Transcript Focused Practical Task 1: Plastics

Exam Preparation
Your exam is NOT just remembering FACTS. It is a DESIGN EXAM
• The Final exam is worth 40% of the final GCSE
• It will be 2 hours and is marked out of 120marks
• That works out to 1 minute per mark
• Your Unit 1 Final Exam is on Monday
22nd June
• Section A of the paper (the first bit you do) is a THEMED
question.
• The Exam Board issues “Preliminary Material” that tells us what
the theme of Section A will be. We can then Research & Prepare
Section A – What to expect
This year the Preliminary Material gives this information:
Context: Pattern and Structure found in
nature can inspire the design and
manufacture of products.
That gives you TIME to research and prepare to answer a DESIGN
QUESTION in Section A that will definitely be related to Pattern
and Structure found in nature
Section A – Initial reaction
Context: Pattern and Structure found in nature can
inspire the design and manufacture of products.
What could this mean? What might you be expected to do?
Jot down (and sketch?!?) as many ideas as you can think of in the
following 2 categories
Natural
Patterns
Natural
Structures
Section A – Practice Question: 30 mins
This question is about Designing a coffee table based on
the natural form of a tree
1 (a)
Complete a 5 point Design Specification
for things that such a coffee table
MUST DO. One has been done for you:
1. The coffee table must safely hold hot drinks cups, remote
controls and magazines securely, and safely to prevent accident
or injury.
2. The coffee table must…
3. The coffee table must…
4. The coffee table must…
5. The coffee table must…
(8 marks)
Section A – Practice Question: 30 mins
1 (b) On one side of plain A4 paper,
Design a coffee table that is inspired
by the natural form of a tree
Marks will be given for:
• A creative solution that shows clear inspiration from the natural
form of a tree
• The construction of the coffee table to securely hold the cups,
magazines and remotes safely
• The material used to make the coffee table
• The surface finish of the coffee table to prevent the material
from being damaged
• Ergonomics to ensure the coffee table’s ease of use.
• Dimensions.
(15 marks)
Section A – Practice Question: 30 mins
1 (c) Evaluate how well your design
Performs the following functions:
• Securely and safely hold cups, magazines and remotes
• Function ergonomically so that it is easy to use
• Be durable to function without damage after continued
use.
(6 marks)
Technology Push
• Advances in technology are used to produce new products.
• Inspiration for new products comes from research and
development labs.
• An innovation based upon a new invention and a
perceived market need.
Market Pull
• Inspiration for new products often comes from the needs
of society, market research improves products, brand
loyalty, “have to have one” psychology.
• An innovation based upon market pull has been
developed by the Research & Development function in
response to an identified market need, fashion or trend.
Obsolescence
• A product is no longer working or useful.
Obsolete
• Consumer demand leads to the production
of new products
Planned Obsolescence
• A Manufacturer deliberately minimises the
‘life’ of a product to maintain sales of future
products –
• Planned obsolescence = Built in obsolescence
Pull Push Analysis
Mobile Phones
Technology Push
What new
technologies
have been
invented that
have led to
new products
being
released.
Market Pull
Office Chair
Technology Push
Market Pull
What
features have
been
demanded
by the Target
Market, that
have then
had to be
invented and
led to new
products
Product Evolution
• Products Naturally Change over time.
• Small improvements can gradually adapt the
design of the product so that after a while it is
very different to how it started but has never
had a MAJOR redesign
• These small changes can be driven by: new
technology, improved production methods,
style and fashion, problems with the old
model etc
Intellectual Property IP
You need to know what each of these mean…
Patents:
Ergonomics & Anthropometric Data
And how it affects designers
Ergonomics is about the relationship of people with
products
From how easy it is to open a jar to the discomfort of sitting on a bus to the
positioning of the controls in a fighter jet, ergonomics is how a person
interacts with a product.
As a designer we always need to consider how easy and comfortable any
product will be to use. One of the ways to do this is to look at
ANTHROPOMETRIC DATA.
ANTHROPOMETRY is the study of statistics that have
been gathered and combined over many years of the
sizes of the human body.
As designers we can use this data to decide on the sizes, weights and
proportions of our products so as to provide the best ergonomics for the
end user.
