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product design > GCSE - The WHOLE revision guide > Flashcards

GCSE - The WHOLE revision guide Flashcards

1
Q

what is automation?

A

the use of machines to do a task automatically, without much human input

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2
Q

Give an example of automation

A

in the car industry, robots can be programmed to weld or do other processes

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3
Q

give 3 advantages of automation

A

robots can increase the speed of production
robots can work with high accuracy, therefore increasing quality
robots can work in dangerous situations

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4
Q

give 3 disadvantages of automation

A

robots can replace human workers
robots can be expensive to buy
can’t carry out tasks that require human judgement

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5
Q

what does smart technology do?

A

develops machines like CAD further by connecting them with other machines and sensors to share data. This creates ‘smart’ machines

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6
Q

what can ‘smart’ machines do?

A

use data to organise what tasks they need to do

work out when they will run out of a material by receiving stock level data.

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7
Q

what can ‘smart’ machines be a part of?

A

‘The Internet of Things’

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8
Q

What is the Internet of Things

A

describes the connection between technologies and the internet, for machines this could mean receiving and processing online customer orders.

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9
Q

What can the use of smart technology do?

A

make automated manufacturing very efficient.

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10
Q

what has been a key development in manufacturing?

A

tracking materials, tools, equipment and products in the factory

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11
Q

How can tracking be done?

A

automatically by tagging each necessary thing (e.g. box of material). These can then be scanned or detected as the item moves around the factory

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12
Q

Name some uses of tracking

A

monitoring stock levels
tracking the movement of the products
getting the number of finished products in stock

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13
Q

Give an example of workers using devices to receive information

A

warehouse workers can use things like tablet to give them the best/ efficient route to required items

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14
Q

What is a modular component in relation to factories?

A

components that can be moved, taken apart or added to. Like extra production space

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15
Q

what can technological advances lead to in relation to factories?

A

reduced need for room. e.g. 3D printing uses a small machine

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16
Q

What are flexible manufacturing systems?

A

they consist of a set of different machines which carry out different stages of production. Automated systems transport materials through the different processes and store the finished product. Fairly quick and easy to change the system

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17
Q

What is lean manufacturing?

A

manufacturing that minimises waste and resources used. Aims to reduce cost and increase efficiency

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18
Q

Give an example of Lean manufacturing

A

Just In Time (JIT)

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19
Q

Give 2 advantages of JIT

A

reduces need for space

less money needed

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20
Q

give 2 disadvantages of JIT

A

system relies on materials being delivered on time

money can be lost if there are faults with the delivery

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21
Q

What can CAD help designers do?

A

model and change their design quickly
experiment with different colours and forms
3D programs enable designers to view the product from all angles

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22
Q

What is CAM?

A

the process of using computers to manufacture products. Computer Aided Manufacture

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23
Q

what can CAM do?

A

follow the X,Y,Z coordinated, given by CAD, to move the tools and cut out or build up your design. They can do this because they are computer numerically controlled (CNC)

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24
Q

give an example of CAM

A

some milling machines, 3D computers, CNC routers and laser cutters

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25
Q

What are the two types of CAM machines

A

2 axis - only cut out 2D shapes

3 axis - can cut out 3D shapes

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26
Q

What can CNC routers be used for?

A

to engrave things on plastics, metals and wood

cut out either 2D or 3D shapes as they can be 2 or 3 axis machines

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27
Q

What can laser cutters be used for?

A

to cut out things from plastic, wood, cardboard, fabrics and some metals. On low power settings they can engrave things. Can only cut through sheet materials and they are 2 axis

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28
Q

What can 3D printers be used for?

A

rapid prototyping, can print with several different materials including plastic and wax. can manufacture final products

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29
Q

Why is CAD/CAM good for global companies?

A

saves shipping costs as designs can be sent electronically

saves labour costs as products can be manufactured in a country with cheap labour

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30
Q

name a disadvantage of CAD/CAM

A

computers can be affected by viruses, software problems and file corruption therefore slowing down production

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31
Q

what does sustainability mean?

A

not causing permanent damage to the environment

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32
Q

what does the sustainability of a product depend on?

