product design - everything

What is the raw form of metals called?

Ores.

Why must metal ores be refined?

To remove impurities and make the metal pure.

What does iron ore become after processing?

Ferrous metal.

What does aluminium ore become after processing?

Non-ferrous metal.

What are ferrous metals?

Metals that contain iron.

Why are ferrous metals prone to rust?

They oxidize when exposed to air and moisture.

What are the physical traits of ferrous metals?

Brown/muddy colour when rusted, magnetic.

How are ferrous metals extracted?

Through mining (surface or underground) and refined using a blast furnace.

What materials are used in a blast furnace?

Iron ore, coke, and limestone.

What are non-ferrous metals?

Metals that do not contain iron.

Are non-ferrous metals magnetic?

No, they are non-magnetic.

Do non-ferrous metals rust?

No, they are corrosion-resistant.

How are non-ferrous metals extracted?

Mining, refining, and electrolysis.

What aids aluminium extraction during electrolysis?

Cryolite.

What is an alloy?

A mixture of one or more metals to enhance properties.

Why are alloys made?

To improve strength, appearance, or resistance.

What is a property in material science?

A characteristic or feature of a material.

What are visual properties of materials?

Aesthetic qualities such as colour and finish.

What does "cost effective" mean?

A material that performs well at a reasonable cost.

What is hardness?

Resistance to scratches, indentations, and penetration.

What is elasticity?

Ability to return to original shape after being stretched or deformed.

What is conductivity?

Ability to transmit heat or electricity.

What is toughness?

Ability to absorb energy and resist breaking.

What is ductility?

Ability to be stretched into a wire or sheet.

What is tensile strength?

Ability to resist pulling forces.

What is compressive strength?

Ability to resist being squashed.

What is shear strength?

Ability to resist cutting or slicing forces.

What is torsion strength?

Ability to resist twisting forces.

What is malleability?

Ability to be deformed without breaking.

Why should you avoid using "strong" in product descriptions?

It is vague and non-technical.

Why should "cheap" be avoided in descriptions?

It implies poor quality; "cost-effective" is better.

What is the purpose of finishing?

To protect and enhance the final appearance of a product.

What is painting used for in materials?

Surface coating for colour and protection.

What is galvanising?

Coating iron/steel with zinc to prevent rust.

What is plating?

Applying a metal layer using electrolysis or chemical methods.

What is polymer coating?

Encasing a material in plastic for protection.

Where do most polymers come from?

Crude oil.

How is crude oil extracted?

Drilling using oil rigs and mining.

What is fractional distillation?

Separating crude oil based on boiling points.

What are natural polymers?

Polymers like PLA that are biodegradable and plant-based.

What are synthetic polymers?

Man-made polymers that are not biodegradable.

When was synthetic polymer invented?

1907.

When was PLA (biopolymer) introduced?

1989.

What are thermoforming plastics?

Plastics that can be reheated and reshaped; recyclable.

What are thermosetting plastics?

Plastics that cannot be reshaped once set; non-recyclable.

What are examples of natural fibres?

Cotton, wool, silk, cashmere.

What are examples of synthetic fibres?

Nylon, polyester, lycra, acrylic, neoprene, kevlar.

What is yarn made from?

Spun fibres.

What is thread used for?

Sewing fabrics.

What is weaving?

Stable fabric made by crossing horizontal (weft) and vertical (warp) threads.

What are the properties of knitted fabric?

Stretchy, adapts to sizes, warm, can unravel.

What is non-woven fabric?

Fibres bonded together by adhesive or pressure.

What is a blended fibre?

A mix of fibres to improve performance.

What is an example of a blended fabric?

Cotton and polyester blend (comfort and durability).

How is paper made?

Timber is shredded into pulp, cleaned, dried, and flattened.

What does GSM stand for?

Grams per square metre (weight of paper).

What are hardwoods?

Deciduous trees, slow growing, dense, durable, good aesthetics.

What are softwoods?

Coniferous trees, fast growing, used in construction, less attractive.

What is seasoning in wood?

Removing moisture to prevent warping or cracking.

What is plywood?

Multiple wood layers glued in alternating directions.

What is MDF?

Medium Density Fibreboard, made from sawdust and resin.

What is chipboard?

Compressed wood chips and glue.

What are new and emerging technologies?

Technologies that are newly developed or becoming widely used.

What is AI?

Artificial Intelligence; machines simulating human tasks.

What is VR?

Virtual Reality; digital simulation of environments.

What is an assembly line?

Linear production process involving automated machines.

What is market pull?

Demand from consumers driving product development.

What is technology push?

New technology leading to new products.

What are benefits of global production?

Cheaper labour, fast production, global distribution.

What are detriments of global production?

Exploitation, poor conditions, environmental damage.

What is CAD?

Computer Aided Design for digital product modelling.

What is CAM?

Computer Aided Manufacturing for automated production.

What is CNC?

Computer Numerically Controlled machining.

What is 3D printing?

Additive manufacturing where objects are built layer by layer.

What are the 6 Rs?

Reduce, Reuse, Recycle, Rethink, Refuse, Repair.

What are the stages of a product life cycle?

Extraction, production, distribution, consumption, disposal.

What is a circular economy?

A system focused on reusing and recycling materials.

What is a lever?

A simple machine with a pivot (fulcrum) that provides mechanical advantage.

What is a first class lever?

Fulcrum between load and effort (e.g. seesaw).

What is a second class lever?

Load between fulcrum and effort (e.g. wheelbarrow).

What is a third class lever?

Effort between load and fulcrum (e.g. tweezers).

What is a crank and slider?

A mechanism that changes rotary motion into reciprocating.

What is a gear train?

A set of gears transmitting motion and force.

What is an idler gear?

A gear placed between others to maintain direction.

What are smart materials?

Materials that change in response to environmental stimuli.

What is electroluminescent wire?

Wire that emits light when electricity passes through it.

What is QTC?

Quantum Tunnelling Composite; changes conductivity under pressure.

What is SMA?

Shape Memory Alloy; returns to shape when heated (e.g. Nitinol).

What is polymorph?

A plastic that becomes moldable at 62°C and solidifies when cool.

What is thermochromic pigment?

Changes colour based on temperature.

What is photochromic pigment?

Changes colour based on light intensity.

What is microencapsulation?

Capsules in fabric that release substances like vitamins or scents.

What is biomimicry?

Innovating by mimicking nature.

What are composites?

Materials made from two or more components for improved performance.

What is CFRP?

Carbon Fibre Reinforced Polymer, strong and lightweight.

What is GRP?

Glass Reinforced Plastic, tough and used in vehicles/boats.

What is Kevlar used for?

Body armour due to high strength and flexibility.

What are technical textiles?

Textiles designed for specific performance needs.

What are interactive textiles?

Textiles embedded with electronics.

What are microfibres?

Fine synthetic fibres with high strength and water resistance.