Studied by 3 people
Will contain all the information (excluding power generation) you need to know to get 100% in your DT written exam. Content that overlaps with Computer Science and Triple Science has been removed
What can every manufacturing System be split up into?
Input: The materials, tools and equipment you start off with
Process: This is what happens to the input to change it into the output e.g. measuring, cutting and forming.
Output: This is the result of the system, the finished product
What is automation?
This is the use of machinery to do tasks automatically without much or any human input.
This can be done for one particular process or the entire product.
Robots are being developed to be smarter and work better with humans. The aim to have a robot which can do a human’s task with more precision and accuracy whilst also able to make good judgements.
Advantages of Automation
Speed: Robots can increase the speed of production as they can work faster than humans and do not need to rest. This can make them cheaper than humans.
Accuracy: They are almost always accurate when doing one task consistently, whilst humans can make mistakes which can cost money (via time, materials etc.)
Safety: They can be used in situations which are too dangerous for humans such as handling radioactive waste.
Disadvantages of automation
Robots can replace human workers so there are fewer jobs for people to do.
Robots can be expensive to buy.
Robots cannot (morally) carry out decisions which require human judgement.
What is smart technology in manufacturing?
And its uses (x2)?
Advantage?
Smart technology develops from the accuracy of computerised machines by connecting them to other machines and sensors in the factory to share data.
These “smart” machines can be programmed to organise tasks without any human input. They could be used to monitor stock levels and automatically order stock when they are running low.
They could be a part of the “Internet of Things” (which is the connection between many machines, devices and technology on the internet.
These uses make smart technology useful in making automated manufacture more efficient
How does tracking work in manufacturing?
How does it help manufacturing?
Tags are added to materials, tools and products. These tags can be detected by a computer system (may be via scanning), this data is logged by a computer system.
This can be useful in tracking the level of stock materials and components. The tracking of products can help such as being able to automatically log when the product is finished and how many are finished and ready to sale.
How can communication systems used in Manufacturing?
How does it help with Manufacturing?
In automated factories, information can be communicated by smart machines without any human input or humans can use telefone, email or video-conferencing to shart information.
This can help as smart devices receive this information and display it in a useful way. Such as a tablet of a worker may inform of task and guide the worker around the warehouse in the most efficient route to maximise efficiency. Such as in collecting customer orders.
What are specialised buildings?
How do they help with manufacturing?
Specialised buildings are when buildings have been optimised to help manufacturing and often increases the efficiency.
They could be made from modular components which helps by making the movement, addition and subtraction of parts of the manufacturing process. This makes it easier to optimise and adapt to advances such as those in technology.
Specialised buildings are often more compact as they have been optimised and often include smart technology e.g. 3D printing which reduces the space taken up.
What is Flexible Manufacturing Systems?
These consist of a set of different machines that carry out the different stages of production. These computer-controlled systems transport materials through different processes and eventually store the final product.
They are easy and straightforward to adapt (“flexible”) if the design of the product being manufactured is changed. For example, more machines could be added if production levels increase.
What is lean manufacturing and JIT?
This is a Japanese approach and aims to minimise the amount of resources used and the waste produced.
It aims to minimise costs and maximise efficiency.
JIT (Just-in-Time) system of stock control is a form of lean manufacturing. This system ensure materials and components are delivered as they are needed and used just after delivery.
Advantages of JIT
It reduced the volume of space needed to store materials and finished products.
Less money is wasted from products detoirateing such as food rotting as they are used up as soon as they are delivered.
Disadvantages of JIT
The system relies on materials and components being delivered on time and being fault free. If this is not so, the entire manufacturing system may stop whilst the error is being corrected.
Advantages of CAD for designers (x4 details)
You can view your product from any angle.
You can easily model and change the design of the product.
You can easily experiment with different colours and forms.
All this can allow you to find a problem before actually modelling.
What is CAM (x4 details)?
Computer Aided Manufacturing
It is the process of making products with the help of computers.
CAD software generates the x, y, z coordinates (0,0,0 is the datum) for the CAM
CAM machines follow the CAD’s coordinates and use tools to make the design
What is subtraction in CAM machines and an example?
This is when material is removed from a larger piece to cut out the specific shape you need.
An example would be CNC milling machines.