A

what materials the product is made of
the processes involved in making the product
how long lasting and efficient the product is

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33
Q

define a carbon footprint

A

the amount of greenhouse gasses produced throughout the lifecycle of a product

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34
Q

what is ‘Design for Disassembly’?

A

a new product is designed so it can be easily taken apart at the end of its lifetime, allowing parts and materials to be reused/ recycled

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35
Q

what are up-to-the-minute designs?

A

designs that go out of fashion therefore become obsolete quickly (like mobile phones)

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36
Q

define ‘Design for Maintenance’

A

products that are designed to last and can be repaired or have parts that can be replaced (like washing machines)

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37
Q

what are modular electronics?

A

electronics made up of different parts that can then be replaced/ upgraded separately making the product more sustainable

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38
Q

why can continuous improvement be harmful?

A

can encourage users to replace existing products with new ones
leads to an increased usage of finite resources and environmental damage due to manufacturing, packaging, transportation etc.

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39
Q

why can continuous improvement be good for the environment?

A

products can be changed to be more efficient therefore having a lower carbon footprint as it uses less energy

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40
Q

name 3 other aspects of products that have a positive impact on the environment

A

avoiding the use of harmful chemicals
making products from materials that can be recycled
minimising the amount of material used.

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41
Q

name the 6 Rs

A 
Repair
Reuse
Recycle
Rethink
Reduce
Refuse
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42
Q

Define Reuse

A

passing on a product e.g. tyre for a swing

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43
Q

Define Rethink

A

thinking about the design from an environmental perspective

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44
Q

name 2 impacts a product can have on people

A 
safe working conditions
health impacts (harmful pollutants)
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45
Q

What is innovation?

A

when an entrepreneur or business come up with a something new

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46
Q

Name 3 innovations in business

A

crowdfunding, virtual marketing/ retail, co-operatives and fairtrade

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47
Q

Define crowdfunding

A

using websites to raise money for an idea. Backers give money/ invest and often get a reward for their investment

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48
Q

Define virtual marketing and virtual retail

A

promoting and selling products on the iternet

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49
Q

Define co-operatives

A

a type of business that is run and owned by its members. Profits are shared out. they can have higher negotiating powers.

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50
Q

Define fairtrade

A

a scheme that ensures farmers are paid a fair price

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51
Q

define market pull

A

designing for what the customer wants/ needs

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52
Q

define technology push

A

the development of new technologies that then drive the design of new products

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53
Q

How does burning fossil fuels power a system?

A

power stations burn fossil fuels to produce heat
water then turns into steam
steam drives a turbine
this turns a generator, generating electricity

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54
Q

name 2 arguments for using fossil fuels

A

they are reliable

fairly cost effective as extraction and running costs are low

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55
Q

name 3 arguments against using fossil fuels

A

they are finite
extraction of fossil fuels have environmental and social impacts
they release greenhouse gases when burnt contributing to global warming

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56
Q

How does nuclear power stations work?

A

in a similar way to burning fossil fuels but nuclear fission is used to create heat instead

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57
Q

name 3 arguments for using nuclear power

A

reliable
quite cheap
produces low levels of greenhouse gases

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58
Q

name 3 arguments against using nuclear power

A

uses finite fuel sources (uranium)
nuclear power plants cost a lot to build and maintain
waste produced is dangerous and difficult to dispose of
risk of major catastrophe

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59
Q

name 3 arguments for using renewable energy

A

generally have a smaller environmental impact

after initial set up costs, the energy provided is usually free

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60
Q

name 3 arguments against using renewable energy

A

set up costs are quite high
less reliable as depend upon external factors (wind)
spoil landscapes
habitat loss

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61
Q

name 2 systems that are used to store extra energy

A

kinetic pumped storage system

batteries

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62
Q

how does a hydro electric power station work?

A

‘spare’ energy pumps water up from a lower reservoir to an upper reservoir. In peak demand, water from the upper reservoir can flow through turbines, generating electricity.

