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Product analysis exerciseMarcel BreuerMeeks Stanton hall chairs

Cantilever chairs have no rear legs, relying for support on the tensile properties of steel tubing, the original material from which they were made. Several people can be credited with the development of this type of Bauhaus chair including the Dutch designer Mart Stam in 1926 and also the Hungarian furniture designer, Marcel Breuer (1902-1981) who is one of the most influential furniture designers of the 20th century. Breuer was the first to incorporate tubular steel into furniture design

Victorian design was typically fussy, eclectic in style (influenced from lots of eras). Excessively decorated and a bit theatrical.

• Function

• Technologies

• Materials

• Making methods

• Market

• Scale of production

• Ergonomics

• Aesthetics

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Product analysis exercise

Candlestick telephone with bakelite No 22 Microphone.

Sony Ericsson F305 mobile phone and camera.

Compare and contrast any two products that perform the same function from different eras and describe how new materials, technologies, and making methods have influenced the form of the product

• Function

• Technologies

• Materials

• Making methods

• Market

• Scale of production

• Ergonomics

• Aesthetics

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Hand and commercial processes.Joining methods

1) Refer back to unit one and be able to describe at least three typical non permanent and three permanent fixing or fastening methods along with relevant uses.2) Describe the difference between a normal screw and a self tapping screw.3) Describe where you would use the following adhesives, what are they made to glue together?a) Tensol Cement, (solvent)b) Polystyrene cement (solvent)c) Copydex or liquid latex.d) Contact adhesive such as Evosticke)P.V.Af) Epoxy resin (two part adhesive). ‘Araldite’g) Glue sticks. h) Inorganic cementsi) Silicon based adhesives and sealantsj) Which adhesive can be used to join dissimilar materials.

2) Name and describe three typical knock down fittings together with their uses. Why do some structures require temporary fixings?3) Describe the term ‘flat pack’.4) What advantages does ‘flat pack construction have for the manufacturer, and retailer

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Joining metals1) Describe using words and pictures how to:

a) Make a brazed join in mild steel.b) Make a soft soldered join in mild steel sheet or copper.c) Explain the difference between a weld and a soldered join. What difference are

their between a soft soldered join and a hard soldered or brazed join?

2) Briefly describe the processes of crimping and producing folded seams in sheet metal.

3) What advantages does seaming and folded joints possess over heat treatments for joining sheet metal.

4) Natural gas is used at the college to make soldered joins or brazed joins. What other gases are more commonly used to make welded joins which also makes a much higher temperature flame.

5) Briefly describe the processes of: a) spot welding b) seam welding.6) Give a typical use for spot and seam welding in the automobile industry, or food

storage and protection.7) Describe the process of pop riveting and give any two, typical applications.

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Ultrasonic welding

1) Describe the process of ultrasonic welding. Give three or four typical uses for the ultrasonic welding process.

Electrical welding processes 1) Briefly describe the following processes: a) Electric arc welding b) MIG and TIG welding c) Which electrical welding process would be used for joining aluminium ?

Integral fixings Describe what an integral fixing is in a moulded polymer product. (Moulded

joining areas and moulded locations for screws, clips , fastenings etc. Describe how the forming processes for polymers allows joining areas, locations for fixings and fastenings.

Task: complete the product analysis exercises into the bicycle and the saucepan

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Corrosion, decay and degradation1) Describe the term ‘atmospheric corrosion’ . What other causes of corrosion, decay,

and degradation exist? Consider friction, ultra violet light damage to polymers, 2) What are the three methods of decay and corrosion for metals. What are the only

group of metals that rust.3) Describe how an oxide layer on a metal can help prevent further corrosion.4) Name and describe the three ways in which timbers can decay.

Degradation of plastics

1) Rubbers or elastomers become brittle and crack due to oxidisation and atmospheric corrosion. 2) Describe how plastics weather and age. What problems does this cause for plastic components? What additive can be added to prevent damage from ultra violet

radiation?

Product analysis exercise 33) Complete the product analysis exercise three, Corrosion, decay, and degradation.

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Finishes and finishing processes for plastics

1) Give 5 reasons for applying a surface finish to a material or component.2) With regard to plastics, describe the term ‘self finishing’ and ‘self colouring’ with

regard to colour, surface, and surface finish.3) Describe the difference between self finishing and self colouring with regard to

moulded polymers.4) How can textures be added at the moulding process stage of plastics forming.

Finishing processes for metals

1) Name and describe the five applied barriers that can be added to metals. Suggest a use for each method.

2) Briefly describe the process of anodising, describe a typical use for anodising.3) Briefly describe the processes of the following surface protection methodsa) Dipping and spraying metalsb) Electroplatingc) Enamellingd) Paintinge) Electrostatic spray painting f) Powder coatingg) Plastic dip coatingSuggest a use for each finishing process.

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Finishing processes for timbers1) Describe the basic stages of applying a painted surface to timber,( Primer /sealer,

undercoat, top coats).2) Name and describe a typical use for the following timber paints and varnishes: a) Emulsion paint b) Exterior gloss paint c) Enamel paint d) polyurethane varnish e) Yacht varnish f) Two stage stain and varnishes. g) Danish oil, teak oil, Linseed oil

Wood preservatives1) What are the four groups of wood preservatives. What is their main purpose.2) Describe the process of tanalising, Describe the advantages of tanalising over

other wood preservative treatments or methods.