Anthropometric Data Explained
• Of course not all people are the same size. There will be huge differences between
the heights, weights, and other dimensions due to: gender, age, diet, growth rate,
genetic make up and other factors.
• Therefore the Anthropometric data needs to be organised in a specific way.
• If we were to plot a graph with
peoples heights along the bottom
and how many people are at that
height up the side we end up with a
graph that looks like this.
• The shape is called a “Bell
Curve”
• The percentage of people at
each height (or weight or whatever)
is called the percentile.
• The average (mean) size is therefore the 50th percentile. We sometimes use
this as the best size to design for. However really we should design for everyone
between the 5th and 95th percentile. The top and bottom 5% being just to big
or too small to practically design for. Tough luck for them!
Example Anthropometric Data
#
Female
Male
5%
50%
95%
5%
50%
95%
A
690
743
795
739
795
850
B
181
226
266
188
235
274
C
406
439
479
447
482
520
D
438
478
525
458
499
544
E
540
585
637
569
616
665
F
352
388
428
395
434
476
G
474
513
558
515
559
605
Ergonomics – Product Analysis
Find a Folding Chair on the internet and stick it in
the middle of a blank page.
Annotate the picture to make (full sentence)
comments about the Ergonomics of:
•
•
•
•
the seat
the back support
the size & weight
the aesthetics
Add further annotations about Function, Materials,
Construction & Manufacture
Make good and bad comments and suggest
improvements
COMPUTERS IN PRODUCT DESIGN
TASK: Write a description for how Computers can be
used when Designing and Developing new products.
Use full Sentences and Explain HOW and WHY
2D CAD: 2 D_______ C________ A_______ D________ can be
used to…
3D CAD: 3 D_______ C________ A_______ D________ can be
used to…
CAD Modelling: Can be used to…
CAM: C________ A_______ M_________ can be used to…
CNC: C________ N_______ C_________ this is how CAM
operates by a computer sending numerical information to a CAM
machine to control what it does and what it makes.
How many mobile phones have you ever owned?
How many broke?
How many did you replace even though they still worked?
Product Analysis - Blackberry
Annotate in full sentences:
•
Materials
•
Construction
•
Manufacture
•
Ergonomics
•
Function
•
Cost
•
Target Market
•
End User
•
How long should it last
Don’t just state facts –
give your opinions
Say good things and Bad
things
Name:_______________
Sustainability and the Environment
Starter: Try to think of 5 reasons we change our
Mobile Phones so often.
(Hint: Think about the work we have covered and the key words
we have learned)
Question: Write a paragraph, in full sentences, to
describe how having a culture that throws
products away so often can be harmful to the
environment.
You will be marked on the quality of your written English
Writing frame: “A culture that throws products away so often is
harmful to the environment because…”
Use words like: because, therefore, furthermore, however, etc
Sustainability and the Environment
Sustainability is where products are
designed in a way that aims to preserve
the world's natural resources for future
generations.
A sustainable design can be made again
and again without serious
environmental problems.
The 6 Rs of Sustainability
• Re-use: Take an existing product that has become waste
and use the material or parts of it for another purpose,
without processing it.
• Repair: When a product breaks down or doesn’t function
properly, try to fix it rather than throw it away.
• Recycle: Take an existing product that has become waste
and reprocess the material to use in a new product.
• Reduce: Minimise the amount of energy and materials
you use.
• Rethink: Ask whether we can sustain our current way of
life and the way we design, make, use and dispose of
products.
• Refuse: Don’t use a material or buy a product if you think
you don’t need it or if it’s unsustainable.
Quality Assurance…
does not check the quality of the final product but the quality of all
systems on the production line, staff training and quality
monitoring.
