A level unit 1 and 2 Flashcards
1
Q
what is critical assessment
A
this where a designer will see if a product is fit for purpose
2
Q
what are the key parts of a critical assesment
A
product annalysis and task analysis
3
Q
why do designers do product analysis
A
to try and generate new concepts deisgneres first carry out extensive primary and secondary research to gather informaition and data about similar products
4
Q
why do designers do product annalysis
A
To help them meet the needs and wants of a client
to improve on existing product designs
to explor new more efficient design solutions
5
Q
what is the total design process
A
Total Design is the systematic activity necessary, from the identification of the market/user need, to the selling of the successful product to satisfy that need – an activity that encompasses product, process, people and organisation
6
Q
what does PDS stand for
A
Product Design Specificaition
7
Q
what does a specificaition need to be for the document to be workable
A
realistic
technical
measurable
fully justified using reasearch
8
Q
for a product to be fit for purpose what must it be
A
appropriate for its intended use
meet the needs of its intended user
meet any necessary qaulity and safety standards
9
Q
what is iterative design
A
iterative design the practice of building, refining, and improving a project, product, or initiative.
10
Q
what are the different sections of iterative deisgn
A
prototyping
testing
analysis
refinment
client feedback
11
Q
what are anthroplometrics
A
they are body measurements such as height weigh shoes ize
12
Q
what are ergonomics
A
this is the use of anthroplometric measuremets
13
Q
what are the different modeling options
A
2d and 3d concept drawings
CAD models
Physical models
14
Q
what is feasability
A
feasibility studies assece wether a proposed product or system has any potential
is it possilbe
is it cost effective
is it viable
is it safe
15
Q
what factors do feasability studies look at
A
technical
economic
market
legal
production
16
Q
what technical factors does feasability look at
A
hard ans software
transport infastruture
human resources
location and resources
17
Q
what is a direct cost
A
a price that can be directly tied to the production of specific goods or services.
18
Q
what is an indirect cost
A
Indirect costs are costs that are not directly accountable to a cost object.
19
Q
what should a feasability study show in relaition to production and logistics
A
A feasibility study should analyse how the design, manufacture and distribution of the product should be managed
20
Q
what can affect feasability
A
laws and regulaitions
21
Q
How is primary research gathered
A
It is gathered directly from the designer
22
Q
What does secondary investigation include
A
This involves the use of information collected and reported by others
23
Q
What is plenary
A
In pair or in small groups discussing the process for re designing the kettle pictured by the elderly
24
Q
what is a coperate identity
A
a coperate identity is the way an organisaition presents itself to the public and society as a whole
25
what contirbutes to a coperate identity
logos and branding
coroprate socila responsibility
packaging and uniforms
business practices
26
why do brands use iconic colours and froms
this is to make ther brand look as recognisable as possible
27
an example of something iconic is
allesi lemon juicers
28
why is a strong identity key to success
a recognisable brand is important for repeat purchases customers that like a product can easily spot it again
29
what is the key charcateristic to describe the target market
consumer identity
30
How might companies tailor their designs and branding to suit different local markets?
Colours (BLACK can mean mourning / death in the west but prosperity in the east. RED may mean warning or love, but in the east – good luck
TEXT – right to left or left to right
WORDS have explicit meanings in some countries (eg PLOPP bars)
Language may mean that their name is similar to another company
Symbols & Actions – can have different meanings eg roses can mean romance or be a funeral flower in Russia.
Technical specs – eg power supply needs are different across the world.
Market place – a companies goods may be low cost in a booming economy or high cost in a struggling economy, needing different marketing strategies
Local regulations on size, weight, materials etc may impact the design and production
Local reputation – companies are often acquired by other companes, the product changes but they keep the name as it already has a degree of brand loyalty
31
fo a brand to achiveve global successs it must be sensitive to
cultral and socila issues
32
how can you be sensitive to cultral issues
the use of langauage, colour and symblos in product logos and slogans must translate well in different cultures
Careful research is required to understand differences in values and customs to avoid embarrassment and failure
33
why do we need good marketing
Good marketing promotes an enterprise and creates and maintains the relationship between retailer and customer
34
how does the internet make it easier to access the global market
it make it easier to access global customers. It is key to undrestand the target market so that you can desighnyour product perfectly for its needs
35
what is the primary purpose ofnpackaging
it is to promote and protect a product.
It potects the key part of the product
36
why is packaging important
it can contain usefull informaition
product specificaition
safecty and qaulity
promotion
useby/sell by dates
disposal/recycling instructions
37
what things can be requieed by law to have on your oackaging
Labelling on the packaging of electrical products often highlights environmental issues e.g. energy efficiency labelling, disposal instructions
38
what are the business sizes
sole trader
medium sized ]
micro
small
larger
39
why is collaberative working good
allows enterprises to call on specilaists
40
what is the total production cost
material cost + manufaturing cost +
direct labour costs
41
what is the total price of one unit
total production cost + total amonts of units made
42
what is an inovaitor and who is an example of one
Innovators create ‘new ideas, devices or methods.’ Innovation is often also viewed as the application of better solutions that meet new needs, or existing market needs. This is accomplished through more -effective products, processes, services and technologies that are readily available to markets and society. The term ‘innovation’ can be defined as something original and more effective and, as a consequence, new, that ‘breaks into’ the market or society. It is related to, but not the same as, invention.