What is Addition in CAM machines and an example?
This is when material is added to from the shape you need. (No waste).
An example would be 3D printers.
2 main types of CAM machines?
Some are 2-axis meaning they can only cut out 2D shapes.
Some are 3-axis meaning that they can also work with 3D shapes.
3 main examples of CAM machines?
CNC routers are able to cut out 2D or 3D shapes from a block of materials using a variety of different sized tools. They can be 2-axis or 3-axis machines. They can also be used to engrave things. CNC routers work in plastics, wood and metals.
Laser cutters can be used on plastic, wood, cardboard, fabrics and some metals. Cutters on high power setting can cut right through materials. But on lower power they can be used for engravings. They only work with sheet materials. They are 2-axis machines which can only cut out 2D shapes
3D printers are useful for rapid prototyping, the CAD design can be converted to a real 3D object. They can print with many materials such as plastics or wax. They are increasingly being used for final products as well.
Advantages of CAD & CAM for Global Companies (x3 points)
It is easy to send files across the world (including CAD files), this can help by saving on:
Shipping costs: By sending the designs to be manufactured near to where they are going to be sold, shipping costs are saved on.
Labour costs: The designs can be sent to be manufactured in another country to save on labour costs and then shipped back to where they are going to be sold.
The benefits of CAD & CAM include the benefits of automation as well.
Disadvantages of CAD / CAM (x3 ideas)?
The computer can be affected by malware, software problems and file corruption
What is sustainability?
Not causing permanent damage to the environment and not using up finite resources.
It can also depend on the process used to make the product. (high energy usage, pollution or waste?).
It can also differ based on the design of the product, the length of its life and how efficient it is.
What is the carbon footprint?
This is the mass of greenhouse gases emitted into the atmosphere during the making, usage, disposing (or reusing or recycling) of a product.
How does product miles affect the carbon footprint?
As product miles increases, the product travels further. This increases the energy usage for the transportation and since much of the energy is produced from fossil fuels, this increases the carbon footprint due to high emissions from more combustion.
What factors affect the carbon footprint?
The product miles it has travelled
The amount of energy used by the product during its lifespan.
The energy (or greenhouse gases produced) used to deal with the product when it reaches the end of it’s lifespan.
How can manufactures make the disposal of their products have a lower carbon footprint and be more sustainable (x3 points)?
They can use biodegradable materials which require little processing and do not cause pollutants to be released.
They can design for disassembly which will make the product easier to take apart and separate the materials in it, making it easier to recycle or reuse.
They can avoid having components made from several different materials which cannot be easily separated as this will cause recycling to be harder (or impossible).
What is planned obsolescence?
Why is this done anyway?
This is when the product is design to become useless quickly.
Hygiene: It often has to be used when hygiene is concerned, such as one-time use surgical masks to maintain hygiene.
Cost: it being cheaper to produce products that are planned for obsolescence as it they are often simpler.
Economics: Finally could be to hook you onto a supply so you keep buying (e.g. printer cartridges)
Why is planned obsolescence bad?
Because more products are made as each product is not reusable but has a limited lifespan. Making products creates a carbon footprint so that is bad.
What is built-in-obsolescence?
This is when a product gets obsolete quickly because it is made from new designs and a newer version always comes out. So it is fashionable to upgrade, such as mobile phones.
What is the term when products are designed to last?
How is this done (x2 ways)?
Design for maintenance. There are many ways to design a product so that it is durable and can be maintained throughout it’s life.
Design for Disassembly: One way is to allow easy product disassembly as this will allow internal components to be replaced more easily.
Modularisation: Another way is to use modules, for example in electronics, if the phone’s processor gets old you can just replace that to boost performance rather than the entire phone.
What is continuous improvement?
This is the process in which manufacturers are always trying to improve their products, such as by introducing new technology.
What are the negatives of continuous improvement (x2 ways)?
It encourages existing products to be replaced with new ones. This increases the waste which needs to be disposed of and new products have a carbon footprint.
Making of new products may use up finite resources or cause environmental damage across it’s life.
What are the positives of continuous improvement (x2 ideas)?
It often improves the efficiency of the product and the manufacturing, decreasing carbon footprint.
New products avoid the usage of environmentally damaging chemicals e.g. CFCs.