• Quality of Materials
• Equipment
• Manufacturing Processes
• Staff Training
Quality Control…
checks the quality of the final product though TESTING
• Drop Test
• HALT (Highly Accelerated Life Testing)
• Mechanical Testing
• Sound Testing
Quality Assurance Systems
• BSI Kitemark
– British Standards Institute symbol
– Recognised symbol of quality and safety
– Companies Pay to be checked by BSI to see if their
product conforms to the standard for
quality/safety
• CE Symbol
– Shows that the product meets the requirements of
the applicable directives in Europe
– Legally required on certain types of product to be
sold in the European Economic Area (EEA) e.g.
products that use an electrical voltage
– Companies Produce a Legal Declaration of
Conformity to show that their product meets the
requirements
Product Packaging - Labelling:
Say what each of these means and where you might find them
Product miles:
Carbon footprint:
Safety: Risk Assessment
• When doing any practical activity in a workshop or factory, someone should
always do a risk assessment
• It is usually in the form of a table like this:
Task
Risk
How Likely
Control measures
What tools &
processes are going
to be used?
What might
happen?
Red/Amber What will you do to minimise
Green?
the risk?
1-10?
e.g. Drilling holes in Trapping fingers, Amber
pine using pillar drill cuts, dust, flying Or
objects
6/10
Apron, Googles, clamp work
securely, ensure guard is in
position
Or e.g.
Cutting Acrylic on the
laser cutter
Ensure extractor fan is switched on,
ensure lid is closed. Ensure that the
machine has been regularly
serviced (filters changed)
Inhaling toxic
fumes, burns to
skin or eyes
Unlikley
Scales of Production
One off / Prototype Production:
•
Where only one of a product is made. This could be to make a test product to
see if it’s any good (prototype) or it could be a unique or “BESPOKE” product
which is the only one of it’s kind
•
e.g. wedding dress, bespoke furniture, new innovative product
Batch Production:
• Where a set number (perhaps 10 to 1000) of a product are made in a set
production run. Batch production techniques can be used to make sure they
are all the same (quality)
•
E.g. wooden toys, designer furniture
Mass Production:
• Where millions of identical products are made using large scale inductrial
processes (e.g. injection moulding) Setup costs are high but once set up each
product can be made quickly and cheaply
•
e.g. coke cans, school chairs, iphones,
Just in Time (JIT) Production:
• Materials, components and Parts to arrive from other factories ‘just in time’ for
production. Finished products are despatched immediately they are made. This
system reduces any storage of stock and allows for changes to the product to
be made quickly without the need to use up stock items first.
Batch Production Techniques:
Manufacturing techniques that will make sure a
product is good quality every time
• Template: a tool that is used to mark out accurately every time
e.g. draw around, mark out where to drill etc
• Jig: a tool that is used to cut or drill in the correct place every
time (not just mark out but actually cut or drill)
• Former: A tool that material can be shaped around to make it
the same shape every time e.g. vacuum forming or line bending
• Mould: A tool that liquid material can be poured into & then set
e.g. Casting Pewter jewellery
• Computer Aided Manufacture (CAM): A specific Computer
Numerically Controlled (CNC) machine that makes parts from
CAD files
e.g. “Laser Cutter”, “3D Printer” or “CNC Plotter/ Cutter”
Quality Control!
JIGS
Used to cut
or drill in an
exact place
every time
TEMPLATES
Used to mark out to
an exact size/shape
every time
FORMERS
Used to shape a material into
an exact form the same every
time
Paper
• Cartridge Paper: Good surface for sketching and rendering with
coloured pencils. More expensive than copier paper. Heavier papers are
more versatile, less prone to yellowing with age.
• Layout Paper: Used by designers- particularly advertisers. It has partial
transparency so designers can trace through previous design ideas to
adapt and develop
• Tracing Paper: Semi transparent for accurately tracing outlines to make
working drawings or templates
• Grid Paper: Used for schematic diagrams and technical graphics.
• Properties of Paper:
– BRIGHTNESS (degree to which they reflect light)
– COLOUR
– OPACITY (how transparent they are: Opaque = shows nothing
through)
– GLOSS (how shiny they are)
– STRENGTH (determined by length of fibres (recycled is less strong))
Card
• Carton Board:
–
–
–
–
The type of card commonly used in cereal/shoe boxes.
Can be bleached white or left unbleached
Thin versions have a printable white side
Can also be LAMINATED with a sealing layer of plastic to make it
watertight
• Corrugated card: 2 layers of carton board with a third
fluted in between to improve; stiffness, protection and
insulation
• Duplex board: Duplex board is stronger and better
quality than carton board
• Solid white board: Strong and high quality with good
printing surfaces on both sides
• Foam core board: Multi-layer board made up of two
outer layers of high gloss card and a middle layer of
foam. Used for mounting photographs &3D modelling.
