GCSE Product Design

What year was ‘Apple’ founded?

1976

Who founded ‘Apple’?

Steve Jobs, Steve Wozniak, and Ronald Wayne

Who founded ‘Dyson’?

James Dyson

How many prototypes did James Dyson use to create the first bagless vacuum cleaner?

5,127

Define ‘egronomics’

Designing products to improve the user experience

Define ‘anthropometrics’

Anthropometry is the science that defines physical measures of a person's size, form, and functional capacities.

What lever class is this?

1

What lever class is this?

2

What lever class is this?

3

Give an example of a Class 1 Lever

Scissors

Give an example of a Class 2 Lever

A wheelbarrow

Give an example of a Class 3 Lever

A stapler

Describe what thermochromic pigments are

Thermochromic pigments change colour when their temperature changes. The term ‘thermo’ relates to heat, and chroma means colour - so thermochromic pigments change colour when they are heated up. These pigments can be mixed with paint or polymers to give the materials the same colour-changing properties as the pigment. An example of this technology is seen on colour-changing mugs or bath items for children.

What is a 'smart material’?

A material whose physical properties change in response to an input.

What is a ‘modern material’?

A material that has been engineered to have improved properties.

What is ‘graphene’?

Graphene is a single carbon layer material, which is hypothetically 100 times stronger than steel. It is hypothetical because we are yet to manufacture it in large enough quantities to prove this.

What is titanium used for? Why?

It is used in sporting and medical applications, such as replacement hip joints and high-performance bicycles. It is an excellent material for these purposes as it has a high strength-to-weight ratio and is resistant to corrosion.

What is ‘metal foam’

Metal foams are a strong but lightweight modern material produced by injecting a gas or foaming agent into molten metal. Typically, only 5-25 per cent of the foam is metal, and this allows the material to retain much of its strength but without the density or weight of solid metal. Metal foams are often used in vehicles such as planes and cars as they absorb shock effectively if the vehicle crashes.

What is an ‘LCD’?

Liquid crystal displays (LCDs) use the light-modulating properties of liquid crystals to display an image. The liquid crystals are between a liquid and solid state. When charge is applied to each liquid crystal, the shape changes to either block light or let light through. This ensures text or images display on the LCD.

How small are nanomaterials?

1 to 100 nanometres

What are ‘shape-memory alloys’?

Shape-memory alloys (SMA) are metal alloys that can remember their shape when heated. These alloys have been utilised on spectacle frames that spring back to shape if they are squashed.

What are ‘photographic pigments’?

Photochromic pigments change their properties when exposed to ultraviolet (UV) light. A well-known example would be glasses where the lenses are clear when worn inside a building, but become more like sunglasses when exposed to the bright sunlight outside. The same technology has been used in windows to prevent rooms from getting too hot in warm weather.

What is ‘QTC’?

Quantum-tunnelling composite (QTC) is an insulating rubber containing tiny particles of metal. When squashed, the metal particles meet and allow the flow of electrical current. As a result, QTC is an insulator when resting and a conductor when pressure is applied. It is often used in outdoor applications where water might otherwise damage tiny micro switches. It has been used in clothing to control smartphones and portable music players, in power tools to give variable speed controls and in touch-sensitive pads.

What two types of polymers are there?

Thermoforming and thermosetting

What type of polymer is ‘acrylic’?

Thermoforming

What are most polymers made from?

Crude oil: A mixture of hydrocarbons, mainly alkanes, formed over millions of years from the remains of ancient dead marine organisms.

What is ‘batch production’?

Where one group of identical products is made at the same time, before moving onto producing the next group.

What is ‘continuous production’?

A production method that leads to many of the same product being made, continuously.

What is ‘mass production’?

When the same product is manufactured many times.

What would a material’s ‘working properties’ relate to?

How it behaves in different environments when subjected to changing conditions, e.g. force or temperature changes.

What is ‘tolerance’?