While a novel device is often described as an innovation and is generally considered to be the result of a process that brings together various novel ideas in a way that they affect society. Innovations are created and found in order to meet growing consumer demands. At the end of the day, a Innovator is the pioneer of a new product; developing it, getting it in front of people.
an example of one is elon musk
43
what is a product champiom and who is one
A Product Champion is a member of an organisation who has an entrepreneurial vision of a new good or service and seeks to create support for its commercialisation.
A product champion is someone who sees value in a product, and creates and develops the product and also entices decision makers to invest, sell or promote the product. The product champion also keeps the product in consumer's minds. A product champion’s role doesn’t stop once the product is established and on the market. Keeping the product fresh in the minds of the consumer is another role they take on.
an example of one is steve jobs
44
what is an entrepreur and who is an example of one
An entrepreneur is an owner or manager of a business enterprise who makes money through initiative and/or risk. Product design entrepreneurship has traditionally been defined as the process of designing, launching and running a new product or business, which typically begins as a small business, such as a start up company, offering a product, process or service for sale or hire, and the people who do so are called entrepreneurs.
‘The entrepreneur is seen as a business leader and innovator of new ideas and business processes.’ Entrepreneurs tend to be good at perceiving new business opportunities and often take risks which makes them more likely to exploit the opportunity. Rather than working as an employee, an entrepreneur runs a small business and takes all the risk and reward of a given venture, idea, or service offered for sale.
an example of an entreprenur is bill gates
45
What are traditional joining methods
Comb joints
Dovetail joints
Housing joint
Half lap joint
Dowel joint
Mortise and tenon
46
What are comb joints also known as
Finger joints
47
What are dovetail joints
Finger joints with a bird tail
48
What are the components used for joining woods
Wood screw
Nuts and bolts
Coach
Knock down fittings
49
What is a pilot hole
A pre drilled hole for screws to it
50
what are smart materials
Smart materials have one or more property that is dramatically altered by an external stimulus
Properties such as colour, shape, viscosity, volume and conductivity are affected by a given stimulus
The stimulus and the properties linked to a smart material affect how and where it is used
51
what is an external stimuli
an external stimuli is what triggers the smart material to do its special feature
52
what are some examples of smart materials
shaoe memory alloys
thermochromic pigment
phosphorescent pigment
photocromic pigment
electroluminescent wire
piezoelctric material
53
what are shape memory alloys
these can be shaped to remember sspecific shapes
54
where can i find shape memory alloys in products
they are often used in glasses
55
how do you set the shape for a shape memory alloy
they are help in the desired place within a jog and then heated by using a furnace
56
what is the activaition temperature in relaition to smart materials
it is the temperature needed to stimulate the smart material
57
what is thermorchromic pigment
this changes the colour or opacity with a change in temperature
58
when is themochromic pigment used
in baby spoons with hot and cold food
59
what is phosphorescent pigment
these are glow in the dark materials which change due to light
60
what is photocromic pigment
this is a smart material which changes opacity with the levle of ultravioler light in a reversible reaction
61
what is electroluminescent wire
this material is made of copper wire coated in phosphur which glows when an alternaiting current is applied
62
what are piezoelectric materials
these materials convert mechanical energy into electrical energy and vice versa like those candel lighters with the triger
63
what are Performance characteristics
Performance characteristics describe how a material behaves in different contexts and what it looks like
64
What are some performance of wood include
Grain pattern or direction
Warpage shrinkage and splitting
Machine quality’s
Toxicity
65
what are ferrous metals
ferrous metals are metal where carbon is a commen additive used to increase the hardness of iron
all ferous metals contain iron
66
what is low carbon steele
low carbon steel is malleable, ductile and relatively inexpensive compared to other metals
67
what is medium carbon steel
medium carbon stele is less ductile when compared to low carbon steel.
68
what is cast iron
grey cast iron distributes heat enevenly and withstands even compression resisting deformation it is a very hard and has good resistance to oxidaition. howevere this can be broken or crack if it is dropped
69
what is white cast iron
White cast iron has excellent resistance to abrasion. Like grey cast iron, it is also hard and brittle but has a greater tensile strength.
