Product Design

Revision:

Mr Edward P Rowberry – Handsworth Girls Academy

Head of Faculty

What is a Design Brief?

A design brief describes what is required of a design. It is a general

description of what the design should be, such as:

Who will use the product,

The standard that will be aimed at in the design and manufacture of

the product,

The materials that the product should be made of,

The processes that might be used to make the product,

How much the product should cost, etc.

What is a Specification?

The specification describes precise details of a design, including such things as materials, dimensions, tolerances, quality, any important safety features, finish, etc.

A specification may have essential elements to it – this is the primary specification

A specification may also have desirable elements to it – this is the secondary specification

ACCESSFMM

{Specific}ation

How to write a GCSE specification?

When writing an evaluation try remembering the following as a prompt.

A.C.C.E.S.S.F.M.M

A – Aesthetics C – Cost

C – Customer

E – Environment

S – Size S – Safety

F – Function/Form

M – Materials

M – Manufacture

Simply write about your product/design

and relate it to each letter of the

acronym.

You must, either at the end or during,

include YOUR OWN opinion. What Went

Well & it could be Even Better If…

Research

What is research?

“the systematic investigation into and study of materials and sources in order to establish facts and reach new conclusions” www.google.com/dictionary

Research helps you understand your brief. It helps you to generate

ideas to meet your brief. It helps you by showing you existing products,

seeing how things work or what other people (target audience) like or

dislike. It is paramount to a successful design solution. Mr Rowberry, Handsworth Girls Academy

Methods of Production

Mass Production • Quantity of 10,000+ • Cars • Electronic goods – phones, kitchen electrical • Flat-pack furniture Batch Production • Quantity low 100’s, maybe low 1000’s • Pottery • Bread • Furniture (sofas) One-Off Production (Bespoke) • Quantity of 1 • Jewellery • Made to measure suit • Specialist equipment for elite sportsman

Methods of Production: One off Production

One-Off Production is where you make a single (1) product.

This is often made to an individual design for one customer, such as

„custom-made‟ furniture.

One-off products are often made by hand by skilled craftsmen.

One-off products are normally expensive, because of the amount of time

taken to make them.

Summary:

Products are highly specialised, custom built

High level of skill required

Costs extremely high

Can reliability ensure very high quality of build and finish

Scales of Production: Batch Production

Batch production makes small quantities, from a few hundred to a few

thousand, depending on the type of product.

Each batch of products will have the same design. However, different batches

might be customised in some way. For example, the same design might be

made in a different colour or size.

Batch production normally uses machine tools, and costs less to make

products than with one-off manufacture, because you don‟t have to spend as

much time setting up machines to make each product.

Summary: • Products are produced intermittently – with gaps between production

• Relatively small volume produced

• Uses some industrial methods, and makes good use of CAD/CAM

• Responds to demand from consumer

• Systems are often flexible (make more than one version or type)

Scales of Production: Mass Production

Mass production makes very large quantities of the same product. Most things that you use every day are mass produced.

Mass production is usually carried out on an assembly line. This is a collection of machines, often robots, that are just used to make that product. Each machine will just do one thing to the product, before passing it on to the next one.

The cost of setting up a production line is very high, so you have to make large quantities of a product to pay for it. Machinery and tooling is often very expensive and specialist.

Summary:

• Products are produced at high volume, cheaply.

• Increased automated systems

• Huge investment needed. Initial set up costs high…long term cost low

Scales of Production: Continuous

Continuous production is used to make products like steel, oil or chemicals.

Many of these products are used as the materials to make other products.

Factories that operate continuous production often run 24 hours a day, seven days

a week. The process needs to be continuous because it would be very expensive

to stop it and then turn it on again.

JIT is when a factory orders in and uses only the materials

they need, when they need them.

Stock is kept to a minimum with products being only

produced when the demand is there for them, warehouse

costs are therefore reduced.

Bulk deals and reliance upon materials and deliveries.

http://www.bbc.co.uk/learningzone/clips/just-in-time-practice/368.html

Just In Time (JIT)

What can we remember?

What is Mass production?

What is batch production?

What is one off production?

What is continuous production?

What is JIT?

Can you give examples of each type of production?