Papers and cards1) Describe two preservation, or protection methods for cards and papers.

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The over moulding process The over moulding process describes a forming technique where a second polymer

or elastomer is injected over a specific area of a component such as a toothbrush. The elastomer, (rubber like material) Acts as a hand grip. Name two products or components that would include an over moulding area or part, give reasons for your choices. T.P.E ( a thermoplastic elastomer, rubbery material) has been used as an over moulding on the body of the toothbrush. This may be done all at once in a ‘duel shot’ injection moulding process or as two separate machine cycles or mouldings. The majority of the handle is acrylic which is self finishing and self colouring as a pigment is added at the powdered material when molten. The injection moulding process is neat and accurate leaving behind no burr, sprue, or sharp edges. The acrylic handle is moulded with grooves and cavities to contain the T.P.E ‘grippy’ over mould. During the forming of the handle, the nylon bristles are moulded into the form.

Complete the product analysis 4: Finishes and finishing processes

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Properties and materials testing1) What determines the physical and mechanical properties of materials.2) Briefly describe something about the atomic structure of metals, polymers and

timbers that give them their unique properties to conduct or insulate against heat and electricity.

3) Describe why timbers are better in compression than tension (fibrous material with fibres arranged in the same direction).

4) What type of molecules are polymers generally made of5) Describe the difference between electrostatic bonds ( Van der Waals bonds) in

thermoplastics and the covalent bonds from which thermoset polymers are formed.

Materials properties and products 1) Give two examples of a product or component together with why the materials used

to make it fulfil its functional requirements. 2) Revise the physical and mechanical properties of materials (from unit one). 3) Workshop testing can be carried out for what four mechanical properties of

materials 4) Describe how each test could be carried out for each of the four mechanical

properties 5) Complete the examination style questions on page 123

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Design, environment and ergonomics1) Describe why designers and consumers must adopt sustainable design2) Describe the importance of recovering, re using, and recycling materials.3) Describe three areas in which designers and consumers can reduce the

ecological impact of a product. Fewer materials and components used in manufacture; consume less energy during manufacture and use; recovery and re use of materials

4) Describe the three R’s of sustainable design.5) Study the Eco- design improvements for a mobile phone. Complete a similar

analysis of a manufactured product and describe how it could be improved to be more eco friendly and sustainable.

6) Describe how the introduction of particular ‘smart materials’ into the production of mobile phones could make the recovery of materials easier at the end of their working life.

a) Smart metal actuators , b) smart screws, c) smart springs. Smart metals like nitinol, memoflex or similar that change size, revert to a previous shape, or expand/ contract when heated

7) Describe the advantages of using mechanical hand cranked generators to power small, electronic devices such as mobile phones.

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Ergonomics and anthropometrics1) Describe the difference between ergonomics and anthropometrics.2) What three specific areas do ergonomists study to assure successful design.

3) In what four ways do ergonomists influence design.

Anthropometrics4) What is anthropometrical data? How does this data influence the designer?5) Describe a list of ergonomic changes or improvements you would make to a product of your

choice such as over moulded grips, or dip coating to add a secure grip to a handle.

6) Complete the product analysis exercises for the mobile phone and personal stereo.

Page 128

Inclusive Design and adapted design1) Describe what is meant by the term ‘inclusive design’. How will an increasingly aged population

affect product design in the future.

2) Choose a product, system or environment you are familiar with. Through analysis; describe how the product, system or environment be improved to meet the needs of the elderly or disabled.

3) In order for design to be inclusive; what other groups anthropometric data and ergonomic needs in society need to be considered.

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Consumer safety1) Which British institution determines safety standards for manufactured products.

Draw the organisations symbol. What is its European counterpart or equivalent. Be familiar with its symbol.

2) Give an example of a specific, British Standard safety standard.

3) Choose a manufactured product, especially electrical items and identify four or five specific safety features on it. (if any).

4) Complete the exam style questions on page 132 (torch and human powered battery charger).

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Materials and components1) What four factors influence the choice of materials for a component or product such

as a drinking vessel.

2) Select a product and describe: a) The materials used in the product b) The suitability of the materials chosen for the purpose for which the product or component is intended. ( an electrical plug for example).

3) Describe the economic and practical advantages of multi cavity injection moulds.

Industrial Testing Methods1) Briefly describe the ten tests carried out on a material within industry to identify its

fitness for purpose.

2) Complete the exam style questions on page 144

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Manufacturing symbols for materials and safety

Common symbols on packaging:1. Made from recycled material;2. 100% recyclable aluminium;3. Dispose of responsibly;4. Recyclable;5. "Green Dot" – recycling paid for by producer in some EU countries (not UK);6. Recyclable steel;7. One of seven types of recyclable plastic;8. Please place in a recycling bank;9. "Recycle Now" campaign symbol

Forestry Stewardship Council F.S.C. A symbol that informs that the timber used in a product is farmed responsibly from sustainable, well managed and sustainable forests.

British Standards safety standards Kite mark

European safety standards symbol

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Symbols on thermoplasticsdescribing what type of plastic the object is made of together with its use and name. The aim of the labelling is to identify the plastic material to make recycling easier