70
what is the most abundant metal in the earths crust
aluminum is the msot abundant metal in the earth's crust. it has excellent strength to weight ratio
71
what are some features of copper co
copper is a metal which gas been used fopr 10,000 of yera it a mealleable and extremely ductile materail
it is an excellent conductor of electricity and heat. applicaitions include electricla wire motors and more
72
what is silver and its features
silver has been used in jewellery and coinage for milennia. It is the best electric and thermal conductor. IT is extremeley ductile and has low reactivity applicaitions include electronics, mirrors and jewlelery
73
what is a ferrous alloy
ferrous alloys contain iron, carbon and one or more other element some good examples of these are stainless steel
74
what are stock forms
metals are availiable in a range of stco forms such as sheets plates, bars, and structural profiles
75
what are the two different tpes of plastic
thermoforming and thermosetting plastics
76
what are some example od thermoforming plastcis
acrylic, Hips, HDPE, PET polypropylene
77
what are some exmaple of thermor settings plastics
epoxy resin, polyester resin urea formaldhyde, phenol formaldehyde, melamine formaldehyde
78
what are mechanical propeties
mehcanical propeties are the charteristcis a materaila displays when subject to an exteranl force. this can be features such as tougness, felxibility, elasticity and mouldability
79
what determines the toughness of polymers
the toughness of polymers is determined by their ability to absorbe energy and deform plastically without cracking
80
what are physical properties
Physical propeties are mesuarable charctersistcis a material displays a good exmaple.
81
what can wood grain affect
it can affect the workability and cost of the wood
82
what would the positives of going against the grain of the wood do in construction
it increase the strength of materials a good example of this is in the process of laminaiting plywood
83
what is a composite
composites are a combination of two or more different materials that are bonded together
84
what do composiote materails have
they ahve enehanced propeties either mechanical or physical;
85
what is paper made out of
both papers and boards are made form cellulose fibres derived from plants
86
what do you need to make paper
the best cellulose fibres for paper production comes from wood due to quality of the fibres length and strength
87
why are softwoods better for paper production
they contain long and soft fibres which makes it ideal for paper production as it can be stretched
88
what goes into the construction of paper
it is made from debarked cellulose fibres, chipped wood or other cellulose fibres
acetic acid and or other chemicals are also used to breakdonw the lignin that bonds the cellulose fibres
fibres like clay and calcium carbonate are often
brightening agents such as bleach
and finally lots of water
89
what temperature does the liquid need to reach the pulp stage
140 degrees Celsius
90
how much water does it take for one sheet of a4 at 80gsm
500ml
91
what is uncoated paper
this is paper which is not treated with any sealant this allows greater and faster absorption of water or ink
92
what are the different types of paper and board appearences
matte- smooth, dull in appearance and for any high-quality print job
Satin- has a lower reflective levels than gloss paper but more than matte
gloss- this is a shiny higher quality coated paper
textures- this is created with a felt roller covered in woven wire
93
what are the factors which determine how tear-resistant paper is
the way cellulose fibres bond to each other
the strength of cellulose fibres
the length of the cellulose fibre
quantity of fillers used; more fillers mean less strength
94
How are paper qualities are considered before their use
the paper's weight
longevity
impact strength
waste and cost efficiency
95
what is die cutting
Die-cutting is a process whereby a die is used to cut through materials such as paper and card on a die press.
96
what is the difference between creasing and folding
creasing involves making a line that is permanantly crushed and weakend resulting in a crease line
Folding in this industry means to create a shape or box and envelope or pamphlet
97
what are perforations
these are minor cuts in a paper or board that allow for portions to be folded or tone off with good accuracy
98
what are the metal shaping methods
milling
turning
flame cutting
plasma cutting
laser cutting
punching and stamping
hand tools
99
what is flame cutting
flame cutting uses oxyacetylene gas and flame cutting torch to focus a flame up to 3500 Celsius
oxygen intensifies the flame and forces the molten metal out
used to cut low carbon and alloy steel plate
100
what is plasma cutting
plasma is an ionized gas which is electrically conductive at very high temperatures
Plasma-cutting generates a faster cleaner cut than flame-cutting
it is suitable for one off batch production
101
what is press forming
press forming shapes sheet metal into 3d forms
metals such as low carbon steele and aluminium are often used
common in mass production or large scale batch production due to the cost of producing the dies
102
what is spinning
spinning is a way of forming sheet metal giving radial symmetry
this is ued for objects like ketals
103
what is cupping and deep drawing
cupping and deep drawing are used to form tube-like shapes form sheet metal
objects such as fire extinguishers and aerosol can are made this way
104
what is sand casting
sand casting is used to form high melting point metals
this is carried out in foundries, using molds made from special green sand
very slow and labor-intensive process
105
what is investment casting and why is it used
Investment casting is used to cast items with awkward shapes that would be difficult to mould using any other casting process
106
what is drop forging
Drop forging is used to shape hot metal
This process is used when the product needs to be tough and hard
Objects such as spanners, pliers and screwdriver shafts are made this way
Hot metals is forced into shape under great pressure therefore retaining the original grain structure
The process is suitable for mass production, however dies can be changed quickly to allow for varied production
107
what is wrought iron forging
Wrought iron has a very low carbon content making it malleable and easy to shape
In addition to hydraulic and mechanically powered rams, it can be shaped using hand tools such as hammers and an anvil
108
what is rolling when it comes to metal
Rolling is used to reduce the thickness of metals
Typically used to make structural steels such as I beams, angle, bar and channel for the construction industry
Rolling is usually carried out with hot metal that has been heated above recrystallisation temperature
Hot rolling can result in surface carbon deposits but has no deformation or stresses
Metal can be cold rolled which gives a fine tolerance
109
what are all of the metal joining methods for metals
Riveting
brazing
hard and soft soldering
oxyacetylene
and spot welding
MIG ( metal insert gas) welding
TIG ( tungsten insert gas ) welding
110
what is MIG welding
MIG welding is used to weld thin gauge metal such as aluminium and some Steele
111
What are the sustainable aspects of injection moulding?
