accuracy in design and manufacture)

Fixtures hold work in place for processes such as welding.

What is a fixture used for?

They maintain accurate alignment of parts by providing framework into which they are securely clamped during manufacture. They are often designed so that parts can only be fitted the right way round, they ensure that every manufactured assembly is of high quality.

What is a template and what is it used for?

Templates ensure the consistent repetition of the same outline by providing a consistent, rigid, profile of a shape.
This helps create identical pieces and are incredibly common in batch production.

What is critical analysis?

Critical analysis is an in depth, research linked, objective study of elements of a design.

How do you critically analyse and evaluate?

During the design process, the research and investigation provide the information for a design specification. Evaluation of ideas includes comparing them to the specification criteria. Methodical checking of points of the specification during idea generation increases the chances of a design being successful. Analysis of existing products is also important.

Product analysis methods:

• Identification of the target market and the product purpose
• Likely specification criteria and how well they have been met
• Product disassembly to study manufacturing and other features

Why is testing and evaluating products in industrial or commercial contexts important?

Product safety is vital to avoid harm as well as product recall issues. Product recall is often 100x more expensive than dealing with an issue during the design process, and mass recall can often harm a company's reputation.
Manufacturers often used testing facilities to check they products, as well as third-party, independent organisations to check for legislation compliance.

What is third-party feedback used for by designers?

Designers use third-party and independent evaluations of their ideas and products to get feedback on improvements and developments. This unbiased feedback often leads to a greater chance of success than using those of the design team.

Example of third party feedback:

British standard Institute - who can certificate the product meeting standards and show this by awarding the BSI Kite mark and the CE mark. There are also focus groups, that are samples of the desired target market. These are organised by independent market research organisations. These groups will interact with the product and be recorded for analysis. As well as asking for their views and opinions.

What is sustainability?

Maintaining our planet and its resources and making a minimal negative impact.

What does non-renewable mean?

Will run out eventually

What does renewable mean?

Will not run out of

Non-renewable energy resources:

Oil, Has, Coal, Nuclear

Renewable Energy Resources:

Hydro, wind, solar, tidal, geothermal, biomass

Advantages of renewable energy

Sustainable, Generally require less maintenance than traditional generators, reduces operational costs, little to no waste, social and economic benefits

Disadvantages of renewable energy

Difficult to produce large quantities, often relies on weather which can be unreliable and inconsistent, cannot be stored in large quantities, currently more expensive than traditional energy due to large capital costs associated with new technologies.

What is circular economy

A cradle-to-grave approach in the product life cycle. There are two 'nutrient' types.

What are the two 'nutrient types'

• Biological nutrients - organics, non-toxic, materials that can simply be composted and can safely re-enter ecosystems.
• Technical nutrients - man-made materials are designed to be used repeatedly, and at the same time high quality with minimal energy.

Circular economy will:

Work against the unsustainable 'take, make, dispose' culture. Reduce use of finite resources. Reduce waste. Avoid Pollution. Deliver a more competitive UK economy. Help reduce environmental impact of product manufacture and consumption.

When was the arts and crafts movement?

1850-1900

Influences of Arts and Crafts movement

Traditional craft and hand skills rather than machinery.

Key designers of arts and crafts

William Morris, Charles Voysey, Richard Norman Shaw

Features of Arts and Crafts

• Traditional wood joints in furniture
• Use of natural forms
• Highly decorative - with birds and florals shown on textiles and wallpapers.

When was the Art Nouveau movement

1880-1910

Influences of the Art Nouveau Movement

• linear patterns of Japanese prints
• French Post-Impressionist art
• Arts and crafts Movement

Key designers of Art nouveau

Alphonse Mucha
Louis Comfort tiffany
Charles Rennie Macintosh,
Antoni Gaudi

Feature of Art Nouveau

-Floral and decorative patterns

• Elegant and graceful lines
• Use of traditional materials

When was Art Deco Movement

1925-1939

Influences of Art Deco movement

End of WW1, growth of mass production. Range of international styles coming into the public eye

Key designers of Art Deco Movement:

Claric Cliff, Eileen Gray, Rene Lalique, Walter Darwin Teague

Features of Art Deco Movement

• Stylised geometric shapes
• Bold colours often paired with black, chromes and metallic.
• Sunburst motifs.

When was the Bauhaus Movement?

1919-1933

Influences of Bauhaus

Post WW1 idealism. Arts and crafts movement, WW1 industry methods and materials, art deco's geometric forms.