Packaging & Printing Processes
Offset Lithography:
A common commercial printing method for paper and card
Video: http://youtu.be/pNZb7CXUjs0
Flexography:
A technique used to print onto flexible plastic film not just flat card e.g. carrier bags
Video: http://youtu.be/vuGptR330VU
Screen Printing:
Where coloured ink is forced through a fine mesh screen by hand.
Video: http://youtu.be/es6iwTjMLhQ
Block Printing:
A hand printing process used to create repeating patterns using a kind of big stamp
Video: http://youtu.be/8De221tJt-w
Dye Sublimation:
Uses a heat & is suitable for printing on materials like acrylic & fabric in short print runs
Video: http://youtu.be/kwV9IAGbYvo
Embossing:
A way to decorate paper/card by pushing it in or out to make 3D patterns
Video: http://youtu.be/zPnKul79eGk
Laminating:
Where at least 2 layers of material are fixed together to combine the properties of both
e.g. plastic and cardboard or foil and cardboard for food packaging
What is Packaging?
When designing packaging you MUST consider these 3 things…
Protect:
Display:
Inform:
Task:
Write a sentence or two for each of
the 3 key words to explain what
packaging must be able to do.
Packaging - Nets
What needs to be
included on Good
Packaging???
•Information about
the product:
–What is it?
–Symbols
•Instructions for use
•Pricing information
•Pictures: Make
them Colourful and
simple
•Company Name,
Logos, slogans
Guarantee, Barcode,
•Window
Die Cutting
In industry companies need to
manufacture packaging in large
quantities.
In order to create the packaging,
nets or cutter guides have to be
designed accurately so that the
final product can be cut out
after it had been printed
Many of the products you use
everyday have been die cut:
tissue boxes, stickers, cereal
boxes, birthday cards, file
dividers etc
The Die Cutting Process
Stage 1
• The first stage is creating a cutter
guide or net for your packaging on
Pro Desktop or an other CAD
programmes.
Stage 2
• The electronic file is then put into a
computerised laser cutter which
burns the design directly on to a
wooden board, it is accurate to
100th of a millimetre.
The Die Cutting Process
Stage 3
The operator uses the design to see
where the die board (the lasered
wood) should use a cutting metal rule
(for cutting lines) or a blunt metal rule
(for fold lines).
Metal rules are bent by hand and
fitted into the wooden board where
the laser cuts were made.
The operator then uses rubber to
cover the blades, this helps to protect
anyone handling the die board and
stops the specialist machinery from
getting damaged.
The Die Cutting Process
Stage 4
The dieboards are inserted into a
machine called a Heidleberg
Cylinder.
The paper or card is fed into the
machine, the cylinder makes one
rotation and the dieboard makes
its cut.
These automatic machines can
even separate the waste and stack
the cut outs, saving time
and money in the finishing process
of making packaging.
Plastic Forming Techniques
Forming
Method
Common
Plastic Used
Products
Scale of
Production
Vacuum
forming
High Impact
Polystyrene
Prototypes,
Yoghurt Pots,
Shower Trays
One off & Batch
Production
Line bending
Acrylic
Restaurant menu
holder, Desk tidy
One off & Batch
Production
Injection
moulding
ABS
Remote controls,
mobile phones,
wing mirrors
Mass &
Continuous
Production
Blow
moulding
PolyPropylene
(PPE)
Drinks Bottles,
Barrels
Mass &
Continuous
Production
Compression
moulding
Foam PVC,
Urea
Formaldehyde
Electrical Fittings,
Hard Hats
One-off, Batch
and Mass
Production
Extrusion
PVC
Plastic window
frames, Pipes
Batch and Mass
Production
Diagram
Life Cycle Analysis
Material
Manufacture
Product
Manufacture
Re Make
Raw Material
Extraction
Re Use
Recycle
Disposal
Use
By the End
User of the
product
Plastics Life Cycle Analysis
Made
Refined
Made into
Plastic
Granules
Into a product
and sent to
shops
Used
By the End
User of the
product
Oil
Pumped out of
the ground
Thrown out
For landfill or
recycling