Topic 1: Designing

Iterative Design

• Iterative design isn't just a straight line from start to finish. It involves going back and forth between different stages.

• It involves Briefing > Analysis > Sketching > Modeling > Testing > Evaluating > Modification

Analysis:

• Start with a design brief.

• Iterative process: test, evaluate, refine design based on findings.

Sketching Design Ideas:

• Create freehand sketches to explore solutions.

• Can be variations of one idea or explore different approaches.

Modeling:

• Create physical models from cards, paper, clay, etc.

• Provides a quick and cheap way to test initial ideas.

• Helps visualize product function and look.

Testing the model:

• Destructive testing: Push the product to its limits to identify best materials and construction methods.

• Non-destructive testing: Evaluate function and identify design flaws without destroying the model.

• Market testing: Get feedback on performance and design from the target market.

Evaluating:

• Analyze data gathered from testing (measurements, user feedback).

• Use evaluation to improve:

  • Aesthetics

  • Function

  • Safety

  • Strength

• Compare the product to the original design brief and target market needs.

Modification:

• Based on evaluation, revisit models and design ideas to improve:

  • Performance

  • Style

  • Function

  • Cost

• Avoid fixation on a single idea by:

  • Collaborating with others

  • Getting user group feedback

  • Testing the product

Design Strategies

• Designers benefit from using a diverse toolbox of strategies.

• This allows them to explore various approaches, gather valuable feedback, and ultimately create the most creative and effective solution that fulfills the project's requirements.

• Different projects might call for specific strategies to be most successful.

Collaboration for Design Feedback:

• Benefits: Gain valuable insights from diverse perspectives (taste, ideas, expertise).

• Method: Teams of designers brainstorm and develop concepts together.

User-Centered Design (UCD):

• Focus: User needs over iterative refinement.

• Process:

  • Gather user input throughout development (questionnaires, interviews, testing, observations).

  • Use feedback to continually improve the product.

Systems Approach for Complex Products:

• Application: Suitable for designing products with defined stages (input, process, output) like electronics.

• Method:

  • Define stages using block diagrams (input, process, output boxes).

  • Plan functionalities for each stage to achieve the desired outcome.

Example: Electric Piano Keyboard * Input: Pressing a key * Process: Generating the correct musical note * Output: Sound through the speaker

Note: This differs from schematic diagrams which show how electronic components connect.

Sketching and Animating

Freehand Sketches:

• Quick capture of initial ideas.

• Created rapidly without rulers or templates.

Formal Drawings:

• Precise and well-organized drawings.

• Can be hand-drawn (using rulers and squares) or created with CAD software.

• Benefits:

  • Easy to modify and share digitally.

  • Suitable for:

    • Client presentations.

    • Highlighting measurements.

    • User group feedback.

Isometric and Perspective

• Technical drawings often use isometric and perspective techniques to create a three-dimensional illusion of an object on a flat, two-dimensional page.

Perspective Drawings:

• Creates a realistic illusion of depth, with objects shrinking in the distance.

• Types:

  • Single-point: Shows an object from the front with one vanishing point on the horizon where all parallel lines converge. Often used by interior designers for room layouts.

  • Two-point: Shows an object from the side with two vanishing points, creating a more realistic view. Commonly used by architects for building sketches.

Isometric Drawings:

• Focuses on clarity and accurate measurements, not depth perception. Lines maintain the same width regardless of distance.

• Key Rules:

  • Horizontal edges are drawn at 30 degrees.

  • Vertical edges are drawn straight up and down.

  • All parallel edges remain parallel.

• Applications:

  • Showcasing object dimensions and how parts fit together.

  • Used by architects and engineers for clear communication of designs to clients and manufacturers.

Working Drawings

• Detailed instructions sent to manufacturers for product construction.

Exploded Diagrams:

• Illustrate product assembly:

  • Breakdown of components with clear separation.

  • Dotted lines indicate assembly sequence (sliding parts).

  • Reveal hidden components within the final product.

• Replace written instructions for international use (e.g., furniture assembly).

• Clearly show assembly steps:

  • Individual components separated.

  • Dotted lines indicate sliding parts and assembly sequence.