What can designers and manufacturers do to improve their sustainability (x8 ways)?
Improve efficiency of manufacturing process (and the product).
Avoid use of environmentally damaging chemicals e.g. CFCs.
Minimise the amount of material used in the product. This means the product use less resources and are lighter to reduces the energy usage when transporting them.
Avoid use of unsustainable materials.
Use more biodegradable and renewable materials.
Making products from recyclable materials.
Making products that are designed for disassembly.
Making products designed with a long lifespan.
What is a LCA?
Life Cycle Assessment. This is when the potential environmental impact for each stage of the life of the product.
Raw materials: Materials used to make the product and it’s packaging
Manufacture: The processes and energy used to make the product
Usage: Damage whilst using the product (e.g. energy usage)
Product disposal: The damage from disposal of the product
What are the 6Rs?
Repair: products rather than disposing them
Reuse: for other purposes or by passing the product on
Recycle: to reduce the energy usage for raw materials
Rethink: the design to make it more eco-friendly
Reduce: the waste and energy usage of the product
Refuse: to buy from a unsustainable source
What do employers have in relation to their employees?
How should they keep to this?
They have legal and moral responsibility to provide safe working conditions. This is very relevant in dangerous jobs such as farming and manufacturing.
They need to provide protective equipment for safety, a safe working environment and training on how to work safely.
What is the ETI
Ethical Trading Initiative
This is when companies sign up to agree to meet certain standards for working conditions fully across the supply chain.
What do Manufacturers have responsibility for the entirety of Mankind?
How can Governments help?
The pollutants release by manufacturing can have health impacts such as the dioxins from bleaching fibres to make paper are very toxic to animals and humans.
Manufacturers need to reduce or stop the release of such chemicals into the environment.
They can introduce legal regulations on release of chemicals into the environment ensuring that the amount released is not harmful.
What is an Enterprise (x2 details)?
This is when new business opportunities are realised and taken advantage of. There is a high risk of failure but a reward for success in the form of profit.
This can involve starting up a business or helping an existing one to expand. Both involve coming up with new ideas. An entrepreneur is someone who does that.
What is innovation?
When a enterprise or entrepreneur comes up with something new.
What is crowdfunding?
How does it differ from old fashion investment?
This involves using websites to promote an idea to a huge number of people. The masses of people choose to invest in an idea which sounds good for them with a chosen amount of money (small or large), they are called backers. These people get a reward for their investment such a discount, percentage share or a free gift.
Older methods include taking out loans from banks which are difficult and have interest on them.
What are manufacturers always trying to do (x3 points)?
Improve their product to make more profit.
This could be by reducing costs of their product and/or making it more appealing to increase sales.
This is often in response to market pull or technology push.
What is Market Pull (x2 points)?
This is when designers design stuff to appeal to the wants and needs of the target market.
Constant changing fashions and social attitudes will mean this desire will also change.
What is Technology Push (x2 details)?
This is when new technology arrives before consumers even realise the need for it.
This can drive the design of new products or improve existing ones to make them cheaper, more functional, more efficient, better aesthetically etc.
What impact does technology have on Jobs (x4 impacts)?
This is always advancing and has an impact on the jobs that are available as well.
Manual jobs have decreased due to automation and the use of machines.
Highly skilled jobs have increased such as the development of the computers has increased jobs such as designing websites, writing computer programs, computer games etc.
Nature of jobs have changed such as the introduction of satellite navigation to work out the routes for delivery drivers or a robot being used so the human does not do the task directly but ensures the robot can do it smoothly.
What is culture?
Culture of a country or a group of people covers everything from religion, beliefs, laws, language, food, dress, art, tradition etc.
What impact does technology have on Culture (x2 points)?
It can offend if not designed properly, such as if there are vegans and vegetarians in your target market, using a product made from animal products may offend them.
Technology can influence fashion and thus culture, such as the introduction of LYCRA in the 1960s.
What should designers try to do to be fair to all parts of society?
They should design to be sensitive to people’s beliefs to not cause offence e.g. putting the symbol of a religion which does not permit alcohol consumption onto a bottle of alcohol will be offensive.
Ensure that all people can equally access and benefit from the product e.g. a mobile phone app could have an option to have bigger text to allow people with poor eyesight to still use them.