Efficient for mass production; can use recycled materials.
112
What are the unsustainable aspects of injection moulding?
High energy consumption; often uses fossil-based plastics
113
What are the sustainable aspects of blow moulding?
Suitable for lightweight products; potential for bioplastics.
114
How does MIG welding work
MIG welding uses a filler wire as an electrode
the wire electrode melts in the arc and fills the gap between the two metal
the weding tourch is gently swirled to from a bead of weld
the electrode wire is stored on a reel and is fed through the nozzle as the trigger is pressed
115
what is TIG welding
TIG ( tungsten inert gas) welding is used to weld stainless steele, aluminium and copper alloys
it is an electric arc welding process, howevere unlike MIG welding the electrode made form tungsten does not melt in the process a filler material is added in the process
116
what is spot welding
spot welding welds sheet metal together without a filler material
117
how does spot welding work
Heat and pressure are applied to the area to be welded
conducting metal surfaces are joined by heat generated form resistance to an electric current
workpieces are held together under a pressure exerted by electrodes
118
what is oxy-acetylene welding
oxy-acetylene welding is used to weld low carbon steel sheet, tube or plate
it mixes two, high pressure gases forming very hot intense flame
the flame is adjusted by changing the gas and oxygen mixture enabling flame cutting, welding or brazing
119
what is soft soldering
soft soldering is uses low melting point metals such as solder to join metals togethere
solder is usually tin/lead alloy with low melting point (320 degrees celcius)
120
What is hard soldering
Hard soldering uses a higher temperature than soft soldering
it is used to join precious materials like gold and silver
121
what is brazing
barzing uses either oxy-acetylene flame or a gas and compresses air brazing hearth
this needs a lower temperature than welding as brazing rods melt at around 850 degrees celcius so the jont is not as strong
122
what is riveting
Riveting is a semi-permanent joining method used to join sheet or plate metal
rivets are metal fasteners that have a head at one end and a shaft or tail at the other end
they are best suited to industrial applications as an alternative to threaded fastenings
123
what are self tapping screws
self tapping screws cut their own thread and they are screwed into the sheet metal and some plastics
124
what is polymer variation
There are synthetic polymers and natural polymers
synthetic polymers are produced from finite resources such as coal, gas and oil
natural polymers come from a variety of sources such as rubber and amber which comes for trees
125
what are processed polymers
polymers in powder or granule form are processed to produce usable stock form for manufacture
126
what is forming polymers
polymers can be formed in a variety of different ways depending
127
what is vacuum forming
vacuum forming is used both in the school workshop and in industry, vacuum formed products include items such as plastic yoghurt pots and bath tubs
128
how does vacuume forming work
a sheet of thermoplastic is heated and pressed onto the former by atmospheric pressure as a vacuum reduces the pressure below the softened thermoplastic
129
what is mould making
To ensure a good products is formed, the mould must have the following features-justify each one
130
What is line bending
this is where strip heaters are used for line bending which is a means of creating a permanent fold in a piece of thermoplastic such as acrylic
131
what is laminating or layup
aminating, also known as layup, is a process of layering materials, typically fabric reinforced with resin, to create a composite material.