Health & Safety

A series of procedures and regulations put in place

in workshops and industry to ensure the safety of

workers and the general environment of the

facility. This involves controls over hazardous

substances, machines and equipment.

Risk Assessments are done in industry to control a

production process and ensure there are

measures put in place to keep encourage safe

working and to have plans in place if anything

does go wrong.

Signage is used to help notify and warn people of

hazardous equipment, substances or areas, and

can also serve as a reminder to wear PPE.

(Personal Protective Equipment)

Health & Safety

COSHH Regulations

Most manufacturing plants use substances, or products that are mixtures

of substances. Some processes create substances. These substances are

identified and monitored.

COSHH Regulations are a good example of how to apply Health and

Safety.

TIP: Think of hazardous substances in DT!

Product Life Cycle

1) Extraction of Raw

Materials

2) Manufacture 3)Transportation

4) Retail

5) Usage

Recycle or Reuse or Remanufacture

6a) Incinerate

6b) Landfill Energy Used

A products life cycle is

not just how long it will

last before it wears out.

A life cycle is concerned

with every stage of a

products life as shown

right.

We can work out the

environmental impact of

a product by looking at

what is used up from the

extraction of raw

material through to its

disposal.

Product life cycles

“How long is a products life cycle?”

This depends on several factors: • Changes in materials and technology (often

known as TECHNOLOGY PUSH)

• Changes in consumer demands( often known

as the DEMAND PULL).

• Sales (is the product selling ).

• What the product is.

• How technically complex the product is.

The overview:

The life cycle is the description of the

stages that a product has to go through

during its life. From raw materials

extraction, to manufacture, use and final

obsolescence and therefore disposal.

Planned Obsolescence

Some companies deliberately plan to keep the lives of their products short. They aim

to produce new products before the previous one reaches its maturity.

Such companies advertise their products to consumers so that they believe that they

must have the latest version of the design.

“THIS IS CALLED PRODUCT CHURNING.” This is mainly found within the field of electronics.

Companies product churn because?

• To maintain a steady volume of sales

• To maintain a market advantage over their competitors

As a result of technological advancement, e.g. developments in microelectronics

“Some products have to have built in obsolescence” these are usually for health and safety

reasons, for example, the hypodermic syringe or disposable razor.

Other products do have the ability to last longer but may be restricted by cost e.g. if

the correct material were to be used to make it last longer by not corroding then it

would be too expensive for the target market.

You have 2 minutes to come up with as many products that you think this applies to?

http://www.technologystudent.com/prddes1/plannedob1.html

Product Life Cycle

1) What are the 4 different stages of product growth?

2) What is meant by planned obsolescence?

3) What is meant by product churning?

4) What type of products normally have planned

obsolescence?

5) Any idea what a market trend is?

Famous Designers

Johnathan Ive

Phillipe Starck

Modelling your designs helps

develop an idea into a tangible

3D & realistic prototype.

It allows you to see what your

intended product MAY look like.

Modelling materials

include Card, Foamboard,

Styrofoam, Blockboard/

modelling board.

Modelling

Automation in industry

Quality Control & Quality Assurance.

What is it?

• Quality Control: a check made to ensure that a component meets the

specification a manufacturer has set. For example: correct shape, size

or colour.

• Quality Assurance: A complete system of ensuring quality control

checks are carried out correctly throughout the manufacture of a

product.

Quality Control & Quality Assurance.

Examples of QC:

o Measurement checks

o Process checklists

o Sign in/sign out of tools (to ensure

they don‟t get left in a car

engine for example!)

o Product testing

o Visual checks

o Use of CAD/CAM

o Use of templates, jigs or gauges

Examples of QA:

o Paperwork – sign off

sheets/checklist

o Systems where certain staff

are responsible for certain

parts/jobs. Traceability.

o On-going staff training

programmes

o Supervisors overseeing staff

checking procedures

o Standard symbols awarded

to approved products

(CE symbol or BSI kitemark)

Quality Control & Quality Assurance.

Benefits of applying QC and QA checks to the manufacturer are:

1. Standard and consistent quality parts reduce manufacturing costs

2. Makes production run more efficiently

3. Reduces the risk of incorrect or bad quality parts being made

4. Allows products to get approval for sale to the public

5. Improves safety standards in production

6. Workers standards and “manufacturing pride” increases

And the benefits to the consumer?

