Product Design - TECHNICAL PRINCIPLES

Manufactured board

A man-made, wood-based composite material.

Stock form

The set of standard sizes in which materials are available, as well as the format e.g. powders, granules, sheets etc.

Mechanical properties

Associated with how a material reacts to an external force.

Physical properties

Associated with the actual make-up or structure of the material.

Compressive strength

The ability to withstand being crushed or shortened by pushing forces.

Tensile strength

The ability to resist stretching or pulling forces.

Hardness

The ability to resist abrasive wear such as scratching, surface indentation or cutting.

Toughness

The ability to absorb impact force without fracture.

Composite

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

Smart material

A material whose physical properties change in response to an input or change in the environment, such as electricity, pressure, temperature or light.

Modern material

A material developed through the invention of new or improved processes, for example as a result of man-made materials or human intervention.

Ferrous metal

A metal containing mostly iron and carbon.

Non-ferrous metal

A metal which does not contain iron.

Alloy

A metal made of two or more metals, or combining two or more elements, one of which must be a metal.

Thermoplastic

A material that can be repeatedly reheated and reshaped.

Thermosetting polymer

A material which when heated undergoes a chemical change whereby the molecules form rigid cross links. Thermosetting polymers cannot be reheated and reshaped.

Elastomer

Materials which at room temperature can be deformed under pressure, and then upon release of the pressure will return to their original shape.

Air seasoning

A traditional, inexpensive method which involves stacking the wood under a shelter, protected from the rain. Air circulates between the planks to slowly release excess moisture.

Kiln seasoning

A more expensive but controlled method which is very quick and can take just a few weeks. Planks are stacked onto trolleys and placed in the kiln where both temperature and humidity are controlled.

Hardwood

A wood from a broad-leaved (deciduous) tree.

Softwood

A wood from cone-bearing (coniferous) tree.

Rough sawn

Wood that comes directly from seasoning and has rough surfaces produced from initial conversion. Rough sawn wood will have nominal sizes rather than accurate finished sizes.

Planed square edge

Wood has only one edge that is planed accurately, the rest are rough sawn. PSE is about 3mm smaller in width from the original nominal size.

Planed all round (PAR)

Wood had sides and edges that are planed square, straight and level, leaving a smooth finish, and is ready to use. The PAR board is about 3mm smaller all round than the original rough sawn nominal size.

Safe working temperature (polymers)

The temperature deemed safe for processing without possible degradation of the polymer properties.

Work hardening

Improved tensile strength and hardness in the localised area when a metal is cold worked.

Annealing

Heating work hardened metal and very slowly cooling it, making it easier to work by making it less brittle and more ductile.

Case hardening

A process for hardening the surface of steels with less than 0.4 per cent carbon content.

Carburising

Changes the chemical composition of the surface of low carbon steel so it absorbs more carbon and increase surface hardness.

Quenching

Rapid cooling of a heat-treated metal.

Hardening and tempering

Heating medium or high carbon steel to a given temperature, rapidly cooling via quenching and then heating to a set temperature to remove excess hardness.

Tempering colour

The colour seen on metal that indicates the temperature at which brittleness is removed.

Critical point

The temperature at which the atoms of carbon and steel mix freely before bonding together to become a solid.

Die cutting

A machine using a hydraulic press and a plywood substrate with cutting dies and creasing rules to cut a net from paper, card or polymer film.

Forming

Shaping stock form material through processes such as bending, rolling, press forming and steam bending.

Redistribution

Shaping materials by melting them and reforming them in a mould that resembles the finished product or component.

Wastage

Shaping stock material by machining it using processes such as milling, turning and routing.

Addition

Shaping materials by adding additional pieces to them, either using the same or a different material.

Adhesive

A substance used to stick materials together.

Substrate

The material on to which the print ink is applied, such as paper or boards.

Embossing

The process of creating raised images or text on paper or card by placing the paper or card in between two dies under pressure.

Debossing

Produces an imprinted depression that sits below the surface of the paper or card.

Screen printing

A printing process in which ink is forced onto the surface of a material through a mesh screen to create a picture or pattern.

Electroplating

Using a metal to coat a (usually cheaper) base metal.

Powder coating

Thermoset polymer powder is positively charged and attracted to the negatively charged product. It is then baked to melt the powder and given an even coating.

Anodising

Commonly uses for aluminium to enhance the natural oxide layer, resulting in increased hardness and toughness.

Scale of production

The consideration of the number of products to be made, using particular manufacturing methods to suit a particular market.

Batch production

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

Division of labour

The efficient organisation of a workforce so that individuals specialise in particular manufacturing tasks.