Key designers of Bauhaus Movement:

Water Gropius, Marcel Breuer, Marianne Brandt, Miles Van Der Rohe

Features of Bauhaus

Form follows function principle, Use of steels, chromes and leather, modernism style-design.

When was the streamlining movement

1930-1950

Influences of streamlining movement

Post WW2 lack of materials, vehicle innovations breaking speed record, rise of bakelite.

Key designers of Streamlining movement

Raymond Loewy, Norman Bel Geddes, Henry Dreyfuss, Walter Darwin Teague

Features of Streamlining

Long horizontal lines and curving forms, aesthetic influences from industrial and nautical design. Sleek appearance, use of metals and plastics.

When was the Scandinavian Modern Movement

1935-present

Influences of Scandinavian Modern Movement

• Dark Scandinavian winters leading to designers maximising light and cozy features.
• Practical and functional designs

Key designers of Scandinavian Modern Movement

Finn Juhl, Hans Wegner, Arne Jacobsen

Features of Scandinavian Modern Movement

Clean lines, Neutral colour palette, sleek and functional.

When was the minimalism movement?

1967-1978

Influences of Minimalism movement

Japanese traditional design and architecture,
De still art and design

Key designers of Minimalism Movement

Donald Judd, Agnes Martin, Dan Flavin, Anne Trutt

Features of Minimalism movement

• Repetition of simple geometric forms
• Monochromatic/limited colour
• Hard-edged
• Little/minimal use of materials

When was the Memphis movement

1981-1988

Influences of Memphis movement

• Rebelling against functional modernism
• Art Deco
• Pop Art

Key designers of Memphis movement

Ettore Sottsass, Michele De Lucchi, Martine Bedine

Features of Memphis Design Movement

• Less if Bore principles
• Post-modernism design
• Bright, colourful and sculptural design
• Bright, colourful and sculptural design
• Simple and Abstract forms
• Use of non-traditional materials

What are microelectronics

the design, manufacture, and use of microchips and microcircuits.

Impact of Microelectronics on products

Advancements in manufacturing technology for electric components e.g. integrated circuits resulted in increasingly powerful and miniaturised range of products.
E.g. 1940s transistor used for portable radios

• LCD displays
• Lithium Batteries used for rechargeable power and longer battery life

Impact of Microelectronics on design and manufacture

Technology developments have impacted how designers and manufacturers work.
E.g. - use of internet searches in research

• Sketching used along side graphics tablets and CAD
• Manufacturing using CNC and automatic machinery

What does IoT stand for

Internet of Things

What is the Internet of Things

The networking of multiple microelectronic devices using Wi-Fi and the internet

• E.g. Smart Fridges using Scanners to identify most used products and automatically ordering them
• Automatic JIT manufacturing that organises its own flow of parts, etc.

Examples of Advancements in CAD
/CAM

Standardised file formats to correct a range of software to hardware

• Use of 3D printing
• Use of FEA and CFD in CAD simulations
• Cloud-based packages
• Virtual reality systems

What are new materials

New materials are ones that have recently been developed and offer improvements over traditional materials

Examples of New Materials and their uses

• Glulam - a layered timber and glue used in buildings and structures
• Kevlar - woven fibres used in bulletproof vests
• Graphene - a nano materials, made form carbon particles with honeycomb structure that is used in medical treatments to battery manufacture
• Precious metal clay - precious metal particles in pliable clay and used to make jewlerry and decorative items.

Examples of new methods of manufacture: and their uses

• Electrohydraulic forming - car parts
• 3D printing of metals - one-off prototyping
• Fibre injection moulding - lightweight parts for aerospace, medical equipment, etc
• Laser beam welding - ship building and construction
• Physical vapour deposition - food packaging, machinery and decorative products

What must designers consider to make a product that has minimal environmental impact?

• How to conserve materials
• How to conserve energy during manufacture
• The products are as sustainable and environmentally friendly as possible
• Total carbon footprint
• The total product miles

What are finite resources

Will run out eventually

What are infinite resources

Can be re-grown and re--bread. Will not run out of.

Finite resources

Plastics metals, polymers (textiles)

Infinite resources

Paper, boards, natural timbers, cotton, leather

What can we do to reduce environmental impact or products and manufacture?