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63
Q

what kind of energy do batteries store and how do they work

A

chemical energy

chemical reactions are used to generate an electric voltage

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64
Q

name the 2 types of batteries

A

alkaline

rechargeable

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65
Q

name properties of alkaline batteries

A

they’re recyclable
last a long time
leak less than some disposable batteries
power output gradually decreases over time

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66
Q

name properties of rechargeable batteries

A

can be charged when it goes flat
more expensive than alkaline batteries
can be used again and again - makes them more environmentally friendly
power output remains constant until they go flat

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67
Q

define an alloy

A

a mixture of two or more metals

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68
Q

what are alloys useful for?

A

they are developed to have a specific set of properties as they have different properties from their individual metals

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69
Q

why would you use cartridge paper?

A

as it is textured, it is good for sketching with different drawing materials

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70
Q

what is layout paper good for?

A

thin and translucent and use for general design work

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71
Q

what is tracing paper used for?

A

semitransparent so can copy images

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72
Q

what is grid paper used for?

A

useful for orthographic and scale drawings

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73
Q

what is bleed proof paper used for?

A

designing with felt tips and marker pens

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74
Q

why is carboard used in packaging?

A

low cost and has a high strength to weight ratio

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75
Q

what is solid white board used for?

A

ideal for printing and primary packaging (individual items)

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76
Q

what is ink jet card used for?

A

ink jet printing, printed image is sharply defined and of a high quality

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77
Q

what is corrugated card used for?

A

secondary packaging (items all in one box) as it is strong and rigid

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78
Q

what is duplex board used for?

A

when only one side is seen like food packaging.

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79
Q

what is foam core board used for?

A

good for making models and mounting posters as it is stiff, lightweight and can be scored

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80
Q

what is foil lined board used for?

A

to package food as it keeps flavor in and air and moisture out

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81
Q

define timber

A

sawn chunks of solid wood that are used as building materials

82
Q

name 3 softwoods

A

pine
larch
spruce

83
Q

give some properties of pine

A

strong, cheap, knotty. used for telegraph poles, fences and cheap furniture

84
Q

name some properties of larch

A

attractive yellow/ red colour
harder, tougher and more durable than most soft woods
resistant to rot
used for decking

85
Q

name some properties of spruce

A 
reddish/ brown colour 
hard
good strength to weight ratio
knotty 
not durable 
used for structural purposes
86
Q

name 4 hardwoods

A

oak
beech
ash
mahogany

87
Q

name some properties of oak

A 
tough
durable
very strong
corrodes steel
used for interior panelling, flooring and furniture
88
Q

name some properties of beech

A

hard
can be bent using steam
used for chairs and toys

89
Q

name some properties of ash

A

tough
absorbs shock well
used for tool handles, some furniture

90
Q

name some properties of mahogany

A

durable
easy to work with
expensive
used for good quality furniture

91
Q

what do ferrous metals contain?

A

iron

92
Q

name 3 ferrous metals

A

cast iron
low carbon steel (mild steel)
high carbon steel (tool steel)

93
Q

name properties and uses of cast iron

A

strong if compressed
brittle
not malleable
bench vices, car brake disks

94
Q

name properties and uses of low carbon steel

A 
quite strong 
cheap 
rusts easily 
can't be hardened 
car bodies, screws, washing machines
95
Q

name properties and uses of high carbon steel

A 
harder than low carbon steel 
can be hardened 
not as easy to work with 
rusts 
tools like files, saws and drills
96
Q

define a non ferrous metal

A

a metal that doesn’t contain iron so they don’t rust

97
Q

name 5 non ferrous metals

A

aluminum, brass, copper, tin, zinc

98
Q

name properties and uses of aluminum

A 
lightweight
corrosion resistant
expensive 
not as strong as steel 
airplanes, cans, ladders
99
Q

name properties and uses of brass

A 
quite strong
corrosion resistant
malleable
ductile
good electrical conductor 
electrical parts, door handles, taps
100
Q

name properties and uses of copper

A 
relatively soft
malleable 
ductile
very good electrical conductor 
electrical wiring, pipes
101
Q

name properties and uses of tin

A 
soft
corrosion resistant 
malleable 
ductile
low melting point
foil, tin cans, alloying metal in solder
102
Q

name properties and uses of zinc

A

not very strong
corrosion resistant
coating steel

103
Q

name 3 useful alloys

A

high speed steel, brass, stainless steel

104
Q

name some properties of high speed steel

A

contains iron and 0.6% of carbon
keeps its hardness when heated
used in high speed cutting tools