“I would be reassured of the quality and know that the product will be safe to use.”

“I would be encouraged to buy from the same company again and again.”

“I can hold somebody to account if something does go wrong.”

Quality Control & Quality Assurance.

The BSI mark is the

body that tests

products against

criteria to approve for

sale.

Companies have the

option to apply for

approval from the

Energy Saving Trust to

help sell products

The CE symbol is like

the BSI mark, and

reassures European

consumers that the

product is safe

This symbol shows

that toys meet

strict British safety

and advertising

standards.

Metals:

The more the reactive the metal the higher the temperature needed to

extract it from its ore. Copper needs 1100°C but iron requires 1500°C. A

metal like Aluminium cannot be extracted by smelting. It is dissolved in a

„cryolite solution‟ and electrolysed (electricity is passed through) at a

temperature of around 650°C.

Metals:

A few metals can be mined from the earth as pure metals. These

include gold and some small amounts of copper and silver.

Natural Gold Silver ore Copper ore

Metals: Non Ferrous/ Ferrous

Non-Ferrous Metals do not contain iron. There are many

different metals that fall into this group.

An Alloy is a material of a mixture of metals or a metal and

a non metal intermixed. Metal alloys have advantages. The

alloy may contain the properties of two or more metals or

other elements.

Ferrous metals are those which are iron based. They

contain Iron and carbon in varying amounts

Metals – Ferrous (High Carbon Steel)

High Carbon Steel is often referred to as Tool steel contains 0.6 - 1.5% Carbon. It is

very hard and is used to make tools such as metalwork files and saw blades.

Metals – Ferrous (Mild Carbon Steel)

Mild Steel is very tough, can be bent or twisted and can resist strong

impacts without breaking. It is easy to weld. Mild steel is used to make

washing machines, construction girders, nuts and bolts and nails. It

contains between 0.15 – 0.35% carbon.

Metals – Ferrous (Stainless Steel)

Stainless Steel Contains about 1% carbon. It also contains other metals,

mainly chromium. There are over 200 different types of Stainless Steel.

They contain a minimum of 11% chromium and also contain nickel.

Manganese is another metal often included. Stainless steel is often used

for medical instruments, kitchen surfaces and pots and pans as it resists

scratching and biofouling.

Metals – Ferrous (Iron)

Wrought Iron is the most pure iron, containing few imperfections. It is

difficult to cast although it makes excellent material for forge work

because it is tough. It has less than 0.1% carbon. It is used for gates and

railings

Metals – Non Ferrous (Copper)

Non-Ferrous Metals do

not contain iron. There

are many different metals

that fall into this group.

Copper is strong and

resists wear and shock. It

is ductile and malleable

and can be joined

easily. It is an excellent

conductor and resists

biofouling although it is

rather expensive

Metals – Non Ferrous (Aluminium)

Aluminium Pure aluminium is

malleable and ductile but has a low

tensile strength (aluminium foil). To

improve strength it is usually alloyed

with copper or magnesium. Because

it resists corrosion it is used extensively

outdoors in satellite dishes and

window frames. Aluminium is very

light metal and has a density a 1/3

that of copper and steel. It is a good

conductor of heat and electricity.

Aluminium alloys are

used extensively in

the aircraft industry

and in motor cars.

Approx 150,000

million aluminium

cans are produced

every year.

Metals – Non Ferrous (Lead)

Lead is a metal that was

once in common use for

plumbing, roof flashing

and car batteries. It has

been replaced by

copper, plastics and

alloys in many cases but

is still used in car

batteries. Lead is a soft

malleable metal. It is also

an accumulative

poison.

Metals – Non Ferrous (Titanium)

It has a low density and is a strong, lustrous, corrosion-resistant (including

sea water, some acid attack and chlorine) transition metal with a silver

color.

Titanium can be alloyed with iron,aluminium, vanadium, molybdenum,

among other elements, to produce strong lightweight alloys for aerospace

(jet engines, missiles, and spacecraft), military, industrial process (chemicals

and petro-chemicals, desalination plants, pulp, and paper), automotive,

agri-food, medical prostheses, orthopedic implants, dental and

endodontic instruments and files, dental implants, sporting goods, jewelry,

mobile phones, and other applications.

