OCR A level Design and Technology: Product design

Injection Moulding

Highly accurate, complex shapes, high quality finish. Draw angles, ejection pin marks, sprue marks, split lines. ABS, polypropylene, polythene, polystyrene.

Rotational Moulding

Hollow, uniform wall thickness, high quality surface finish, imprinted details such as logos/text. LDPE, polypropylene, nylon.

Vacuum Forming

Thin wall thickness, patterns or textures imprinted, tapered edges, rounded corners, thinning at corners. ABS, acrylic, polythene, PVC.

Extrusion

Uniform wall thickness, cross section, highly accurate and complex shapes. Polythene, PVC, polypropylene.

Centre Lathe Turning

Cylindrical products, can be carried out using a variety of metals and plastics.

Die Casting

High accuracy and quality surface finish, complex shapes, tapered edges, ejection pin marks, runner marks, split lines. Low melting point alloys I.e. zinc, magnesium, aluminium.

Sand Casting

Rough in appearance, tapered sides, rounded corners, runner and riser marks. Low melting point alloys I.e. brass, bronze, cast iron.

Press Forming

Sharp bends, deep draws, flanges, ribs, pierced shapes. Sheet metal I.e. steels, aluminium.

Piercing & Blanking

Sheared surfaces which show areas of deformation or fracture. Sheet and strip metal.

Drop Forging

Products which require tensile or compressive force to be used I.e. tools, cutlery. Most metal alloys.

Scots Pine

Softwood - straight grained, quite strong, easy to work, white/yellowish brown colour

Red Pine

Softwood - straight grained, strong and quite easy to work, red/orange colour

Cedar

Softwood - straight grained, very light but durable, quite soft, orangey colour

Oak

Hardwood - hard, tough, heavy, durable, light brown/golden colour

Mahogany

Hardwood - medium weight, quite strong, easy to work, durable, warps easily, red/brown colour

Ash

Hardwood - flexible, tough, bends well, varnishes well, light in colour

Beech

Hardwood - hard, tough, strong, tends to warp but bends well, mid-brown colour

Teak

Hardwood - coarse, uneven texture, oily, straight or wavy grain, expensive, golden to dark brown colour

MDF

Manufactured Board - high strength, easily machined, shapes and paints well. Tightly compressed wood fibres.

Plywood

Manufactured Board - very strong, stable and easy to work/machine. Thin sheets glued together; grain of each layer goes in a different direction

Blockboard

Manufactured Board - very strong, heavy, rigid, good load bearing capabilities. Parallel strips of timber with veneer glued either side; grains running crosswise

Chipboard

Manufactured Board - heavy, strength dependent on density of wood chips. Wood chips mixed with bonding mixture and compressed

Acrylic

Thermoplastic - stiff, hard, durable, scratches easily, brittle. An be made opaque, transparent or translucent. Good substitute for glass.

ABS

Thermoplastic - strong, light, durable, scratch resistant, chemical resistant. Toys, kitchenware, plastic furniture, crash helmets.

LDPE (low density polyethylene)

Thermoplastic - soft, flexible, good electrical insulator. Bags, plastic bottles, cable covers.

HDPE (High density polyethylene)

Thermoplastic - durable, tough, chemical resistant. Wheelie bins, buckets, bowls, detergent bottles.

Nylon

Thermoplastic - very hard wearing, durable, rigid. Gears, ropes, bearings, clothing, upholstery.

Polystyrene

Thermoplastic - light, stiff, water resistant. Food packaging, containers, games/DVD cases.

Polypropylene

Thermoplastic - light, rigid, chemical resistant. Films, medical equipment, ropes, kitchenware.

Melamine Formaldehyde

Thermosetting Plastic - waterproof, resistant to some chemicals, hard wearing, scratch resistant. Laminated worktops, tableware, buttons, electrical insulation.

Urea Formaldehyde

Thermosetting Plastic - good adhesive qualities, stiff, strong, hard, brittle, good electrical insulator. Electrical fittings I.e. sockets, plug casings, door handles, adhesives.

Cast Iron

Ferrous metal - relatively inexpensive, brittle, casts well. Engine parts, machine tools, vices.

Mild Steel

Ferrous alloy - malleable, ductile, relatively easy to work. Car body panels, nuts, bolts, springs.

Stainless Steel

Ferrous alloy - hard, tough, corrosion and wear resistant. Cutlery, sinks, kitchen appliances.

High-carbon Steel

Ferrous alloy - Malleable and ductile, can be hardened and tempered. Cutting tools, knives, files, drills, saws, lathe tools.

Aluminium

Non Ferrous metal - very good strength to weight ratio, casts easily. Drinks cans, food packaging, kitchen utensils.