105
Q

state what brass is made of

A

copper and zinc

106
Q

state properties of stainless steel and what it is made of

A 
iron, carbon, chromium, nickel 
strong 
tough
ductile 
decreases rust 
used in surgical equipment, sinks and cutlery
107
Q

name the two main sorts of plastics

A

thermoforming and thermosetting plastics

108
Q

name properties of thermoforming plastics

A

recyclable, bendy, doesn’t resist heat, easily formed into shapes

109
Q

name 6 thermoforming plastics

A

acrylic (PMMA), HDPE, PET, HIPS, PVC, PP

110
Q

Name properties of acrylic (PMMA)

A

hard, stiff, shiny, resists weather well, brittle

used for motorcycle helmet visors, baths, signs

111
Q

name properties of high density polyethylene (HDPE)

A

stiff, strong, lightweight,

used for washing up bowls, baskets, folding chairs, gas and water pipes

112
Q

name properties of polyethylene terephthalate (PET)

A

polyester that is light, strong, tough

used to make see through water bottles and fibres for clothing

113
Q

name properties of high impact polystyrene (HIPS)

A

rigid, fairly cheap

used for smoke detector cases and CD cases

114
Q

name properties of polyvinyl chloride (PVC)

A

quite brittle, cheap, durable

used for window frames, vinyl records, some clothing

115
Q

name properties of polypropylene (PP)

A

quite tough, flexible, can be made into bright colours

used for plastic chairs

116
Q

name properties of thermosetting plastics

A

non-recyclable, rigid, resist heat, permanently become hard and rigid

117
Q

name 5 thermosetting plastics

A

ER, UF, MF, PF, PR

118
Q

name properties of epoxy resin (ER)

A

rigid, durable, corrosion- resistant, good electrical insulator
used for circuit boards and wind turbine rotor blades

119
Q

name properties of urea-formaldehyde (UF)

A

hard, brittle, good electrical insulator

used for plug sockets and cupboard handles

120
Q

name properties of melamine-formaldehyde (MF)

A

strong and scratch-resistant

used to laminate chipboard and for plates and bowls

121
Q

name properties of phenol-formaldehyde (PF)

A

hard, heat resistant, very easily moulded

used for bottle caps, snooker balls and to form composites

122
Q

name properties of polyester resin (PR)

A

hard, stiff, cheap, good electrical insulator
can form glass reinforced plastic e.g. for kayaks
waterproof so used for shower stalls and garden furniture

123
Q

name general properties of natural fibres

A

absorbent, strong when dry, poor resistance to biological damage like moths

124
Q

name 3 natural fibres

A

cotton, wool, silk

125
Q

name 3 advantages and disadvantages of cotton

A

hard wearing, doesn’t cause allergies, washes easily

creases easily, poor elasticity, can shrink when washed

126
Q

what is cotton used for?

A

used in denim, corduroy and calico

used for jeans, t-shirts, blouses and soft furnishings

127
Q

name 3 advantages and disadvantages of wool

A

warm, crease-resistant, good elasticity

can shrink, itchy, fairly expensive

128
Q

what is wool used for?

A

used in felt, knitted fabrics and Harris Tweed

used for suits, jumpers, carpets

129
Q

name 3 advantages and disadvantages of silk

A

resistant to shrinking/ stretching, good drape, lightweight

creases easily, weak when wet, expensive

130
Q

what is silk used for?

A

used in chiffon, satin

used for ties, shirts, dresses

131
Q

name general properties of synthetic fibres

A

less sustainable than natural fibres, resistant to biological damage, can be changed by heating, not very absorbent so hard to dye

132
Q

name 3 synthetic fibres

A

elastane, polyester, polyamide

133
Q

name 3 advantages and disadvantages of elastane

A

extremely elastic, lightweight, hard wearing

not absorbent, high flammability, not biodegradable

134
Q

what is elastane used for?