132
what is injection moulding
injection moulding is commonly used in industrial production to produce complex shapes
133
how is injection moulding done
injection moulding works where the hopper feeds an Archimedes screw that drags the granules past the heater where they are plasticised
when the soft, pliable plastic reached the end of the screw a hydraulic piston forced into the mould
134
what is blow moulding
blow moulding uses a two part mould and compressed air to make hollow shapes
135
what is the blow moulding process
polymer granules are heated and extruded to create a plastic tube known as a parison
136
what is compression moulding
compression moulding is used to form thermosetting polymers using a hydraulic press
137
what are the different shaping methods when it comes papers
creasing, die cutting, bending, laser cutting
138
what is creasing
creasing compresses the cellulose fibres which allows paper or board to fold more easily
139
how are dies for die cutting used
dies are fairly costly to make but will produce many high quality cuts
140
what is rotary and flatbed dies
rotary die cutting has higher set up costs but is more efficient and more accurate
141
what is laser cutting
laser cutters can be used to shape paper and board but it can vary depending on the board thickness
142
what are paper and board adhesives
many water based solvent and hot melt adhesives are used with paper and board
143
what is polyvinyl acetate
(PVA)
Polyvinyl acetate (PVA) is a non-toxic, water-based white glue that dries clear
Can be applied with a roller or brush for fast coverage but is only suitable for use with absorbent substrates
144
what are hot melt glues
Hot-melt glues are used extensively in packaging
Easily integrates into automated, high speed manufacturing lines
Dries quickly and bonds dissimilar materials
Makes packaging easy to open
Not suitable for heat sensitive materials as it can damage the substrate
Not suitable for use in environments or during processes that operate at high temperatures
145
what are solvent cements
solvent cement dissolve the surface of a material allwoing parts to be fused together this is often used in the form of polystyrene cement
146
what are contact adhesives
contact adhesives is applied to both of the surfaces to be bonded and is then left to go tacky and allowing it to bond on contact
this is quite hard to apply discreetly due to its very distinctive yellow color and thick consistency
147
what are spray adhesives
spray adhesives give a thin and even coverage layer allowing papers and boards to be glued together
148
what is food-safe packaging and what glues are used to bond it together
water based and hot melt glues are the most widely used adhesives for food packaging
149
what fixings and components are used in papers and boards
For example, rivets and eyelets can be used to join dissimilar sheet materials and fabric
They can create spinning parts and add reinforcement
Rivets also add an aesthetic accent to key features
150
what are some examples of jigs which are used for papers and boards
papper trimmer (guillotine)
151
what is a fixture
a fixture holds a workpiece in position while a task is performed
152
What are the names of the two different colour processes
RGB Red, green and blue is a colour mode linked to visula displays that produce light e.g screens, cameras and tvs
CMYK print media is usually created by overalying cyan, magneta, yellow and black
153
what are spot colours and when can they be used
Spot colors can be used when the perfect colour cant be mixed from the CMYK range or may be used to cut costs
154
What are layers of colour when it comes to printing and why is it important
RGB graphics software converts RGB colour to layers of CMYK ready for priniting.
this is importna as it helps to achivee realistic colouring
155
what are the different printing processes
Screen printing
Flexographic printing
Offset lithographic printing
Digital printing
156
what is screen printing
this is a process which is ideal for short print runs and used to print posters, t-shirts and tote bags
this is easily set up in a home workshop or on an indstrial scale
jigs can be used with this form of printing
157
how do you prepare the screens before printing
screen printing
Before printing can begin, the screen must be prpared-every colour requires a different screen.
fistr a meesh is coated with photo emulsion and left to dry in the dark
then a monochrome transparencey of artwork is placed on top of the screen
light is sued to fix the exposed photo emulsion to the screen
excess photo emulsion is them rinsed away
158
What happens once the screen has been prepared
once the screens have been prpared thay are laid on the substarte and ink is forced through the screen
as squeegee is used to apply a tin even coating of ink
159
which printing method is the most common and c commercial printing method, suitable for high volume productive cost-affective
Offset lithography
160
how do offset lithography printing plates work
the artwork is separated into different layers of colour (CMYK)
Each layer is used to etch a printing plate made from thin aluminium sheet
Printing plates are treated to make an oleophilic image area and a hydrophilic non-image area
Oil-based ink is attracted to the oleophilic image area only
161
how does offset litho wokr
First a printing plate is installed on the palte cylinder then ink is added and is layed offset onto the smooth blanket cylinder the print is created whn the substarte is passed between the blanket and impression cylinders
162
what is flexographic printing
this is a type of printing which uses water based inks which dry fast this makes the process efficient
this is also the cheapest method for high-volume printing which works on a wide range of materials
163
what is flexography
a rotary relief printing method using rubber or plastic plates and fluid inks or dyes for printing on fabrics and impervious materials such as plastics, as well as on paper.
164
how does flexographic printing wokr
Ink is collected from the reservoir and transferred to the anilox roller
Tiny cells on the surface of the anilox roller collect the ink
The doctor blade controls how much ink reaches the flexographic printing plate
165
what type of printing is flexo
flexo is a form of relife printing
166
what is digital printing
this si the most commonly used form of printing at home or school the two main types of digital printing are ink jet printinv and laser printing which both print ink directyly onto the substrate
