Tools, Equipment and Processes

What is one-off/bespoke production?

One product is made at a time, could be a prototype. Tools and equipment are used to make many different products. Usually takes a long time for each product and a high level of worker skill.

What is batch production?

A group of identical products are made together. Dedicated jigs may be used and some processes may be automated. The cost of equipment to set up is typically high.

What is mass production?

Large quantities of identical products are made. The equipment is only used to make the same products. Most processes are automated with dedicated jigs. Cost per product is lower than batch.

What is continuous production?

Typically used to manufacture commodities. Very large quantities of identical materials are produced and this runs 24/7. Processers are usually fully automated and the initial set-up cost is high.

How can designers eliminate waste from cutting?

• Use a stock form

• Tessellate/nest shapes together

• Use digital lay planning computer software

What are some tools used for cutting paper and card?

• Scissors (can also be used to score)

• Scalpels or craft knives

• Compass and circle cutters

• Rotary trimmer and guillotines

What are die cutters?

They cut shapes and holes when large numbers of products are needed. Creases and folds can be marked using a blunt blade.

What are some adhesives?

• Polyvinyl acetate (PVA)

• Aerosol adhesive (spray mount)

• Glue guns

What does lamination involve?

Involves adding layers of material making a composite e.g. using heat to enclose paper between two plastic layers

What happens during screen printing?

1. Stretch the mesh over a wooden frame and place a paper stencil and place it under the screen

2. Squeeze ink through the mesh using a squeegee

3. Ink will pass through the unblocked area of the stencil

What is offset lithography?

The image to print is in relief on the printing plate and attracts grease applied to it. The plate is dampened which repels ink from any non-image areas which is passed through a rubber cylinder which presses the image onto the card.

What are some sawing tools used for timber-based materials?

• Tenon saws (for straight cutting)

• Coping saws & powered fretsaws (used for curved cuts)

• Band saws (straight and curved)

• Circular saws (straight cuts in large wood pieces)

What are the four types of chisel?

• Bevel-edged, for corners

• Firmer chisel, for general use

• Mortise chisel, for deep holes for joints

• Gouge, which has a curved blade for carving

What is planing?

Using a wedge shaped cutting blade to shave off thin layers of wood

What are some different types of plane?

• Jack plane

• Smoothing plane

• Block plane

• Rasp or surform plane

How can the surface of a timber-based product be smoothed?

By sanding

What does drilling do?

It makes holes by rotating a drill clockwise as its pushed into the material

What are CNC routers used to make?

Grooves and edge profiles. Very common in furniture industry and school workshops

What is laminating in regards to timber?

When thin sheets of timber can be glued together and shaped around a former. They must be clamped in place until they dry.

How can fabrics be cut?

• Scissors or rotary cutters

• Pinking shears

• Band saws on large quantities

What do overlockers do?

Give seams and hems a professional finish or add decorative edging

What happens when fabrics are bonded together?

Strips of adhesive web is placed between fabrics and the heat from an iron then fuses them together

What is quilting?

Sandwiching wadding or stuffing between layers of fabric and stitching through the layers

What is piping?

A type of trim made from a strip of folded fabric inserted in a seam. Its used to define edges or style lines.

What is batik?

When wax is applied to the surface of the cloth using a tjanting. The cloth is then soaked in a dye and the areas with the wax resist the dye.

What happens during rotary printing?

When ink is applied to fabric through a series of rollers and the fabric moves continuously

What happens during flatbed printing?

When an automated squeegee applies ink through a screen as the fabric progresses in a series of small movements

What does gathering do?

It allows a garment to increase fullness or widen out

What is pleating?

A type of gathering in which the folds are larger

Where are measurments taken from?

A datum surface, or reference point

What are the main production aids?

• Jigs

• Templates

• Patterns

What are jigs?

Custom-made tools designed to achieve accuracy during manufacture. They ensure that parts are always made exactly the same.

What are templates?

Used to draw a shape onto a material which can then be cut around. Particularly useful when a large number of complex shapes have to be cut.

What are textiles/fabric patterns?

They’re used to trace the parts of a garment onto fabric before its cut. They’re usually made from paper but may be made from cardboard if they’re used repeatedly

What are casting patterns?

A pattern used when casting in metal or plastic resin. The pattern prepares the cavity into which the molten material will be poured.

What is accuracy?

The degree of closeness of a measurement to its true value

What is precision?

How repeatable or reproducible the measurement is

Why is accuracy important?

• Design spec will give the measurement and dimensions required

• If it has two parts and one doesn’t fit then it will have to be remade

What tools can improve accuracy?

• Jigs

• Templates

• Patterns

• CAM and CAD

What is tolerance?

The permissible limits of variation in the dimensions or physical properties of a manufactured product/part

What could a dismissal of tolerances lead to?

• Improper fits

• Wasted materials

• Additional cost of remaking a part

What is a specialist example of tolerance?

Resistor tolerance. A gold band means the resistor has a tolerance of 5%, silver means 10% and no band means 20%

What is quality control?

Testing and checking that a product meets the specification or a set of defined quality standards

What is quality assurance?

Putting systems in place that ensure the quality of the processes used to manufacture the product