The two most useful properties of the metal form are corrosion resistance

and the highest strength-to-weight ratio of any metal. In its unalloyed

condition, titanium is as strong as some steels, but 45% lighter.

Metals – Non Ferrous (Zinc)

Zinc is usually used to coat steel

because of its resistance to

corrosion. Steel coated with zinc

is said to be galvanised. Zinc is

also use in the manufacture of

protective paints.

Metals – Non Ferrous (Tin)

Tin was used in the past to make

brass. Today it is used mainly as an

addition to alloys to increase

strength and resistance to

corrosion, as well as changing their

appearance. Tin plate is not tin

but steel with a thin protective

layer of tin. Other alloys of tin are

pewter (Tin, copper and

Antimony) and soft solder (Tin and

Lead) which is used to join

electrical components

Pewter tankard Tinplate

Soft Solder

Metals – Alloys (Brass)

Brass is an alloy of copper and Zinc.

Copper is malleable, resists corrosion

and is a good conductor of electricity.

Zinc is hard but brittle. Brass is used in

musical instruments, Valves and in

electrical plugs and sockets.

An Alloy is a material of a mixture of metals

or a metal and a non metal intermixed.

Metal alloys have advantages. The alloy

may contain the properties of two or more

metals or other elements.

Plastics

A polymer is a material made up of loooooong

chains of molecules. You know this material as

“plastic”

There are two types:

Thermoplastics : These plastics have generally

more plasticity than the other kind, making them

flexible but strong.

They can be remoulded and are recyclable.

Thermosetting: These plastics are very rigid due to

crosslinks between the molecules. These are

impossible to reuse.

(Plasticity is the ability of the

polymer chains to be stretched

out.)

(Crosslinks make the chains

REALLY strong.)

Plastic Moulding Methods

Objectives:

o To learn about the 4 main polymer manufacture methods

o To look at examples of products made using them

o Understand the main stages

o Identify good points and bad points about each process

Plastic Moulding Methods

How are these made?

Plastic Moulding Methods

(Injection Moulding)

4.The screw winds back and the hydraulic ram comes forward into position.

5. The mould is closed and sealed as the ram forces the melted plastic into the mould.

6. The plastic is allowed to cool and the halves of the mould release.

7. The “sprew” is machined off.

1. Plastic granules are fed into the hopper.

2. The screw in the chamber below the hopper sends the granules forward.

3. Heated jackets around the screw melt the polymer.

Plastic Moulding Methods

(Vacuum Forming)

How are these

made?

Plastic Moulding Methods

(Vacuum Forming)

1. The mould is placed

into the former.

2. A sheet of thermo-

softening plastic, such

as HIPS is clamped

over the mould.

3. The plastic is slowly

heated to become

soften.

4. The mould is raised and the air is sucked, drawing the plastic over the

mould to take on it‟s shape.

5. The plastic is allowed to cool and then removed from the mould.

6. The edges must then be trimmed and finished.

Plastic Moulding Methods

(Extrusion)

How are these made?

Plastic Moulding Methods

(Extrusion)

1. A motor turns a thread which

feeds granules of plastic

through a heater.

2. The granules melt into a

liquid which is forced through

a die, forming a long 'tube

like' shape.

3. The extrusion is then

cooled and forms a

solid shape.

4. The shape of the die

determines the shape

of the tube.

Plastic Moulding Methods

(Blow Moulding)

How are these

made?

Plastic Moulding Methods

(Blow Moulding)

3. Mould is clamped shut, leaving only a small hole for the air

hose.

4. Air is forced into the mould at high pressure. The plastic is

forced to the mould sides and cools.

1. Mould is opened into it‟s

two halves. A hollow tube

of polymer known as the

parison is heated.

2. The parison is loweredinto

the mould.

Plastic Moulding Methods

Spot Test…..

Vacuum forming Test…

Put these images into the correct sequence.

Woods & Joining methods

Manufactured Boards, Composites &

Joining methods

o Definition of a composite – when two or more materials are combined

through bonding they form a composite.

o Composites are materials that have improved mechanical and

physical properties.

o Most composites will have high weight to strength ratios.