167
whta is an issue with digital printers
digital printers only operate on a four colour printing process ink/toner catridges are avaliable in monochrome ( black) or colour (CMYK)
168
how is laser printing done
electorstatic energy transfers toner to the substarte each colour in a digitl printers requires a seperate drunm in the printer
these drunms are then positvly charged with electrostatic energy then a laser nagetivly charges certain areas of the drunm
the positivly charged toner powder, sticks to all the nagativly charged areas
a transfer belt picks up the toner from all four drunms and deposits them onto the substrate in one operaition
169
how is inkjet printing done
The printer is loaded with ink cartridges (CMYK) which act as reservoirs for the printhead
The printhead passes over the substrate from right to left, squeezing out tiny droplets of translucent ink with each pass
High quality prints (720 DPI or more) need at least six passes to build up the image in sufficient detail
170
what are the different finishing methods for papers and boards
embossing
laminating
varnishing methods
debossing
foil blocking
171
what is embossing and debossing
these finishes raise or indenrt the surface or a substrate to add fubnctionality and or enhance aestheics this ius commonly used for braile
172
how is embossing and debossing done
This is where the substrate is stamped between two shaped steel plates under heat and pressure
173
what is foil blocking
A decorative dry process which applies colored metallic foils to papers and boards
this is often combined with embossing and debossing
an example of where it has been used in in passports
174
what is lamination
Laminatio adds a highly durable tear proof and wipe clean film to packaging, posters and books
175
what is encapsulation
Encapsulation is a form of lamination that is carried out using a desktop laminator
176
what is varnishing and spot varnish
Varnishes add a protective barrier and offer different finishes and textures
it is applied in a liquid form and is printed onto a substate like an ink
this can cover the entire surface or can be added to specific areas only which is what spot varnish is
177
what re the six traditional methods of joining woods
comb joint
dovetail joint
housing joint
Half lap joint
dowel joint
mortise and tenon
178
what are comb joint and where are they used
Comb joints are used to form boxes and carcasses – they are also known as finger joints
This simple and effective joint is made from interlocking fingers which fit tightly together and are reinforced by glue
Accurate work can result in a very strong, aesthetically pleasing joint
Best created using a router jig on natural or manufactured timbers or using a laser cutter on some materials
179
what are dovetail joints
Prized for their strength and aesthetics, dovetail joints are ideal for cabinets and drawer construction
Dovetail joints demonstrate a high level of skill but can be cut fairly easily with a router and jig
Like the comb joint, their strength relies on interlocking fingers and accurate marking and cutting
The dovetail shapes means that these joints have superior directional strength
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what are housing joints and where are they used
A housing joint is commonly used for shelves and dividers
A channel is cut through one piece of timber which houses a second perpendicular piece
It is fairly strong, when supported with glue but can be used without glue to create sliding parts
Easy to make – only one piece of timber needs to be machined
181
what is a half lap joint and where is it used
A versatile joining method that is easy to construct
Made by two overlapping materials glued together
Used in picture frames, doors and cabinet making
Quick and easy to make but not particularly strong
The shoulder helps resist diagonal distortion
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what is a dowel joint and where is it used
Dowel joints are a quick simple and effective method used to join a variety of materials
Used in both frame and carcass construction, flat-pack furniture and to reinforce edge to edge joints
Holes are machined easily with a drill and jigs can be used to speed up the process further
Suitable for use in natural timbers and manufactured boards
Cost effective alternative to mortise and tenon joints
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what is mortise and tenon joint and where is it used
this is a he joint used in load bearing timber frameworks
this joint hs a high shear strength these are often glued or pinned and made easily using CNC machines
184
what are the main joining components for woods
wood screws
nuts and bolts
coach bolts
knock down fittings
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what are wood screws and what are there positives and negatives
Screws are available in different lengths and widths, with a variety of head shapes and finishes
Most screws are made from mild steel and are then plated in brass, zinc, chrome or another non-corrosive metal
Screw heads are often countersunk so the screw hole can be filled or plugged, others have a domed head which can make a feature of the joint
Screws are quick to install and can join dissimilar materials
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what are the different head types on the screws
Philips and slot head screws also are commonly available c
187
what are pilot holes
pilot holes are pre-drilled and pilot holes reduce the risk of wood splitting when a screw is inserted
188
what are nuts and bolts
these can be a temporary and permanent fixing
Screws are available in different lengths and widths, with a variety of head shapes and finishes
Most screws are made from mild steel and are then plated in brass, zinc, chrome or another non-corrosive metal
Screw heads are often countersunk so the screw hole can be filled or plugged, others have a domed head which can make a feature of the joint
Screws are quick to install and can join dissimilar materials
189
what are coach bolts and where are they used
Coach bolts are used to build wooden structures such as summer houses, benches and sheds
this is identified by a square section just under the head of the bolt from spinning during assembely
once installed its impossible to rmeove from the head
190
what is the main positive for using wood fixings
using screws nuts and bolts and coach bolts requires minimal time and skill
191