• Planting more tree to reduce deforestation
• Recycling products and materials
• Using less finite resources
• Reducing Pollution by using less plastics, efficient manufacture, less waste and using renewable energy (like solar and wind)
• Reducing Product miles by making the product in the country it is sold in
• Repairing products rather than throwing them away

What is a life cycle assessment?

This is when a designer looks at the environmental impact a product makes over its life time and how it could be reduced.

What are aspects a designer looks at in a life cycle assessment?

• Impact of materials
• Impact of processes
• Impact of packaging
• Product Miles (how far a product has to travel to get from factory to consumer)
• Impact while in use
• Impact when disposed of (6Rs)

Examples of lowering impact of packaging, to have optimum amount of packaging to protect and preserve products and prevent waste.

• Making packaging lightweight
• Using recycled content
• Making the packaging recyclable or reusable
• The use of refills and concentrates
• Using minimal packaging materials
• Charging for items - like supermarketer carrier bags

What is iterative design

A repetitive proces, that cycles through designing, modelling and testing constantly until the designed product has been made. Designers by themselves, or in teams, have to constantly evaluate their work in order to improve.

Advantages of iterative deisgn

Consistent testing helps solve problems earlier. Constant feedback. Easy Evidence of Progress

Disadvantages of iterative design

• Designers can loose sight of 'the big picture'
• Time Consuming

Research methods to help designers be aware of the needs, wants and values of consumers:

• Physical needs of age groups (babies, teens, adults and elderly) and those with disabilities
• Emotional needs - likes, dislikes, aspirations, etc.
• Intellectual needs of age groups (babies, teens, adults, etc.) as well as those with mental disabilities
• Sociological needs and values - social pressures, cultures, etc.

What is User centred Design

USD aims to improve user experience of products. The International usability standard (ISO 13407) makes this likely, and products that comply with this standard should:

• Take full account of users and their environment
• Involve users in design and development
• Result from a repetitive (iterative) process
• Consider the whole user experience
• Be developed by a multi-skilled team (engineers, designers, ergonomists, etc.)

Advantages of user-centred design

• user feels listened to
• Makes sure the product meets their needs

Disadvantages of user-centred design

• Requires extra time to get customer feedback
• If focused on just person it can limit appeal to others

Primar Research methods

• Questionnaires and Surveys
• Interviews
• Designers going through user experiences
• Focus groups
• Product Analysis
• Anthropometric Data
• Observing users using a product for ergonomic data

Secondary research methods

• Online
• Books
• Using existing research
• Using others anthropometric data

What is the BSI

The BSI is a national organisation that devises agreed standard procedures.

• The portfolio currently exceeds 30,000 standards
• The BSI Kite mark shows that the standards have been met
• The BSI Kite mark is influential when consumers decider on purchases.

What does ISO stand for

International Organisation for Standardisation

What is ISO

The iso consists of 150 notional standards bodies, including BSI.

• Implements internationally recognised standards
• The CE mark means the product conforms to all relevant EU safety standards

Mobius loop recycling symbol

• Internationally recognised
• Shows product can be recycled
• Helps separate materials

Restriction of Hazardous Substances (RoHS) Directive

• European directive
• Restricts use of hazardous materials in electrical products
• Aims to protect human and environmental health

Waste from Electrical and Electronic Equipment (WEEE) Directive

• European directive
• Covers end of life of electrical equipment

EC energy label

• Compulsory European scheme
• Shows consumers energy consumption of household appliances.
• Scale from A+++ to D

NAPM Recycled Mark

• National Association of Paper Merchant's scheme
• Encourage the use of recycled paper

European Ecolabel

• Voluntary certification
• Shows product has had a life cycle assessment

Forest Stewardship Council Logo

• Applies to timber products, sources from sustainable forests
• People and wildlife have been protected
• Local, trained and fairly paid workers have been used

EU Energy Star

• Collaborative scheme between EU and USA
• Standardises IT equipment energy labelling

Green Dot

• Used in Europe
• Shows the manufacture has made a financial contribution to recycling packaging in Europe.

Stages of Product Life Cycle (PLC) Chart

Introduction to Growth to Maturity to Decline.

What is the purpose of the Product Life Cycle Chart

It helps companies track and predict product sales. This is not to be confused with the life cycle assessment of products in regards to sustainability.

What are the axis of the Product Life Cycle chart

Sales on Y, Time on X

What strategies will companies employ to maintain their sales

Demand/Customer pull, Technology Push, Planned Obsolescence, Evolution of Products.