There are three main groups of composite materials:

• Fibre reinforced composites

• Particle-based composites

• Sheet based composites

The most important of these are the fibre-reinforced composites, as these

are most commonly used in products.

Fibre Based Reinforced Composites

General characteristics of fibre-reinforced composites:

• Good strength to weight ratio (ie. Light in weight with low density

and strong compared to their weight).

• Resistant to corrosion

• Good fatigue resistance

• Low thermal expansion.

Particle based Reinforced Composites

Sheet based Reinforced Composites

Smart Materials & Joining methods

Smart materials are reactive materials.

Their properties can be changed by exposure to stimuli or input, such as

electric and magnetic fields, stress, moisture and temperature.

They react to environmental conditions.

Smart Materials Thermo chromic Pigments

Pigments that change colour with temperature

Useful on marketing materials

Interesting gimmicks !

Has your egg been hot enough

for long enough?

A 2D

temperature

gauge

And this

Smart Materials: Photochromic & Electrochromic

And this

Photochromic inks and materials darken as the light level

increases.

Some photochromic materials and inks change colour. In

fact, it is UV light that causes the darkening of the ink or

material, which means the ink or material works best in

natural light.

This special ink or material has two main applications;

sunglasses and spectacles. It is also used as a security

marker that can only be seen in ultra violet light.

Smart glass or switchable glass is glass or glazing whose

light transmission properties are altered when voltage,

light or heat is applied.

Smart Materials: Polymorph

And this

Polymorph is a thermoplastic material that can be shaped and

reshaped any number of times.

It is normally supplied as granules that look like small plastic beads.

In the classroom it can be heated in hot water and when it reaches 62

degrees centigrade the granules form a mass of „clear‟ material. When

removed from the hot water it can be shaped into almost any form and

on cooling it becomes as solid as a material such as nylon.

Smart Materials: Shape Memory Alloy

And this

For most materials, if they are bent out of shape, they stay that way (plastic

deformation). However, if a part made from a shape-memory alloy (SMA) is

bent out of shape, when it is heated above a certain temperature it will

return to its original shape.

This property makes it useful for making spectacle frames - they return to their

original shape if they are put in hot water after bending

Dental braces are made

of Nitinol wire they exert

a constant force on the

teeth to return the teeth

to their correct position

Modern Materials Modern Materials are those that generally have been discovered

and used within the last century. They do not react to their

environment like smart materials.

Titanium

Components

for armour

piercing

ammunition

Some mobile

phone cases.

Hip Replacements

The two most useful properties of the metal are corrosion resistance and the highest

strength-to-density ratio of any metallic element. In its unalloyed condition, titanium

is as strong as some steels, but less dense. Titanium can be alloyed with other

elements, to produce strong, lightweight alloys for aerospace and spacecraft,

medical prostheses, orthopaedic implants, dental and endodontic instruments and

files, dental implants, sporting goods, jewellery, mobile phones, and other

applications.

Modern Materials: Precious Metal Clay

Metal clay is a crafting medium consisting of very small particles of metal

such as silver, gold, bronze, or copper mixed with an organic binder and

water for use in making jewellery, beads and small sculptures.

Metal clay can be shaped just like any soft clay, by hand or using moulds.

After drying, the clay can be fired in a variety of ways such as in a kiln, with

a handheld gas torch, or on a gas stove, depending on the type of clay

and the metal in it. The binder burns away, leaving the pure sintered

metal.

After drying, the model is heated

to burn away the binder that

contains the metal particles

Modern Materials: Kevlar

Currently, Kevlar has many applications, ranging from bicycle tyres and

racing sails to body armour because of its high tensile strength-to-

weight ratio; by this measure it is 5 times stronger than steel. It is also

used to make components that need to withstand high impact. When

used as a woven material, it is suitable for mooring lines and other

underwater applications.

A Kevlar

weave

Body armour

Car tyre with

Kevlar weave

inserts for

strength

Canoe made with fibreglass and

Kevlar composite construction.

Modern Materials:

Glass Reinforced Plastic (G.R.P)

Fiberglass is a strong lightweight material and is used for many

products. Although it is not as strong and stiff as composites based on

carbon fibre, it is less brittle, and its raw materials are much cheaper. Its

bulk strength and weight are also better than many metals, and it can

be more readily moulded into complex shapes.

