5.1 Main Categories of Materials Available to Designers

a. Papers and Boards

Papers:

• Layout Paper: Lightweight, smooth, used for sketches and design work.

• Cartridge Paper: Thick, slightly textured, used for drawing and painting.

• Different Weights and Coatings: Ranges from lightweight tracing paper to heavyweight watercolor paper; coatings can include gloss, matte, or satin finishes.

Card:

• Carton Board: Used for packaging, thick and stiff.

• Bleached Card: Bright white, often used for printing high-quality images.

• Corrugated Card: Fluted middle layer sandwiched between two liners, used for shipping boxes.

Boards/Sheets:

• Foam Board: Lightweight, with a foam core sandwiched between paper or plastic layers, used for mounting and displays.

• Styrofoam: Expanded polystyrene, lightweight, and used for insulation and model making.

• Polypropylene Sheet: Flexible, tough, and resistant to fatigue, used for packaging and stationery products.

Laminated Layers:

• Reflective Surfaces: Layers with reflective coatings, used in safety signs and mirrors.

b. Natural and Manufactured Timber

Hardwoods:

• Oak: Strong, durable, with a prominent grain, used in furniture and flooring.

• Birch: Hard, fine-grained, light-colored, used in plywood and furniture.

• Teak: Highly durable and water-resistant, used in outdoor furniture and boat building.

Softwoods:

• Pine: Light, easy to work with, used in construction and furniture.

• Cedar: Durable, aromatic, resistant to decay, used in outdoor structures and closets.

• Spruce: Strong, lightweight, used in construction and musical instruments.

Manufactured Boards:

• MDF (Medium Density Fiberboard): Smooth, consistent, easy to shape, used in furniture and cabinetry.

• Plywood: Layers of wood veneers glued together, strong and stable, used in construction and furniture.

• Blockboard: Strips of wood sandwiched between veneers, used in doors and paneling.

c. Ferrous and Non-Ferrous Metals

Ferrous Metals:

• Iron: Heavy, strong, prone to rust, used in construction and machinery.

• Mild Steel: Iron with low carbon content, ductile, and malleable, used in construction and manufacturing.

• Stainless Steel: Alloy of iron, chromium, and nickel, resistant to corrosion, used in kitchenware and medical instruments.

Non-Ferrous Metals:

• Aluminum: Lightweight, corrosion-resistant, used in aircraft and beverage cans.

• Copper: Good conductor of electricity and heat, used in electrical wiring and plumbing.

• Tin: Soft, malleable, resistant to corrosion, used in coating other metals to prevent rust.

Alloys:

• Brass: Alloy of copper and zinc, strong and corrosion-resistant, used in fittings and musical instruments.

• Pewter: Alloy of tin with antimony and copper, used in decorative objects.

• Tin/Lead Solder: Alloy used for joining metal parts, primarily in electronics.

d. Thermo and Thermosetting Polymers

Thermo Polymers:

• PET (Polyethylene Terephthalate): Clear, strong, lightweight, used in bottles and food packaging.

• HDPE (High-Density Polyethylene): Strong, resistant to impact, used in containers and piping.

• PVC (Polyvinyl Chloride): Durable, used in pipes and window frames.

• LDPE (Low-Density Polyethylene): Flexible, used in plastic bags and film.

• PS (Polystyrene): Lightweight, used in disposable cups and packaging.

• PP (Polypropylene): Tough, resistant to heat, used in automotive parts and textiles.

• ABS (Acrylonitrile Butadiene Styrene): Tough, used in automotive parts and Lego bricks.

• Acrylic: Clear, shatter-resistant, used in lenses and display cases.

• TPE (Thermoplastic Elastomers): Flexible, rubber-like, used in grips and seals.

Thermosetting Polymers:

• Silicone: Flexible, heat-resistant, used in kitchenware and medical devices.

• Epoxy Resin: Strong adhesive, used in coatings and composites.

• Polyester Resin: Used in fiberglass and casting.

e. Textile Fibres and Fabrics

Natural Fibres:

• Cotton: Soft, breathable, used in clothing and textiles.

• Wool: Warm, elastic, used in garments and upholstery.

• Silk: Strong, lustrous, used in luxury fabrics.

Synthetic Fibres:

• Nylon: Strong, elastic, used in clothing and ropes.

• Polyester: Durable, resistant to shrinking and stretching, used in textiles.

• Acrylic: Wool-like, used in knitwear and upholstery.

Mixed/Blended Fibres:

• Cotton/Polyester: Combines the comfort of cotton with the durability of polyester, used in clothing.

Fabric Types:

• Woven: Interlaced threads, strong and durable, used in garments and upholstery.

• Non-Woven: Bonded fibers, used in disposable products and filters.

• Knitted: Interlooped threads, stretchy, used in clothing and accessories.

f. Awareness of Developments

Modern and Smart Materials:

• Graphene: Extremely strong, lightweight, and conductive, used in electronics and materials science.