What is leading the drive to use more renewable energy (x4 reasons)?
The knowledge of the damage of fossil fuels to the environment.
Knowing that the sources will eventually run out.
Improving efficiency of renewable power production making to more cost effective and attractive.
Pressure from the public to use less environmentally damaging means of energy production.
Why is energy storaged in the national grid?
Most large power stations keep running even when power demand is low, such as at night.
This leads to a surplus of energy and to prevent it from being wasted it should be stored.
What is the best way we have of storing electricity?
How does it work?
Kinetic pumped storage system.
When there is surplus energy generated by other power plants, it is used to pump water in the lower hydroelectric reserve up to the higher reserve.
This water is then let back down flowing through turbines during peak power demand to generate electricity supplementing the steady power output of other power stations.
What is another way to store energy?
What are they often used for?
What are the 2 subtypes?
Batteries, these store energy in the chemical energy store and through chemical reactions this is transferred to the electric energy store.
They are often used to power portable electronics.
Alkaline and Rechargeable batteries.
Describe the usage of the shorter lifespan type of battery (x4 details)
Alkaline batteries are normally disposable and cannot be used again when they go flat.
They are recyclable, have a long lifespan and leak less.
Their power output steadily decreases across their lifespan.
They are typically used for toys, remotes, torches and clocks.
Describe the usage of the longer lifespan type of battery (x5 details)
Rechargeable batteries can be charged when they go flat, the electricity input is used to reverse the chemical reaction that the batteries used to make electricity to allow the battery to work again.
These are more expensive than alkaline batteries but because of their longer lifespan they are cheaper in the longer run.
Their reusability make them also more environmentally friendly than alkaline batteries.
Their power output remains constant until they run out.
They are usually built into products such as mobile phones.
What is strength in a material?
What type of property is it?
Strength is the ability to withstand forces without breaking.
Working
What is hardness in a material?
What type of property is it?
The ability to withstand scratching, abrasion or denting
Working
What is toughness in a material?
What type of property is it?
The tougher the material, the harder it is to break or snap (the material may change shape slightly instead). The opposite of this is being brittle
Working
Difference between durability and toughness?
Durability is the ability of the material to withstand environmental forces for longer life.
Toughness is the resistance against impact loads or forces.
What is malleability in a material?
What type of property is it?
The more malleable a material is, the easier it is to bend and shape.
Working
What is ductility in a material?
What type of property is it?
The more ductile a material is the easier it is to be drawn into a wire.
Working
What is thermal conductivity in a material?
What type of property is it?
The better of a thermal conductor a material is, the easier it is for heat to travel through them.
Physical
What is electrical conductivity in a material?
What type of property is it?
The more electrically conductive a material is, the easier it is for electricity to travel through it. (Electrical insulators are the opposite).
Physical
What is fusibility in a material?
What type of property is it?
Materials with a higher fusibility have lower melting points so it is easier to melt them.
Physical
What is density in a material?
What type of property is it?
The density of a material is a measure of its mass per unit of volume.
Physical
What is absorbency in a material?
What type of property is it?
The more absorbant a material is the easier it is for it to gain water (even from just moisture).
Physical
What physical properties do non-metals typically have?
More brittle (less tough)
Not always solid at room temperature
Poor electrical conductors
Dull looking
Less dense
What physical properties do metals typically have?
Strong
Malleable
Good conductors of heat and electricity
Not very fusible
What is an alloy (x3 points)?
This is a metal that has been mixed with more metals and/or non-metallic elements.
They have different properties to the materials they are made up from.
They are developed to have a specific set of properties for a purpose.
What does cartridge paper physically look like?
What is it used for?
It is textured and thick type of paper.
It is high quality and used for different drawing mediums such as pencil, crayons and inks.
What does layout paper physically look like?
What is it used for?
It is thin and translucent.
It is used for sketching and developing design ideas.
What does tracing paper physically look like?
What is it used for?
It is semi-transparent.
It is used to make copies of images.
What does grid paper physically look like?
What is it used for?
It may have a square grid or an isometric grid.
Square grid is used for orthographic and scale drawings. Isometric is good for isometric drawings.
What does bleed-proof paper physically look like?
What is it used for?
Slightly textured with a white coating.
