PRODUCT DESIGN

TYPES OF PAPER

Tracing, layout,copier,cartridge

tracing paper

40-90 gsm, translucent, smooth and strong, non absorbent, copy sketches

layout paper

50gsm,smooth, translucent, cheap to buy, design, sketch.

Copier paper

80gsm, smooth, opaque, finishes well when printed on

cartridge paper

80-140gsm, thick, textured, paints, watercolours.

how are boards measured and categorised?

weight, thickness, microns, 1/1000 mm

corrugated cardboard

strong, lightweight, 2+ layers of wavy sheets to provide rigidity

mounting board

rigid and smooth surface, architectural modelling

folding boxboard

stiff, made from recycled paper. scores and folds well, packaging foods

types of boards

corrugated cardboard, mounting board, folding boxboard.

coating paper, card, board

adds thickness, weight, strength for specific purposes. known as laminating, keep food fresh, laminated cardboard for book binding

surface finishes to papers, cards, boards

edge staining - visual quality - book

embossing - raised shape - cards

glossy finish - something stands out - cards

hardwood-how and types

trees that lose their leaves during autumn

oak, beech, mahogany

oak

tough, durable, polishes well, furniture,doors

beech

tough,durable,smooth to finish, things that need hard wearing material

mahogany

cuts and polishes easily, furniture

softwoods

evergreen trees that have pinecones and needles

pine,cedar,larch

pine

lightweight, easy to work with, furniture

cedar

lightweight,more expensive that pine but not as strong,fences

larch

water resistant,durable,more expensive than other softwoods, boats.

manufactured boards

made from wood fibres from recycled wooden materials, bonded together to form sheets

MDF,Chipboard,plywood

MDF

medium density fibreboard-interior diy furniture

small fibres + wax and resin - heat and compress into desired thickness

chipboard

small chips bonded together into sheets. kitchen worktops

plywood

layers of wood bonded at 90 degrees to increase strength and rigidity.furniture

finishes for hard/softwoods

high traffic areas like floors need a hard wearing and sealing finish - glossy/matte finish

wax/oil

stains varnishes add colour

preservatives provide protection and ensure the wood is long lasting

heat scratch water resistance

product life cycle stages

introduction - product launched into market

growth - sales steadily increase

maturity - sales reach their peak

decline - sales drop off

obsolescence

product no longer sells/only at a discounted rate. no longer desired

market pull

new product or improved one is developed as a result of market demand.

technology push

developments in tech and materials, lead to new products being developed.

consumer rights and protection

consumer rights act - all goods of a satisfactory standard as described when purchased and fit for purpose

covers online purchases too, entitled to refund or repair if expectations not met

metal finishes

oil and wax

galvanising

primer

electroplating

timber finishes

varnishes - make it more durable

stains - enhance appearance

oils - repel water moisture

paints - can protect

marking out

required shape marked out

tape measure, steel rule

cutting

coping/tenon/hack/band saw

drilling

hand drill/drill press/pillar drill

types of holes

pilot - guide hole prevent splitting

clearance - large enough for screw to fit through

countersunk - top surface is flared

counterbore - flat bottomed that enlarges another hole

joining metals

permanently using welding, soldering

temporary using nuts bolts hinges

metal machines

lathe - create differently shaped round pieces

milling - cut slots into blocks of metal and face off edges

box joints

butt - simple but weak

housing

lap

dovetail

comb

frame joints

dowel

mortise and tenon

mitre

bridle

joining polymers

nuts bolts screws hinges

adhesives can bond them

types of production

one off - single products, bespoke

batch - limited numbers at one time

mass - identical, large volume, accuracy and efficiency.

ONE OFF PRODUCTION

original, like no other product

manual labour, expensive

BATCH PRODUCTION

satisfy demands as small numbers of similar items made at one time

may be delay until next batch made

MASS PRODUCTION

more profit because materials bought in bulk and machines are automated so less workers needed

initial set up costs are high, not much flexibility available

continuous flow

24/7 without stopping

automated for speed accuracy and quality control

saves time energy and workers

a single fault can stop the process and be costly

jigs

device to hold or secure material and guide cutting or drilling tools to ensure accuracy and repeatability

pattern / template

shape attached to the surface of material to help to shape it

tool for making out a shape repeatedly so its exactly the same each time

polymer production

blow moulding

vacuum forming

press moulding

compression moulding

blow moulding

forming bottles, soft plastic tube inflated to fill cavity.

vacuum forming

sheep of acrylic heated and pulled over a mould by extracting air using a vacuum

yoghurt pots

press moulding

polymer sheets heated, placed over the mould, press down to take shape. toilet seats

compression moulding

polymer placed into cavity, closed, compressed. saucepan handles

embossing/debossing

a feature stamped raised above or below surface

forms for metals

round/square rods

strips

round / square tubes

knock down fittings

screws

nails

nuts and bolts

hinges

dowels

paper and board fittings

drawing pins

velcro

treasury tags

staples

binding books

hand stitching is skilled and time consuming

comb binding is more common and less specialist

calculating costs

design, features, manufacturing processes

LCA life cycle analysis

source of materials

energy used and pollution from manufacturing

energy used and pollution from its life

disposal

6 R’S

reduce

reuse

recycle

repair

rethink

refuse

planned obsolescence

making a product intended for a specific time span so newer produces can be introduced to succeed older versions