• Super Alloys: High-performance alloys resistant to heat and corrosion, used in aerospace and turbines.

• Biopolymers: Polymers derived from biological sources, biodegradable, used in packaging and medical applications.

• Nano-Materials: Materials engineered at the nanoscale, used in electronics and materials science.

Composite Materials:

• Applications in Contrasting Scenarios: Combining different materials to achieve desired properties, used in construction and automotive industries.

Technical Textiles:

• Use in Various Products Based on Context: Specialized textiles with functional properties, used in medical, sports, and protective applications.

5.2 Factors to Consider When Selecting Appropriate Materials and/or System Components

a. Characteristic Properties

Each material has unique properties making it suitable for specific applications. Here are some key properties to consider:

• Density: Mass per unit volume, affecting weight and strength.

• Strength: Ability to withstand an applied force without failure.

• Hardness: Resistance to deformation or scratching.

• Durability: Ability to withstand wear, pressure, or damage.

• Strength to Weight Ratio: The strength of a material relative to its weight, crucial for applications requiring light but strong materials.

• Elasticity: Ability to return to its original shape after deformation.

• Stiffness: Resistance to bending or stretching.

• Impact Resistance: Ability to absorb energy and resist impact without breaking.

• Plasticity: Ability to undergo permanent deformation without breaking.

• Corrosive Resistance: Ability to resist chemical degradation.

• Flammability: Ability to catch fire and burn.

• Absorbency: Ability to absorb moisture or liquid.

• Fusibility: Ability to be melted and fused with other materials.

• Electrical Conductivity: Ability to conduct electric current.

• Thermal Conductivity: Ability to conduct heat.

b. The Physical and Working Properties of Specific Materials and/or System Components

1. How easy they are to work with:

   • Machinability: Ease with which a material can be cut, shaped, or finished. Materials like aluminum and acrylic are known for good machinability, making them easier to process using various tools.

   • Formability: Ability to be formed into desired shapes without defects. Metals like aluminum and polymers like ABS can be easily formed.

   • Workability: General ease of working with the material, including cutting, joining, and finishing. Wood like pine is often chosen for its workability.

   • Adhesion: How well the material bonds with adhesives. Some materials, like certain plastics, require special adhesives to bond effectively.

2. How well they fulfill the required functions of products in different contexts:

   • Performance: Suitability of the material for the intended use, considering factors like strength, durability, and resistance to environmental conditions.

   • Durability: Ability to withstand wear and tear over time. Durable materials like stainless steel and high-density polyethylene are chosen for products expected to have long service lives.

   • Suitability for Environment: Appropriateness of the material for the specific environment it will be used in. For instance, marine environments require corrosion-resistant materials like marine-grade aluminum or fiberglass.

   • Functionality: The material's ability to perform its intended function effectively. For example, rubber is chosen for gaskets due to its elasticity and sealing properties.

c. Other Factors that Influence the Selection of Materials and/or Components

1. Required functionality of the design solution:

   • Structural Requirements: The need for materials to support loads or provide rigidity. Structural steel and concrete are common choices for their strength and load-bearing capabilities.

   • Thermal Properties: Needs related to heat resistance or insulation. Materials like ceramics and certain polymers (e.g., PTFE) are chosen for high-temperature applications.

   • Electrical Properties: Requirements for electrical conductivity or insulation. Copper is widely used for wiring due to its excellent conductivity, while materials like rubber are used for insulation.

   • Chemical Resistance: The need for materials to resist chemical corrosion or degradation. Stainless steel and certain plastics like PTFE are used in chemically harsh environments.

2. Aesthetic attributes:

   • Appearance: Visual qualities like color, texture, and finish. Materials like polished marble or brushed aluminum are chosen for their aesthetic appeal.

   • Surface Finish: The final appearance after processing. Some metals and plastics can be finished to a high gloss or matte finish, depending on the desired look.

   • Color and Texture: Specific visual and tactile qualities that contribute to the overall design. Designers may choose materials that can be dyed, painted, or textured to achieve the desired effect.

   • Style and Design Trends: Current trends and styles that influence material choice to ensure the product appeals to consumers. For instance, natural wood and minimalist designs are currently popular in furniture design.

3. Environmental considerations:

   • Sustainability: The environmental impact of sourcing and using the material. Materials like bamboo are chosen for their renewability, while recycled materials reduce waste.

   • Recyclability: Ability to be recycled at the end of its life. Metals like aluminum and materials like glass are highly recyclable.

   • Energy Consumption: The energy required to produce and process the material. Low-energy materials reduce the overall environmental footprint.

   • Environmental Impact: Consideration of the overall impact on the environment, including pollution and carbon footprint. Eco-friendly materials like biodegradable plastics are chosen to minimize environmental harm.

4. Availability and cost of stock forms:

   • Material Availability: The ease with which materials can be sourced. Common materials like steel and plywood are widely available.

   • Cost: The price of materials, considering both initial purchase and long-term costs. Cost-effective materials are often chosen to keep production within budget.