Line production

The manufacture of large numbers of products in factories set up so that processes can be efficiently carried out by workers and/or teams organised in a specific sequence.

Mass production

The manufacture of large numbers of products in factories that are usually highly mechanised.

Unit production systems (UPS)

The use of overhead transporters for component transfer between workers to improve factory efficiency.

Quick response manufacturing (QRM)

The use of mainly computer-based technology to facilitate efficient competitive production of low-volume, customised products.

Vertical Integration / verticle in-house production

The organisation of manufacture to reduce dependence on externally sourced parts and sub-assemblies.

Just in time (JIT) production

The manufacture of products as needed, in response to existing orders.

Bespoke (one-off) production

The design and manufacture of products to individual specifications.

Flexible manufacturing systems (FMS)

Production work of CNC machines and robots that can be used to make a wide range of different products, typically one-off bespoke items or in small batches.

Modular / cell production

The use of groups of CNC machines, robots and AGVs to facilitate efficient, flexible manufacturing.

Standardised components

Parts such as screws and light bulbs that are made to a common standard to ensure interchangeability.

Bought-in components

Product parts that are sourced from external suppliers rather than being manufactured in-house.

Sub-assembly

A self-contained element of a product that is made separately and incorporated in the final assembly stages.

Computer aided design (CAD)

Using computers to draw in 2D or 3D and develop products.

Computer aided manufacture (CAM)

Using computer controlled equipment to machine materials.

Computer numerically controlled (CNC)

Using a program to convert CAD drawings to drive CAM equipment.

Computational fluid dynamics (CFD)

Using software to virtually tests products in liquid or gases.

Finite Element Analysis (FEA)

Using software to test components and products to identify potential stress or weak points.

Electronic point of sale (EPOS)

Shop tills or similar that use barcodes or computer entry to transmit customer orders to suppliers and manufactures.

Just In time (JIT) production

A production method that relies on materials and components arriving at the point of manufacture, just in time for production.

Master production schedule (MPs)

A plan used to determine how many products will be made in a given time period.

Kanban

A system used to control the movement of materials and components from suppliers and through factory.

Radio frequency identification (RFID) tags

Small electronic devices that can be scanned and used to track items as they move through a factory and into dispatch.

Automatic guided vehicle (AGV)

Robots, similar to forklift trucks, used to carry materials and finished goods around a factory.

Ergonomics

The scientific study of people and their working conditions.

Aesthetics

The features of a product that make it visually appealing.

Anthropometrics

The use of scientific measurements of the human body in the design and construction of products.

Task analysis

The study of individual tasks performed by consumers to allow for successful product development.

User-centred design (UCD)

The use of the end user throughout the design process, to ensure the developed product is focused on their actual needs and not the perceived needs determined by the the designer.

Inclusive design

The concept of designing products that will allow the maximum number of possible users to successfully use the product without discomfort.

Empathetic design

The process of simulating conditions experienced by potential; users of products, to assist with the development of successful products.

COSHH

Control of Substances Hazardous to Health regulations 2002.

Risk

The likelihood or chance that someone may be harmed as a result of being exposed to a hazard.

Hazard

Anything that could cause someone harm.

Health of Safety at Work Act (HSWA) 1974

The main piece of legislation for British health and safety law.

Safety precaution

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

Risk assessment

Consideration of what might cause harm to people, and if reasonable steps are being taken to prevent that harm.

Intellectual property (IP)

A novel, physical; creation that is entitled to protection for its originator in the form of copyright, design rights, patent, registered design or trademark.

Intellectual property rights (IPR)

The legal protection of IP.

Copyright

Unregistered rights that protect original works such as books, photographs and plays.

Unregistered design rights

Rights that give the automatic protection to prevent copying the appearance of a product.

Patent

Legal protection for inventions relating to the way in which the products function.

Intellectual Property Office (IPO)

The official UK government body responsible for IP.

Registered design

A product whose appearance or decoration has been legally protected to counter copying.

Logo

A graphic symbol that often serve as an important element of a trademark brand identity.

Trademark

A unique combination of words, sounds, colours and logos used for marketing, and the legal protection of brand identity.

Open design

A design that has not been protected by IPR, so that it can be freely used and developed by others.

Six Rs of sustainability

The key points that need to be considered in order to make products sustainable.

Sustainability

The management of resources to minimise depletion and pollution.

Lean manufacturing

The concept of reducing waste in manufacture. This can be a waste of time or materials, or idle machines.

Buffer zone

An area adjacent too a point on a production line for the temporary storage of partially completed products.

Cycle time

The amount of time it takes for a manufacturing process to be completed.