7.1 How can materials and processes be used to make iterative models?

a. The processes and techniques used to produce early models and/or toiles to support iterative designing

Iterative Models:

• Purpose: Iterative models are used to test and refine design ideas quickly. These models help in identifying potential issues and areas for improvement before final production.

• Techniques:

  • Sketching: Quick drawings to visualize ideas and concepts.

  • Mock-ups: Simple physical models using basic materials like cardboard, foam board, or paper. These are quick to produce and allow for immediate feedback.

  • 3D Printing: Rapid prototyping using CAD software and 3D printers to create detailed models for testing form and fit.

  • CAD (Computer-Aided Design): Using software to create digital models that can be easily modified and tested.

  • Toiles: In fashion, a toile (or muslin) is a preliminary version of a garment made from inexpensive fabric to test the fit and design.

7.2 How can materials be manipulated and joined in different ways in a workshop environment when making final prototypes?

a. The use of specialist techniques, hand tools, and equipment used to shape, fabricate, construct, and assemble high-quality prototypes, with exemplification of the following processes:

i. Waste Processes

1. Paper and Boards (e.g., cutting and punching)

   • Cutting: Using knives, scissors, or guillotines to shape paper and boards.

   • Punching: Creating holes or shapes using punches and dies.

   • Applications: Packaging, mock-ups, and templates.

2. Timber (e.g., sawing, drilling, and turning)

   • Sawing: Cutting timber to size with handsaws, circular saws, or bandsaws.

   • Drilling: Creating holes with drills and drill presses.

   • Turning: Shaping timber on a lathe to create cylindrical objects.

   • Applications: Furniture making, joinery, and decorative items.

3. Metals (e.g., sawing, drilling, shearing, and turning)

   • Sawing: Cutting metal using hacksaws or bandsaws.

   • Drilling: Making holes with drill bits and presses.

   • Shearing: Cutting metal sheets with shears or guillotines.

   • Turning: Shaping metal on a lathe.

   • Applications: Engineering components, automotive parts, and construction materials.

4. Polymers (e.g., sawing and drilling)

   • Sawing: Cutting plastic sheets with handsaws, bandsaws, or laser cutters.

   • Drilling: Creating holes with drill bits suitable for plastics.

   • Applications: Product casing, prototypes, and household items.

5. Fibers and Fabrics (e.g., cutting and shearing)

   • Cutting: Using scissors, rotary cutters, or laser cutters.

   • Shearing: Trimming fabrics with shears for precise edges.

   • Applications: Garments, upholstery, and textile art.

6. Design Engineering (e.g., etching)

   • Etching: Using acid or other chemicals to create designs on metal surfaces.

   • Applications: Printed circuit boards, decorative metalwork, and jewelry.

ii. Addition Processes

1. Paper and Boards (e.g., adhesion and laminating)

   • Adhesion: Using glue, tape, or adhesive to bond paper and board layers.

   • Laminating: Applying a protective layer to enhance durability and appearance.

   • Applications: Posters, book covers, and packaging.

2. Timber (e.g., adhesion, joining, and laminating)

   • Adhesion: Using wood glue or adhesives to bond timber pieces.

   • Joining: Techniques like dovetail joints, mortise and tenon, and doweling.

   • Laminating: Gluing thin layers of wood together to create stronger composite materials.

   • Applications: Furniture, cabinetry, and structural components.

3. Metals (e.g., adhesion, welding/brazing, and riveting)

   • Adhesion: Using adhesives suitable for metal bonding.

   • Welding/Brazing: Using heat to join metals (welding fuses the materials, brazing uses a filler metal).

   • Riveting: Joining metals using rivets.

   • Applications: Structural frameworks, automotive parts, and appliances.

4. Polymers (e.g., adhesion and heat welding)

   • Adhesion: Using glue or adhesives designed for plastics.

   • Heat Welding: Fusing plastic pieces using heat (e.g., hot air welding, ultrasonic welding).

   • Applications: Plastic containers, toys, and automotive parts.

5. Fibers and Fabrics (e.g., sewing, bonding, and laminating)

   • Sewing: Using needles and thread to join fabric pieces.

   • Bonding: Using adhesives, heat, or ultrasonic methods to bond fabrics.

   • Laminating: Applying a protective layer to fabric.

   • Applications: Clothing, upholstery, and industrial textiles.

6. Design Engineering (e.g., soldering)

   • Soldering: Joining metal components with a filler metal that has a lower melting point.

   • Applications: Electronic circuits, plumbing, and jewelry.

iii. Deforming and Reforming Processes

1. Paper and Boards (e.g., perforating and folding)

   • Perforating: Creating small holes or cuts to allow easy tearing or folding.

   • Folding: Bending paper or board to create shapes or structures.

   • Applications: Packaging, origami, and books.

2. Timber (e.g., steaming and pressing)

   • Steaming: Using steam to soften wood fibers for bending.