what are knock down fittings
knock down fittings offer strong but collapsible joints ideal for flat pack furniture and fitted kitchens
192
what are the differnt types of KD fittings
Barrel nut and bolt
cam fittings
modesty blocks
193
what are modesty blocks
Modesty blocks, also known as connecting or screw blocks, are small, rectangular plastic fittings used to create secure, 90-degree angled joints when assembling furniture, cabinets, or worktops
194
what are cam fittings
Cam fittings require highly accurate pre-drilled holes to function properly
Jigs or CNC can be used to prepare parts for assembly but once cut, joints can be assembled easily with a screwdriver
Cam fittings are commonly used in flat-pack furniture made from laminated manufactured board e.g. storage units
195
what are barrel nut and bolt fittings
Also known as cross dowels, these are used to assemble furniture with large frameworks such as beds, chairs and tables
Jigs can be used to ensure accurate positioning of the holes and the joint is easily tightened with an Allen key
The bolt tightens in a barrel nut which is installed at 90° to the bolt shaft
These fittings have excellent sheer strength and clamping force ideal for large, load-bearing furniture
196
how do you make curves in wood
lamination and steam bending are two processes used to make wavy wooden structures
an exmaple of when this has been done is through marcel breuers iconic short chair (1937)
197
what is laminating when it comes to wood
Thin veneers or flexible plywood are glued together to make a permanent curved profile
198
why is preparation key when it comes to laminating
The design, manufacture and preparation of a mould is crucial to a successful lamination
Moulds are often covered in wax or parcel tape to prevent the laminate sticking to the mould
The mould must allow for the thickness of the laminate
Even coatings of glue give uniform strength to the laminate
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what is the vacuum bag method when it comes to laminating
Laminate is placed on a one-part mould and encapsulated in a heavy duty polythene bag
A pump sucks the air from the sealed bag
The resulting atmospheric pressure forces the laminate into position
200
what is steam bending
this is where a steam box heats and softens the wood fibres to make them pliable and easier to bend
Woods with a straight grain and open pore structure, such as ash, oak or beech, are ideal
201
what is a steam box
steam boxes take many forms but all are made up of a vented container and a steamer of some kind
in this the stema needs to be able to circulate around thw workpiece and excess water and steam must be able to escape
202
what is a fomer when it comes t steam bending
this is where a shaope is made for your wood to match
203
what hand processes are used when it comes to woods
chisels, gouges and planes have been used for centuries to manipulate wood by hand
nowadays many wasting processes are carried out by machines
204
What machine processes are used to shape wood
turning between centers
turning with a chuck and a faceplate
miling
routing
205
what are lathes and what do they do
lathes hold and spin the workpiece while cutting tools are presented to waste away wood bit by bit
wood can be wasted, sanded and finished on the lathe
206
when do you turn wood between centers
this is a technique used to create long cylindrical froms such as spindles and chair legs
207
what are the positives with turning with a chuck and a faceplate
When turning wood on a lathe, both faceplates and chucks offer distinct advantages: faceplates provide a strong, secure hold, especially for rough or irregular blanks, while chucks offer more precision and versatility, particularly for shaping bowls and other complex forms
208
what is the chuck method when it comes to shaping woods
chucks grip or secure a workpiece at the headstock different chucks are used based on the form of the product
the three jaw chuck and combination chuck are shown below
209
how does using a faceplate help with wood shaping
The workpiece is screwed to the faceplate, then the faceplate is screwed on to the lathe
This gives a very secure hold, especially for larger pieces
Alternatively, the faceplate is screwed to a wooden disc which is temporarily glued to the workpiece – a paper separator allows the workpiece to be removed easily
210
how does routing and milling shape woods
routing and milling shape wood by using a rotating cutting tool (router bit or milling cutter) to remove material from the wood surface, creating desired shapes, grooves, and contours according to a programmed design or pattern.
211
what are the positves of hand held routers
Handheld routers are sping loaded which allows for steady up and down movement for cutting holes
212
what is special about routers
routers have shaped blades this allow it to run along the edge of the workpiece to create a decorative or rounded edge
213
how can templates be made for routers
templates are made by hand or using CAD/CAM can be used route complex shapes and cavities
214
what do you need to do to the wood before applying new finishes
timber must be snaded somooth along the grain
rubbing down the timber with methylated spirit removes surface dust and grease essential foor goo adhesion
finishes are applied with a brush, cloth, roller, pad or spray
pressure trteatment finishes are applied professionally
215
what are the different types of wood finishes
polyurethane varnish
acrylic varnish
water based paints
stains
colour wash
wax finishes
danish oils
teak oil
216
what are the facts about polyurethane varnish
This an extremely tough and hardwearing finish that is highly resistant to heat water and chemicals
a liquid plastic suspended in a water or solvent based carrier and sold as a matt, satin or gloss finish
this may be clear or tinted to highlight enhance or alter natural wood tones
217
what is acrylic varnish
Acrylic varnish has a milky-white appearance but dries clear
Compared to polyurethane, acrylic varnish has a faster drying time and doesn’t yellow with age
Acrylic varnish is often used on top of paint finishes to add durability
It’s hardwearing but less resistant to solvents and heat compared to polyurethane varnish
Non-toxic and virtually odour-free
218
what are water based paints and whats good about them
Water-based paints offer several advantages, including low odor, quick drying time, easy cleanup, and a more environmentally friendly profile compared to oil-based paints.