The amount by which a measurement can vary without affecting the ability of the product to be manufactured accurately.

What is the difference between ‘thermoforming’ and ‘thermosetting’ polymers?

Thermoforming plastics can be reformed when heated, and therefore can often be recycled. Thermosetting polymers can only be formed once as they cannot be reheated and therefore cannot be recycled.

Name 4 stock forms of timber

Dowel

Planks

Logs

Sheets

Name 7 hardwoods

* beech
* mahogany
* oak
* balsa
* jelutong
* birch
* ash

Describe hardwood trees

Hardwood comes from deciduous trees with broad leaves. Hardwood trees take a long time to grow, around 60 years (sometimes up to 100). This means that they are rarely planted and are very expensive. The majority of hardwoods grow in tropical regions, such as Amazonian climates, while others grow in temperate climates such as Europe. Their growth rings are much smaller than softwood, making the grain closer.

Describe softwood trees

Softwood comes from coniferous trees with needle-like leaves that normally stay on during the winter - larch is an exception as it loses its needle-like leaves during the winter. Softwoods naturally grow in colder regions such as Alpine climates. Softwood trees grow quickly so their growth rings are wider making the grain wider. This ability to grow quickly means that softwood trees can be used for timber after 20-30 years - making them cheaper than hardwood.

Name 3 softwoods

* pine
* cedar
* larch

How are manufactured boards made?

Manufactured timbers can be made from leftover wood such as sawdust and wood chippings. This means they can be made into large sheets rather than being restricted to the size of a tree trunk. They are much cheaper than both hardwoods and softwoods and are often used in low-cost furniture.

Name 3 manufactured boards

* medium-density fibreboard (MDF)
* plywood
* chipboard

What is a ‘knot’?

A knot in timber marks where a branch once grew out on the tree. Knots often fall out from planks as they shrink, leaving a hole. It is preferable to use timber without knots, unless for a decorative purpose.

Name the 6 R’s

Reduce, reuse, recycle, refuse, rethink, repair

Name 6 finishes

* staining
* varnishing
* oiling
* waxing
* painting
* shellacking

A piece of oak costs £1,700 per m^3 and the piece to be valued is 1,000 mm × 50 mm × 250 mm. Calculate the price.

£21.25

A plank of ash will be used in the design of a guitar body. It costs £1,850.00 per m^3 and the neck design requires 650 mm × 60 mm × 55 mm. Calculate the cost of the neck section.

£3.96

Name and describe the 5 forces

* tension - a pulling force
* compression - a pushing force
* bending - forces at an angle to the material
* torsion - a twisting force
* shear - forces acting across the material

What does ‘CADCAM’ stand for?

Computer-aided design, computer-aided manufacure

What is a laminate?

A thin layer of material

What is a veneer?

A thin layer of wood

How many layers does plywood have?

An odd number, at 90º to each other

Name 7 wood joints, and list the advantages and disadvantages of each

\

What are the 3 types of paint?

Glossy matt and silk

How do wood stains work?

Wood stain is applied so that the appearance of the timber is enhanced. It is possible to buy many different wood stains that are designed to look like a different wood type. Often, pine is stained to look like a darker hardwood - hardwood is expensive, so staining a piece of cheaper timber is often a good alternative. The wood stain gives some protection to the timber, but an additional coat of varnish after staining is often a good idea.

When are oil and wax used on timbers?

Oil and wax soak into timber and can be used to enhance the natural appearance of the timber. Often kitchen worktops and chopping boards are oiled or waxed so that the surface repels water.

How is varnish used on timber?

Varnish can be applied to timber so that a shiny appearance is achieved. Varnish is usually applied in many layers so that the thickness of the varnish is more durable. Varnish can be glossy or matt depending on the type used.

What is ‘shellac’?

Shellac is a resin secreted by a beetle. Several layers are built by rubbing the polish on to create a finish called French polish. It tends to be used on expensive furniture to give it a glossy shine but can be easily damaged by heat and water.