This is used when drawing with felt-tips or marker pens, to prevent the ink from bleeding.
What does solid white board physically look like?
What is it used for?
It is a high quality bleached surface.
It is used for printing on and for primary packaging.
What does inkjet card physically look like?
What is it used for?
Bright white and smooth on both sides.
It does not bleed so it is used for high quality sharp printing
What does corrugated board physically look like?
What is it used for?
This is made out of fluted inner core sandwiched between two outer layers, the liners.
It can be printed on but is is decently strong and rigid so is used for secondary packaging to protect items during transit.
What does duplex board physically look like?
What is it used for?
This board has different colour and texture on each side. It is often used when only one side is seen
Often food packaging: only one side needs to be smooth for packaging.
What does foam core board physically look like?
What is it used for?
It is made by sandwiching polystyrene foam between two layers of card. It is stiff, light and outer layer can be scored.
It’s used for making models and mounting posters.
What does foil lined board physically look like?
What is it used for?
This is a board with aluminium foil lining.
It is used to package food because it keeps flavours in, air and moisture out.
What two groups does wood come in?
Hardwoods and softwoods
What is timber?
This is sawn chunks of solid wood used as building materials.
What do softwoods tend to be like (x6 points)?
They grow in colder climates
faster growing
cheaper & readily accessible
needle like leaves
evergreen
cones for their seeds
What is pine’s properties?
What is it used for?
Yellow brown with streaks, quite strong, cheap but knotty.
Hard to work with, used for telegraph poles, fences and cheap furniture
What is larch’s properties?
What is it used for?
Yellow to reddish-brown colour. It is harder, tougher and more durable than most softwoods and is resistant to rot.
Decking, cladding and fence posts
What is spruce’s properties?
What is it used for?
Reddish-brown colour, hard and high strength to weight ratio, knotty but not very durable.
Used in structural purposes in crates, ship masts and old airplanes
What do hardwoods tend to be like (x6 points)?
Grow in warmer climates
More expensive
Deciduous
Tighter grain
Mostly harder and denser than softwoods (except Balsa & few more)
Broad flat leaves.
What is oak’s properties?
What is it used for?
Light brown, tough, durable and very strong. Attractive grain, finished well.
It does corrode steel screws and fixings. It is used in interior panelling, flooring and furniture.
What is Mahogany’s properties?
What is it used for?
Red-brown. Durable and easy to work with
Expensive and used for good quality furniture.
What is beech’s properties?
What is it used for?
Pinkish-brown. Hard enough to resist dents and can be bent using steam.
Chairs and toys.
What is balsa’s properties?
What is it used for?
White or tan. For a hardwood, very low density and very soft. Easy to shape, high strength to weight ratio.
Great for modelling.
What is ash’s properties?
What is it used for?
Pale cream colour. Tough and absorbs shock well. Attractive grain.
Tool handles, wooden sports equipment, furniture
What is a ferrous metal?
These metals or alloys contain iron. Almost all are magnetic.
What is cast iron’s properties?
What is it used for?
Very strong in compression but brittle and not malleable.
Bench vices, car brake disks, manhole covers.
What is low-carbon steel’s properties?
What is it used for?
Quite strong, cheap but rusts and cannot be hardened
Car bodies, screws, nuts, bolts, nails and washing machines.
What is high-carbon steel’s properties?
What is it used for?
Harder than low-carbon steel, can be hardened. Not as easy to work with and it rusts.
Chisels, files, saws, drills
What are non-ferrous metals?
These metals or alloys do not contain iron so do not rust.
What is aluminium’s properties?
What is it used for?
Light, corrosion-resistant, expensive, not as strong as steel (but has about same strength to weight ratio), hard to join.
Aeroplanes, cans and ladders.
What is brass’s properties?
What is brass made of?
What is it used for?
Quite strong, corrosion resistant, malleable, ductile, looks good (more hard and strong than either copper or zinc)
65% Copper, 35% Zinc
Electrical parts, door handles, taps
What is copper’s properties?
What is it used for?
Relatively soft, malleable, ductile and very good electrical conductor.
Electrical wiring, pipes
What is tin’s properties?
What is it used for?
Soft, corrosion-resistant, malleable, ductile, low melting point.
Foil, tin cans, alloying metal in solder