Cradle to cradle

taking a product start to finish eg putting it to good use at end of its life

aluminium

non ferrous,lightweight,malleable,strong,conducts heat and electricity, corrosion resistant,

saucepans

copper

non-ferrous,corrosion resistant, malleable, durable,ductile, conducts heat and electricity

plumbing - oxidises

Brass

alloy of copper and zinc

corrosion resistant, harder than copper, malleable, ductile, conducts heat and electricity, easily scratched. hinges

pewter

alloy, low melting point, good for casting, tarnishes easily

mild steel

high tensile strength, ductile, malleable, easily corrodes

high carbon steel

hard,birttle,conducts head and electricity

screwdrivers

low carbon steel

ductile,tough,conducts heat and electricity,corrodes easily

bronze

non ferrous alloy, hard, corrosion resistant

stainless steel

ferrous alloy, hard, corrosion and stain resistant

cutlery

cast iron

conducts electricity and head, corrodes. can be cast in a mould.

gates

silver

malleable when hot, good conductor

jewellery

metal heat treatments

Process	Quick meaning
Annealing	Softens metal, makes it easier to shape
Normalising	Removes stresses, improves structure
Case hardening	Hard outside, tough inside
Tempering	Reduces brittleness after hardening
Hardening	Makes metal very hard

a naughty cat taught hamsters

what is paper made from + machine to make it + measurement

wood pulp papermill weight in grams per square metre gsm

renewable sources

Energy source	How it works	Advantages	Disadvantages
Solar	Sunlight hits solar panels and generates electricity.	Renewable, no pollution while operating.	Expensive to install, depends on sunlight.
Wind	Wind turns turbine blades connected to a generator.	Renewable, no fuel needed.	Noisy, only works when windy.
Hydroelectric	Flowing water turns turbines.	Reliable, renewable.	Expensive dams, can damage habitats.
Tidal	Tides move turbines to generate electricity.	Predictable, renewable.	Expensive, affects marine life.
Wave	Waves drive generators.	Renewable, no fuel needed.	Expensive, weather dependent.
Biomass	Plant material is burned for energy.	Renewable if replanted.	Produces carbon dioxide when burned.
Geothermal	Heat from inside the Earth is used to generate electricity or provide heating.	Renewable, reliable, low emissions.	Expensive to build, only suitable in some locations.

non renewable sources

Energy source	How it works	Advantages	Disadvantages
Coal	Burned to heat water, producing steam to turn turbines.	Cheap, lots of energy.	Causes pollution and climate change.
Oil	Burned as fuel or for electricity generation.	High energy output.	Non-renewable, polluting.
Natural Gas	Burned to generate electricity.	Efficient, reliable.	Produces greenhouse gases.
Nuclear	Uranium atoms split (fission) to release heat and generate electricity.	Large amounts of energy, low carbon emissions.	Radioactive waste, expensive power stations.

acrylic

Thermoforming Hard, bends when heated, weather resistant, scratches easily, brittle, visors

polypropylene pp

Thermoforming , Lightweight, strong, tough, heat resistant, toys

polyvinyl chloride pvc

Thermoforming, Cheap, strong, weather resistant, flexible or rigid, window frames

high density polythene hdpe

Thermoforming, Stiff, lightweight, chemical resistant, moulds easily, bottles

polystyrene

Thermoforming ,Cheap, sheet or foam, vacuum forms easily, packaging

thermoforming polymers

can be heated

and shaped repeatedly

thermosetting polymers

cananot be reformed

melamine formaldehyde

Thermosetting – heat resistant, moisture resistant, scratch resistant, stain resistant, kitchen worktops

epoxy resin

Thermosetting – strong adhesive, chemical resistant, heat resistant, good insulator, adhesives

urea formaldehyde

Thermosetting – hard, stiff, excellent electrical insulator, plugs

polyester resin

Thermosetting – tough resin, formed from acids and alcohols, printer toner

what makes solar energy work

PV photovoltaic cells

• The cells convert light energy into electrical energy.

• electricity produced

carbon fibre

carbon atoms bond in crystals, weave into fabric, Lightweight, very strong, stiff, heat resistant, corrosion resistant, Formula One cars

kevlar

Lightweight, extremely strong, heat resistant, impact resistant, Bulletproof vest

grp glass reinforced polymer

high tensile & compressive strength, boats

smart materials

display a physical change due to

external stimuli

QTC (Quantum Tunnelling Composite)

Insulator, conductor when compressed, Switches

Photochromic

Changes colour in UV light Glasses

Thermochromic

Changes colour with temperature, baby stuff to indicate temp

Shape Memory Alloy (SMA)

Returns to original shape when heated, glasses, braces

Polymorph

Becomes mouldable at 62°C, Prototypes, modelling

Styrofoam (Expanded Polystyrene Foam)

Lightweight, easy to cut and shape, good insulator, prototypes models