   • Pressing: Applying pressure to shape wood or create composites.

   • Applications: Furniture making, curved wooden components, and veneers.

3. Metals (e.g., pressing, bending, and casting)

   • Pressing: Shaping metals by applying pressure (e.g., stamping, forging).

   • Bending: Forming metal into angles or curves using presses or brakes.

   • Casting: Pouring molten metal into molds to create shapes.

   • Applications: Automotive parts, structural components, and tools.

4. Polymers (e.g., molding, vacuum forming, and line bending)

   • Molding: Shaping plastics using molds (e.g., injection molding, blow molding).

   • Vacuum Forming: Heating plastic sheets and forming them over molds using vacuum pressure.

   • Line Bending: Heating a line in a plastic sheet to bend it.

   • Applications: Packaging, toys, and plastic parts.

5. Fibers and Fabrics (e.g., heat treatments, pleating, and gathering)

   • Heat Treatments: Using heat to alter the properties of fabrics (e.g., shrinking, setting pleats).

   • Pleating: Folding fabric into pleats and setting them with heat or pressure.

   • Gathering: Drawing fabric together to create ruffles or gathers.

   • Applications: Clothing, curtains, and textile art.

6. Design Engineering (e.g., molding)

   • Molding: Shaping materials using molds (e.g., plastic injection molding, metal die-casting).

   • Applications: Industrial components, consumer products, and prototypes.

7.3 How do designers and manufacturers ensure accuracy when making prototypes and products?

a. The use of appropriate and accurate marking out methods, including:

i. Measuring and Use of Reference Points, Lines, and Surfaces

• Measuring Tools:

  • Rulers and Tape Measures: For linear measurements.

  • Calipers: For precise internal and external measurements.

  • Micrometers: For highly accurate measurements of small dimensions.

  • Protractors: For measuring angles.

• Reference Points: Establishing fixed points on the material to serve as a basis for measurements and alignment.

• Lines and Surfaces:

  • Datum Line: A reference line used as a starting point for all measurements on a workpiece.

  • Centre Lines: Used to align parts symmetrically.

  • Surface Plates: Flat surfaces used for marking out and inspecting the accuracy of flat workpieces.

• Techniques:

  • Marking Out: Using scribers, pencils, and markers to outline shapes and dimensions on the material before cutting or machining.

  • Using Squares: For ensuring right angles and straight lines.

ii. Templates, Jigs, and/or Patterns

• Templates:

  • Definition: Pre-made guides used to mark out shapes and ensure uniformity.

  • Uses: Ideal for repetitive shapes in processes such as sewing, woodworking, and metalworking.

• Jigs:

  • Definition: Custom-made tools that hold, support, and locate the workpiece while guiding the tool during a manufacturing process.

  • Types:

    • Drill Jigs: Ensure accurate hole placement.

    • Sawing Jigs: Guide saw blades for precise cuts.

• Patterns:

  • Definition: Full-size models of the finished product used in casting and mold-making.

  • Uses: Commonly used in metal casting to create molds.

• Benefits: Ensure consistency, accuracy, and efficiency in production by reducing the likelihood of errors and variations.

iii. Working Within Tolerances

• Definition: Tolerance is the acceptable range of variation in a physical dimension.

• Importance: Ensures parts fit together correctly and function as intended.

• Types:

  • Linear Tolerances: Specify the allowable variation in length, width, or height.

  • Geometric Tolerances: Specify allowable variations in shape, orientation, and position.

• Techniques:

  • Quality Control: Regularly checking dimensions against specifications.

  • Using Precision Instruments: Tools like micrometers, calipers, and gauges for precise measurements.

  • Adjustments: Making necessary corrections during the manufacturing process to stay within tolerances.

iv. Understanding Efficient Cutting and How to Minimize Waste

• Efficient Cutting:

  • Optimizing Material Layout: Planning the arrangement of parts on the material to maximize usage and minimize offcuts.

  • Cutting Techniques: Using appropriate tools and methods for clean and accurate cuts (e.g., CNC machines, laser cutters, precision saws).

• Minimizing Waste:

  • Planning: Careful design and layout planning to use materials efficiently.

  • Recycling: Reusing offcuts and scrap materials in other projects or processes.

  • Material Selection: Choosing materials that are easier to recycle or have a lower environmental impact.

  • Process Improvement: Continuously refining processes to reduce waste and improve efficiency.

7.4 How do industry professionals use digital design tools when exploring and developing design ideas?

a. The use of 2D and 3D digital technology and tools are used to present, model, design and manufacture solutions, such as:

Rapid Prototyping

• Definition: Quickly creating physical models using CAD data.

• Techniques:

  • 3D Printing: Layer-by-layer construction of a model using materials like plastic or resin.

  • Stereolithography (SLA): Uses a laser to cure liquid resin into hardened plastic.

  • Selective Laser Sintering (SLS): Uses a laser to sinter powdered material into solid form.