Copper

Non Ferrous metal - tough, ductile, malleable, good conductor of electricity, expensive. Coins, plumbing/water pipes, electrical wiring.

Brass

Non Ferrous alloy - corrosion resistant, hard, casts well, easily joined, polishes well, good conductor. Hinges, door handles, screws, decorative items.

Duralumin

Non Ferrous alloy - very good strength to weight ratio, hardens with age, machines and finishes well. Aircraft parts.

Biscuit joint

Butt joint

Corner halving joint

Cross halving joint

Dovetail joint

Dowel joint

Finger joint

Lap joint

Mitre joint

Mortise and tenon joint

T halving joint

Additive manufacture

involves joining or building up material such as the creation of models in a FDM 3D printer

Additive Printing

A manifacturing process joining materials from 3D model data.

Aesthetics

aspects relating to the visual appeal of products.

Anodising

coating (usually aluminium) with a protective oxidised layer by electrolysis.

Anthropometrics

scientific measurements of the human body applied to the design and construction of products.

Assembly Jigs

can be used to hold a part in place while a process is being carried out.

Batch Production

The manufacture of groups of products to increase efficiency and economy.

Bespoke

A product specially made to order for a customer.

Biological Nutrients

Organic non-toxic materials that can safely re-enter ecosystems.

Carbon Footprint

The total amount of carbon dioxide released into the atmosphere as a result of the activities of an individual, a community, or an organisation.

CFRP

Carbon fibre reinforced plastic

Cloud computing / storage

Web-based hosting of computer files / applications for access in multiple locations.

Collaboration

Working as a team, rather than individually, to achieve a goal.

Composite Material

A material comprised of two or more different materials, resulting in a material with enhanced properties.

Compressed Boards

Made from chips, strands, or particles of timber glues together under a compressive force.

Computational Fluid Dynamics (CFD)

3D CAD simulation tool for fluid flows in or around a product.

Computer-aided Engineering (CAE)

The simulation and analysis of product and component performance using computer software.

Continuous Flow Production

A highly automated 24/7 production process, usually requiring a small workforce.

Control Measure

Any action carried out in advance that protects against a possible danger or injury.

Control of Substances Hazardous to Health Regulations 2002

Legislation to prevent, reduce, or control people's exposure to hazardous substances in the workplace.

Copyright

Gives rights to creators of original ideas, information, or intellectual works.

Critical path analysis (CPA)

Analysis of the stages in a project to ensure time-efficient completion.

Culture

The social behaviour of different societies influenced by their customs and ideas.

Customer Reach

The number of potential customers a company can reach through a marketing strategy.

Cycle time

The time taken to complete a manufacturing process.

Demographic

A particular sector of the population. This may relate to age, education level, spending power, geographical location, etc.

Design for disassembly (DFD)

A strategy that considers the future need to disassemble a product for it to be repaired, refurbished, or recycled.

Design Rights

Gives rights to the designer or creator of a design (does not cover 2D work).

Direct Digital Manufacturing (DDM)

A system where parts are produced by machines such as 3D printers directly from CAD files.

Eco-Materials

Often called environmentally friendly materials, those materials that enhance the environmental improvement throughout the whole lifecycle.

Ecological Footprint

The impact on the environment and natural resources.

Electronic Point of Sale (EPOS)

A computerised system used in retail shops to record sales and track levels if stock.

Electroplating

Involves the coating of an object in a thin layer of metal by using electricity.

Emerging Technologies

New technologies which are currently being developed.

Enterprise

A business venture or project.

Ergonomics

The promotion of optimum design usability and efficiency through the study of how people interact with products and their working environment.

Exploded View

A drawing, usually in isometric projection, showing the relative position of parts for assembly.

Fairtrade

Involves better prices, decent working conditions, local sustainability, and fair terms of trade for farmers and workers in the developing world.

Fast Fashion

A term explaining a quick transaction from catwalk to high-street stored to capture current trends.

Feasibility analysis

A consideration of how possible and realistic it is to proceed with a project.

Ferrous

Metal that contains Iron.

Finite Element Analysis (FEA)

Software which analyses the stress in elements of a CAD design.

Fixture

Holds work in a given position while a manufacturing process takes place. Fixtures are always fixed to the machine bed.

Flowchart

A diagrammatic representation of a process using standardised symbols.

Former

Used to make sure that parts are formed or bent to the same shape.

Functional Performance

How the product works for functions.

Galvanising

A process in which steel is coated with zinc.

Gantt Chart

A graphical method (bar chart) of showing the time allocation for organising the stages of a manufacturing process.

Generative Design

The production of large numbers of alternative design possibilities using biomimicry-related techniques.

GRP

Glass-Reinforced Plastic