  • Reveal hidden internal components.

Orthographic Projections:

• Detailed 2D representations of a 3D object, used for production planning.

• Show each side of the design without perspective:

  • Front view as the starting point.

  • Construction lines ensure accurate alignment of side and top views.

  • Drawn to scale with dimensions for each part.

• Types:

  • First Angle Projection: Views depicted as if looking through an X-ray.

  • Third Angle Projection: View from right is drawn on the right side. (Most common)

• Standard lines are used to represent different features of the drawing.

Topic 2: Making

Minimizing Waste

• Manufacturers aim to reduce scrap material during cutting to save costs.

• Savings can be passed on to consumers through lower product prices.

Optimizing Material Usage:

• Tessellation: Arranging shapes to minimize wasted space on material sheets (e.g., wood, metal).

• Nesting Software: Automatically placing irregular shapes close together for cutting with minimal gaps (used with CAD software).

• Lay Plans: Manual layout for fabrics that consider nap (directional appearance) and limit nesting effectiveness.

Material Calculations:

• Challenges: Determining reference points can be complex for non-square shapes.

Right Equipment

• Choosing the right tools and equipment is vital for producing high-quality products.

Selection Tips:

• Research online:

  • Use search engines and instructional videos.

• Community resources:

  • Read forums and blogs for production tips.

• Consult with experts:

  • Ask experienced people or visit specialist workplaces.

• Library research:

  • Look for techniques in specialist books.

• Manufacturer instructions:

  • Consult online guides from tool companies.

Health and Safety (Everyone's Responsibility):

• Employer's duty: Ensure proper training for tool and equipment use.

• Personal protective equipment (PPE): Wear recommended gear for specific tasks.

  • Examples:

    • Heat-resistant gloves and aprons (brazing metals).

    • Goggles (chemical use, using a band saw).

    • Chainmail gloves (cutting with fast blades).

    • Thimbles (hand sewing thick materials).

    • Ear protection (noisy equipment).

Safe Work Practices:

• Common-sense practices: Tie back hair, secure loose clothing.

• Follow employer's safety rules:

  • No unattended machines.

  • Use isolating switches when changing tools (e.g., drill bits).

  • Use guards and dust extraction whenever possible.

  • Clamp down workpieces before cutting.

  • Store tools safely when not in use.

  • Obey signage regarding health and safety risks.

• Electrical safety:

  • Use Portable Appliance Tested (PAT) equipment.

Risk Assessments (Required by Law):

• Identify hazards and necessary precautions for materials, chemicals, and equipment.

• COSHH (Consideration of Substances Hazardous to Health) symbols act as a warning system.

• They indicate different hazards associated with substances covered by COSHH regulations, like the dangers of storing or using corrosive liquids (e.g., acids).

• Employers are required to provide COSHH reports for any material identified as hazardous for use.

Surface Treatment and Finishes

• Purpose: Enhance a product's look (aesthetics) and performance (functionality).

Benefits:

• Prevent corrosion, decay, UV damage.

• Protect against insects, fungus, etc.

• Improve hygiene, durability, insulation.

• Enhance decoration, color, smoothness.

Examples by Material:

• Paper & Board: Printing, coating, laminating, varnishes, embossing.

• Textiles: Stain/waterproof coatings, antimicrobial treatments, printing, dyeing, flame retardants.

• Wood: Painting, varnishing, waxing, staining, preservatives.

• Metals: Powder coating, dipping, galvanizing, electroplating, shot blasting.

• Plastics: Polishing, decals, printing.

• Electronics: Protective insulation, lacquering, lubrication.

Ways of Surface finishing:

• painting and rolling

• spraying

• electroplating

• adhesives

• sandblasting

• heat or pressure bonding

• printing

Note:

Surface prep is key:

• Ensure a clean, smooth surface for better adhesion. Roughening (keying) might be needed for some finishes. Fabrics may need pre-washing.

Application methods:

• Painting, rolling, spraying, electroplating, adhesives, sandblasting, heat/pressure bonding, printing.

Safety first:

• Wear proper PPE and follow manufacturer's instructions when applying finishes.