• Applications: Early-stage concept models, functional prototypes, and production-ready parts.

Image Creation and Manipulation Software

• Tools: Software like Adobe Photoshop, Illustrator, CorelDRAW.

• Uses:

  • Concept Art: Creating initial design sketches and concepts.

  • Graphic Design: Designing logos, packaging, and marketing materials.

  • Photo Editing: Enhancing and modifying images for presentations and marketing.

Digital Manufacture

• Processes:

  • CNC Machining: Using computer-controlled tools to cut, drill, and shape materials.

  • Laser Cutting: Using a laser to cut or engrave materials with high precision.

  • CAM (Computer-Aided Manufacturing): Software that translates CAD models into machine instructions.

• Applications: Custom parts, intricate designs, and precision components.

Interpretation of Plans, Elevations of 3D Models

• CAD Software: Tools like AutoCAD, SolidWorks, Rhino.

• Functions:

  • 3D Modeling: Creating detailed 3D representations of parts and assemblies.

  • Orthographic Projections: Creating 2D views (top, front, side) of 3D models.

  • Rendering: Producing high-quality images of models for presentations.

CAD, CAM, CAE

• CAD (Computer-Aided Design): Designing and modeling parts and assemblies.

• CAM (Computer-Aided Manufacturing): Planning and controlling manufacturing processes.

• CAE (Computer-Aided Engineering): Analyzing and simulating designs for stress, heat, and other factors.

7.5 How do processes vary when manufacturing products to different scales of production?

a. The methods used for manufacturing at different scales of production, including:

i. One-off, Bespoke Production

• Definition: Manufacturing a single, unique product tailored to specific requirements.

• Characteristics: High customization, labor-intensive, high costs.

• Examples: Custom furniture, bespoke jewelry, prototypes.

ii. Batch Production

• Definition: Manufacturing a set number of identical products in a series of batches.

• Characteristics: Flexibility in production, economies of scale, downtime between batches.

• Examples: Seasonal products, limited edition items, small appliances.

iii. Mass Production

• Definition: Manufacturing large quantities of standardized products.

• Characteristics: High efficiency, low unit costs, specialized equipment.

• Examples: Automobiles, electronics, consumer goods.

iv. Lean Manufacturing and Just-in-Time (JIT) Methods

• Lean Manufacturing: Minimizing waste and maximizing productivity.

  • Principles: Continuous improvement, value stream mapping, eliminating waste.

• Just-in-Time (JIT): Producing goods only as they are needed.

  • Benefits: Reduced inventory costs, improved cash flow, minimized waste.

b. Awareness of manufacturing processes used for larger scales of production, such as:

Paper and Boards

• Processes:

  • Offset Lithography: Printing technique for high-volume production.

  • Screen Process Printing: Stencil-based printing for varied surfaces.

  • Digital Printing: Direct printing from digital files.

  • Vinyl Cutting: Cutting designs from vinyl sheets.

  • Die Cutting: Using dies to cut shapes from paper and board.

• Applications: Packaging, posters, books, and promotional materials.

Timber

• Processes:

  • CNC Routers: Computer-controlled cutting and shaping of wood.

  • Sawing: Cutting timber to size.

  • Steam Bending: Softening wood with steam to bend it into shapes.

  • Lathes: Turning timber to create cylindrical shapes.

• Applications: Furniture, construction, decorative items.

Metals

• Processes:

  • CNC Milling: Precision cutting and shaping of metal parts.

  • Turning: Rotating a metal workpiece against a cutting tool.

  • Sheet Metal Folding: Bending sheet metal to form parts.

  • Pressing and Stampings: Shaping metal using presses and dies.

  • Die Casting: Molding metal under high pressure.

• Applications: Automotive parts, machinery, structural components.

Polymers

• Processes:

  • Compression Molding: Shaping polymers by compressing them in a mold.

  • Injection Molding: Injecting molten polymer into a mold.

  • Vacuum Forming: Heating plastic sheets and forming them over molds.

  • Rotational Molding: Rotating a mold while heating to create hollow parts.

  • Extrusion and Blow Molding: Forming continuous shapes and hollow parts.

• Applications: Packaging, automotive components, household items.

Fibers and Fabrics

• Processes:

  • Band Saw Cutting: Cutting fabrics using a band saw.

  • Flatbed and Rotary Screen Printing: Printing designs onto fabric.

  • Digital Lay Planning: Arranging fabric pieces for efficient cutting.

  • Industrial Sewing Machines and Overlockers: Stitching and finishing fabric edges.

  • Automated Presses and Steam Dollies: Pressing and shaping fabrics.

• Applications: Clothing, upholstery, industrial textiles.

Design Engineering

• Processes:

  • Laser Cutting: Precision cutting and engraving of materials.

  • Rapid Prototyping: Quickly creating models and prototypes.

  • 3D Printing: Creating objects layer by layer from digital models.

• Applications: Prototypes, custom parts, complex geometries.