DT theory paper

Continuous improvement

Ongoing testing, evaluating, and improving a product and its processes to make it better over time.

Lean manufacturing

Producing goods efficiently by reducing waste, saving time, and using fewer resources.

planned obsolescence

Designing a product to have a limited lifespan so it needs replacing sooner.

Inclusive design

Designing products to be usable by as many people as possible, including those with disabilities.

• Adjustable sizes

• simple controls

• ergonomic shapes

modern material

Materials developed recently to improve performance, often lighter, stronger, or more durable.

• CF

• Titanium

• PLA

• Kevlar

smart materials

Materials that change properties in response to stimuli like heat, light, electricity. In a controllable and reversible way.

• Shape Memory Alloys

• Piezoelectric Materials

• Self healing polymers

Manufacturing production techniques

• Mass production

• Batch production

• Continuous production

• JIT production

• Job production

Job production

Custom production designed to meet specific customer orders, producing one item at a time.

Mass production

High volume standardised products using automation

Batch production

Producing a set number of identical items

Continuous production

24/7 uninterrupted manufacturing. often used for items like chemicals and beverages

JIT production

Materials are delivered immediately before they are needed, reducing storage costs and waste.

Automated Production Technologies

• CAM: Utilizing CAD data to control machinery such as 3D printers, laser cutters, and milling machines.

• Flexible Manufacturing Systems (FMS): A series of automated machines that can be reprogrammed to switch between different production tasks, enhancing adaptability.

Plastic deformation

• Permanent, irreversible change in shape that occurs when a material is stressed beyond its elastic limit

• causing it to remain deformed after loading

Elastic deformation

temporary, reversible change in shape where a material returns to its original form once a load is removed

material hardness

resistance to localised external forces that result in plastic deformation, such as denting, scratching, abrasion, or cutting.

material strength

• The ability to withstand internal forces without failure (breaking, bending, or deforming)

• It measures the maximum load a material can take.

material malleability

The ability to to deform under stress (external force) without fracturing

material elacisity

ability to deform under stress (external force) and automatically return to its original shape and size when the stress is removed

Market pull

• Market pull is innovation driven by consumer demand and identified market needs

• Examples: Cameras becoming smaller and integrated into phones, electric cars due to environmental demand, and improved medical diagnostic tools.

• Pros: High likelihood of market acceptance and faster adoption, as the demand already exists.

• Cons: Often leads to incremental, minor innovations rather than disruptive ones.

Technology push

• technology push is innovation driven by new scientific discoveries or R&D, pushing new products into the market

• Examples: The internet, lasers, and artificial intelligence, which were developed without a direct initial consumer request.

• Pros: Potential for radical innovation, competitive advantages, and the creation of entirely new industries.

• Cons: Higher risk of failure if the market is not ready or has no need for the technology.

Standard component

pre-manufactured parts created to set specifications and dimensions, readily available for use in manufacturing to ensure consistency and speed up production. Can be easily replaced and readily available.

• M5 screw

• Dowel

Anthropometrics & ergonomic

• Ergonomics: science of designing products, systems, or processes to fit the user, enhancing comfort, safety, and efficiency.

• It relies on anthropometrics: the scientific measurement of the human body (size, weight, reach) to ensure products fit the target population

Ferrous metal

A metal/alloy that contains iron

• Magnetic

• Vulnerable to rust and corrosion

Non-Ferrous metal

materials that do not contain iron

• Resistant to rust and corrosion

• Non magnetic

Thermo-forming polymers

• plastics that soften when heated and harden when cooled

• Makes them easily reusable

Prototyping

• Creates waste in the prototyping stage

• significantly reduces waste by validating designs before mass production

• 3D modelling, CAD simulations, cardboard modelling, scaled down products

Polymer modification

• Reinforcements: Adding fibres (glass, carbon ect)

• Cross-linking: Turning thermoplastic into thermoset through irradiation (electron beam) increases heat resistance.

Polymer manufacturing techniques

• Injection moulding

• Extrusion

• Blow moulding

• Vacuum forming

• 3D printing

Wood modification

• Thermal Modification (Heat Treatment): resulting in a durable, stable, and rot-resistant product with a dark, rich color.

• Chemical Modification: Modifies the wood's cell structure to improve stability and prevent moisture absorption, making it highly rot-resistant.

• Impregnation: Fills the wood's voids with substances to increase density, hardness, and wear resistance

• Kiln drying: removes moisture

Wood manufacturing techniques

• CNC

• Laser cut

• Cutting/joining

Metal modification

• Alloying

• Forging: strengthened grain structure

• Painting to reduces rust/corrosion

• Electroplating

Metal manufacturing techniques

• Casting: Liquid metal is poured into a hollow mold

• Rolling: Thin sheets of metal

• Extrusion: Pushing heated metal through a die to create long, continuous shapes

• CNC, Laser, water jet, electron beam

• Cutting/bending

• Electroplating

jigs

A jig is device used to hold a piece of material and guide cutting tools and they are used to ensure the process can be repeated accurately and to a high quality

Patterns

A pattern is a collection of shapes (similar to a template) that are attached to the surface of the material to aid shaping it.

Templates

a tool used to mark out shapes repeatedly.

Life Cycle Assessment

a scientific methodology used to evaluate the total environmental impact of a product, process, or service across its entire lifespan