   • Supply Chain Reliability: The stability of supply chains to ensure consistent material availability. Reliable suppliers ensure that materials are delivered on time and meet quality standards.

   • Standard Sizes and Shapes: Availability of materials in standard dimensions to reduce waste and processing time. Materials available in standard stock forms, like sheets, rods, and beams, simplify manufacturing.

5. Social, cultural, and ethical considerations:

   • Social Responsibility: The impact of material sourcing on communities and workers. Ethically sourced materials ensure fair labor practices and community welfare.

   • Cultural Significance: The cultural relevance of materials. Traditional materials like certain woods or fabrics may be chosen for their cultural significance in specific regions.

   • Ethical Sourcing: Ensuring materials are sourced in a way that does not exploit labor or harm the environment. Materials certified by organizations like Fair Trade ensure ethical practices.

   • Consumer Perception: How the choice of materials affects the perception of the product. Sustainable and ethically sourced materials can enhance brand reputation and consumer trust.

5.3 Why is it important to understand the sources or origins of materials and/or system components?

a. The sources and origins of specific materials and/or system components.

• Importance:

  • Understanding where materials come from helps in making informed choices about sustainability.

  • Knowing the geographical origin can influence decisions based on the environmental regulations and ethical practices of the region.

  • Helps in identifying the potential environmental and social impacts of material extraction, such as deforestation, habitat destruction, and labor conditions.

b. An overview of the processes used to extract and/or convert the source material into a workable form.

• Importance:

  • Provides insight into the various methods used to obtain raw materials and the energy required for these processes.

  • Helps in identifying opportunities to improve efficiency and reduce waste in production.

  • Understanding processes like smelting, refining, and chemical treatments aids in choosing materials that align with sustainability goals.

c. Consideration of the ecological, social and ethical issues associated with processing specific materials and/or system components to convert them into workable forms, such as:

• Mining:

  • Impact on landscapes and ecosystems due to mining operations.

  • Pollution of water bodies and soil contamination from mining waste.

  • Social issues, including displacement of communities and working conditions of miners.

• Harvesting:

  • Sustainability of methods used to harvest natural materials (e.g., logging practices for timber).

  • Impact on biodiversity and local communities.

• Manufacturing:

  • Energy consumption and carbon emissions during production.

  • Waste generation and management.

  • Ethical labor practices in manufacturing facilities.

• Transporting:

  • Carbon footprint of transporting raw materials and finished products.

  • Impact of transportation on local communities (e.g., traffic, noise, and pollution).

d. The lifecycle of specific materials and/or system components when used in products.

• Importance:

  • Lifecycle analysis helps in understanding the total environmental impact of a product from raw material extraction to disposal.

  • Enables designers to create products with longer lifespans and reduced environmental impact.

  • Encourages the development of products that are easier to recycle or repurpose at the end of their useful life.

e. Consideration of recycling, reuse and disposal of specific materials and/or system components, such as:

• Recycling and sustainability schemes:

  • Benefits of recycling in reducing waste and conserving resources.

  • Understanding different recycling processes and their effectiveness for various materials.

• Eco-materials:

  • Use of materials that are either more sustainable or have a lower environmental impact.

  • Development of new materials designed for easy recycling or biodegradability.

• Upcycling:

  • Transforming waste materials into products of higher value or quality.

  • Reduces waste and promotes creative reuse of materials.

5.4 Why is it important to know the different available forms of specific materials and/or systems components?

a. Awareness of commonly available forms and standard units of measurement of specific materials and/or system components when calculating costs and quantities, including:

• i. Weights and sizes:

  • Essential for accurate planning and costing in design projects.

  • Helps in determining the amount of material needed for a project, thus minimizing waste.

• ii. Stock forms such as:

  • Lengths, sheets, pellets, reels, rolls, rods:

    • Knowing these forms allows designers to choose the most appropriate material form for their project.

    • Helps in understanding the limitations and possibilities of different material forms.

• iii. Standard components, such as:

  • Paper and boards:

    • Used in packaging, stationery, and model making.

    • Available in various thicknesses, textures, and strengths.

  • Timber:

    • Widely used in construction and furniture making.

    • Available in various forms like beams, planks, and boards.

  • Metals:

    • Essential in construction, automotive, and aerospace industries.

    • Available as bolts, rivets, hinges, and other fasteners.

  • Polymers:

    • Used in a wide range of products from packaging to automotive parts.

    • Available as caps, fasteners, and other molded components.

  • Threads and fabrics:

    • Essential in the textile and fashion industries.

    • Available in various forms like clips, buttons, and zips.

  • Electrical components:

    • Used in electronic circuits and devices.

    • Includes resistors, capacitors, and diodes.

  • Electronics components:

    • Crucial for building and repairing electronic devices.

    • Includes transistors, microcontrollers, and other semiconductor devices.

  • Mechanical components:

    • Used in machinery and mechanical systems.

    • Includes gears, cams, pulleys, belts, levers, and linkages.