219
what are wood stains and whats good about them
These water based stains apply colour to paint while keeping the natural grain of the wood exposed
They provide an aesthetic finish but offer no protection against decay and degradation
Stains are available in bright colours as well as natural wood tones so softwoods mimic darker hardwoods
220
what is a colour wash and whats good about them
These water based stains apply colour to paint while keeping the natural grain of the wood exposed
They provide an aesthetic finish but offer no protection against decay and degradation
Stains are available in bright colours as well as natural wood tones so softwoods mimic darker hardwoods
221
what are wax finishes and whats good about them
Wax finishes are easy to apply and give a natural looking finish that nourishes and protects the wood
Wax offers limited protection against moisture, heat or scratches and should be reapplied regularly
Several coats are needed for the best results
Wax is applied with a lint free cloth and left to sink in
Residual wax is then buffed up to a shine
Some waxes are food safe and non-toxic
222
what is good about oi finishes and why are they good
Used to replace natural oils lost over time and revive the natural beauty of the wood
As oils seep into the wood, they offer little protection against scratches, heat or liquid
In their raw form, oils are non-toxic and food safe finishing methods e.g. coconut oil, sunflower oil
Oil-based finishes have been developed to enhance the performance of raw oils e.g. Danish and Teak oil
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what is different about danish oil to other oils
danish oil is catagorised as an oil but is actually a mix of oil and varnish thoil enhances the wooods natural beatuy and the varnish water proof the wood
224
what is special about teak oil
Teak oil isn’t made from teak but is ideal for use on dense hardwoods like teak
Like Danish oil, it’s a blend of oils and varnish
Suitable for indoor or outdoor applications and provides UV protection
Used on boats and garden furniture
Teak oil is not ideal if a high-sheen is required or in high-traffic areas
225
what is good about pressure treated timber
Pressure treated timber is treated prior to being sold using an antimicrobial copper-based preservative
Used for high level protection where timber is exposed to constant weathering and possible insect/fungal attack
Common uses include construction, landscaping, fencing and playgrounds
A common pressure treatment is called tanalising
226
what is an electronic system
An electronic system is a series of parts or components that control a task or activity
227
what are the things you need to think about when it come to system thinking
What is the input?
What is the output?
How does the system make a decision to operate?
228
what are subsystems
subsystems or subtasks are events or tasks tat happen within a system e.g steering in car
229
what des a system diagram show
they explain how a system works which acn be confusing o a simple bloc diagram is used to simplify it
230
what is an open loop system
an open loop system also called a non-feedback system is a type of systme whcih does not meausre conditions or feed data back into the system. conce activated they will continue until stopped by an external fcator
231
what do diamond blocks reprsent in a closed lopp system
they represent decisions
232
what aer the positives and negatives of closed loop systems
closed loop systems can control external factors
they are morereliabe and stable outputs
thye are resiliant to disturbances and changes
howevere they are more complex
require tunning or interegaition
susceptible to oscilaition or runaway consitions
233
what are some exmaples of innput componenets
exmaples of these are switches
234
What ore is aluminium extracted from?
Bauxite.
235
What process is used to refine bauxite into alumina?
The Bayer Process.
236
What chemical is used to dissolve bauxite in the Bayer Process?
Sodium hydroxide (NaOH).
237
What process is used to extract aluminium from alumina?
The Hall-Héroult Process.
238
What is alumina dissolved in during the Hall-Héroult Process?
In the Hall–Héroult process, alumina is dissolved in a molten cryolite bath within a carbon-lined steel pot.
239
What happens during the electrolysis in the Hall-Héroult Process?
Aluminium forms at the cathode; oxygen is released at the anode.
240
What are the environmental issues with aluminium extraction?
High energy use and red mud waste.
241
How is the aluminium industry becoming more sustainable?
By using renewable energy in electrolysis.
242
what are design methodologies
a design methodology is an overarching approach to design that includes a set of strategies, philosophies, principals, processes and or techniques
243
what are the different design methodologies
Human cenetered design
Sustainable design
systems driven design
244
what is Human centered design
HCD is based on the philiosophy that devloping useful products involves learning from the people from which the solution is being created
245
what is ethnography
this is a type of qualitive research that involves immersng yourself in a particular comunity or organisaition to observe their behaviour and interactions up close
246
what is sustainable design
sustanable design aims to reduce any neagtive impact on the enviroment and improve the health of people
247
how do people achieve sustainable deisgn
sustainable design can use many different approaches such as having
a circular economy approach
life cycle ananlysis
Biomimicry
6Rs
The Hannover priniciples
248
what are the 6 Rs
refuse
rethink
reduce
reuse
repair
recycle
249
what are the Hannover principles
Insist on rights of humanity and nature to co-exist
Recognize interdependence
Respect relationships between spirit and matter.
Accept responsibility for the consequences of design
Create safe objects of long-term value
Eliminate the concept of waste
Rely on natural energy flows
Understand the limitations of design
Seek constant improvement by the sharing of knowledge
250
what is systems driven design
Technology driven design uses systems thinking to distil the complexity of systems in design practice
251
what are the different methods for system driven design
Systems analysis
New material development
Manufacturing innovation
FEA (finite element analysis)
AHP (analytical hierarchy process)
CFD (computational fluid dynamics)
252
what is high speed steel
High-speed steel (HSS) is a type of tool steel alloy designed for cutting applications that require high hardness and wear resistance at elevated temperatures
253
What are the unsustainable aspects of blow moulding?
Limited to certain shapes; recycling challenges.
254
What are the sustainable aspects of compression moulding?
Can utilize natural fibres and biocomposites
255
What are the unsustainable aspects of compression moulding?
Less precise; may still rely on non-renewable materials.
256
What are the sustainable aspects of rotational moulding?
Low material waste; suitable for large hollow items.
257
What are the unsustainable aspects of rotational moulding?
Slow cycle times; energy-intensive for large parts.