Applications of fiberglass include aircraft, boats, automobiles, bath tubs

and enclosures, swimming pools, hot tubs, septic tanks, water tanks,

roofing, pipes, cladding, casts, surfboards, and external door skins.

Modern Materials: Carbon Fibre

Carbon fibres are usually combined with other materials to form a

composite. When combined with a plastic resin such as epoxy and wound

or molded it forms a carbon-fibre-reinforced polymer (often referred to as

carbon fibre) which has a very high strength-to-weight ratio and is

extremely rigid although somewhat brittle. The fibre glass weave is soaked

in liquid plastic, and then pressed or heated until the material fuses

together. The angle of the weave, as well as the resin used with the fibre,

will determine the strength of the overall composite. The resin is most

commonly epoxy, but can also be polystyrene. products made of carbon

fibre include:

High-end automobile components

Bicycle frames

Fishing rods

Shoe soles

Baseball bats

Standard Components

Standard or pre manufactured components simply make manufacturing

products simpler.

Imagine making a cabinet and having to manufacture all the screws as well.

Imagine baking 1000 cup cakes and having to make all the icing and roll it

before hand. Imagine making a coat and rather than just sewing in a zip you

purchased in bulk to reduce the cost you have to make the zip first.

Standard components are items such as screws, nails, zippers, pre rolled

icing. This helps the manufacture ensure accuracy and quality of each

product made (QA) it helps speed up the manufacturing process.

Make a list of as many different pre manufactured/standard components as

you can think of?

Tools & Equipment - You need to know a range of tools and

equipment and what each one is used for.

Scribe

Used for marking on metal

Engineers Square

Measure right angles in metal

Centre Punch

Marks metal ready for drilling

Hacksaw

Cuts larger sections

of metal

Junior hacksaw

Cuts thinner sections o metal

Tap / Tap wrench

Used for cutting an

internal thread

Die / Die holder

Used for cutting an

external thread.

Tools & Equipment - You need to know a range of tools and

equipment and what each one is used for.

Chisel Used to remove pieces of wood by cutting into the wood through

pressure.

Rasp/File Used to reduce the material. A

rasp is for wood & a file is for metal.

Soldering Iron Used for melting solder in order to add a one metal object to another.

Tenon Saw Used to cut/saw wood and manufactured board. A Tenon saw is for straight cuts.

Try Square Used to draw straight lines onto the material.

Metal Vice Used to hold your metal work whilst cutting o filing etc…

Claw/Ball Pein Hammer Used to knock in nails, remove nails, planish metal.

Claw/Ball Pein Hammer Used for cutting wood & manufactured board in a curved line

Use of data (Excell)

CAD/CAM & ICT

Sustainability: Starter

Working in small groups - look at the two products that you‟ve been given

in class (or the bags below).

Make a mind map of all the positives and negatives of each bag

Make a list on your worksheet of the design specifications that you think

the designer followed to design the three products.

Sustainability: 6R’s

We use so much and so many materials.

Many of the products we use daily are from materials that are in scarce

supply and are non-renewable.

If everyone in the world used as any resources as we do in the UK, we‟d

need approximately 3 planets to sustain us.

Big issues…

Many products use a lot of energy to;

Process materials and produce

Transport

Use and dispose

The energy used throughout the product „lifecycle‟ releases carbon

dioxide, which contributes towards climate change.

Sustainability: YOU MUST KNOW THESE

RETHINK: Do we make too many products? Design in a way that considers people and the environment.

REFUSE: Don‟t use a material or buy a product if you don‟t need it or if it‟s bad for people or the environment.

REDUCE: Cut down the amount of material and energy you use as much as you can.

REUSE: Use a product to make something else with all or parts of it.

RECYCLE: Reprocess a material or product and make something else.

REPAIR: When a product breaks down or doesn‟t work properly, fix it.

Packaging Logos: Lets see what you know?

Adhesives: Lets see what you already know?

Health & Safety Symbols

Drawing Systems: Lets see what you already know?

Isometric

Orthographic (1st & 3rd)

Oblique