A

used in lycra

used for sportswear, underwear and added to other fibres to add stretch

135
Q

name 3 advantages and disadvantages of polyester

A

cheap, resists creasing, hard wearing

damaged by strong acids, melts as it burns, not absorbent

136
Q

what is polyester used for?

A

used in dacron

used for bed sheets, curtains, tablecloths, sportswear

137
Q

name 3 advantages and disadvantages of polyamide

A

warm, fairly cheap, crease resistant

not very absorbent, damaged by sunlight, melts as it burns

138
Q

what is polyamide used for?

A

used in nylon

sportswear, tights, furnishings, carpet

139
Q

what are yarns?

A

threads that are woven or knitted to make fabrics

140
Q

what are yarns made of?

A

fibres. short fibres are staple fibres. long fibres are filaments

141
Q

what are yarns made from filaments like?

A

smooth

142
Q

what are yarns made from staple farmers like?

A

hairier than yarns made from filaments

143
Q

name the three main ways to turn yarns/ fibres into a fabric

A

weaving, knitting, bonding

144
Q

How are woven fabrics made?

A

by interlacing two sets of yarn

145
Q

How are knitted fabrics made?

A

by interlocking one or more yarns together using loops. The loops trap air, so they insulate. They stretch more than woven fabrics

146
Q

How are non-woven fabrics made?

A

layers of fibre held together by bonding or felting. They don’t fray and can be cut in any direction, little waste when laying out a pattern. They don’t stretch and aren’t very strong

147
Q

what is the weft?

A

the yarn in woven fabrics travelling from right to left

148
Q

what is the warp?

A

the yarn in woven fabrics travelling up and down

149
Q

what are the properties of plain weave fabrics?

A

hard wearing, strong, holds its shape, smooth finish, cheapest weave to produce. used to make fabrics like cotton based one

150
Q

What are woven fabrics used for?

A

shirts, upholstery and trousers

151
Q

What are the 2 types of knitted fabrics?

A

weft-knitted and warp-knitted

152
Q

how are weft knitted fabrics made?

A

yarn runs across the fabric, making interlocking loops with the row beneath

153
Q

what are weft knitted fabrics used for and why?

A

they stretch but can lose their shape and if the yarn breaks it can unravel. used for jumpers, socks and t shirts

154
Q

how are warp knitted fabrics made?

A

yarn runs up the fabric in loops which interlock vertically.

155
Q

what are warp knitted fabrics used for and why?

A

they stretch and keep their shape and are hard to unravel. made by machines
used for tights, swimwear and fleeces

156
Q

what are bonded fabrics?

A

‘webs’ of synthetic fibres glued, needle punched, stitched or melted together. they are used for interfacing, artificial leathers and disposable cloths

157
Q

what are felted fabrics?

A

made by combining pressure, moisture and heat to interlock a mat of wool fibres. used for carpet underlay, craft material, hats and snooker table coverings.

158
Q

name the two ways of combining fibres to get fabrics with different properties.

A

blending or mixing

159
Q

what is the difference between blending and mixing?

A

blending combines two fibres into one yarn but mixing combines two yarns to make one fabric

160
Q

name benefits of blending cotton and polyester fibres together

A

strong and hardwearing, less absorbent so dries quickly, soft, comfortable, resists creasing, doesn’t shrink, but is highly flammable

161
Q

name properties of MDF

A

tiny fibres of softwood timber held together with glue. no natural grain, cheap, dense, smooth uniform surface, damaged by moisture. used for shelves and flat pack furniture

162
Q

name properties of plywood

A

several layers of soft or hardwood, glued together with grains at right angles. very strong for its weight. used for building and furniture.

163
Q

name properties of chipboard

A

made by compressing wood chips, shavings and sawdust together with glue. cheap but not very strong, absorbent, damaged by moisture. used in cheap self assembly furniture

164
Q

what are printed circuit boards (PCB)

A

boards with thin copper tracks connecting components. They are used to reduce the size and manufacturing costs of electronic systems

165
Q

what do input devices do?

A

they change the electrical current in a circuit by receiving an external signal. Examples include switches and variable resistors

166
Q

how does a thermistor function?

A

when conditions are hot the resistance falls increases

used in central heating

167
Q

how do LDRs function?

A

in brighter light the resistance falls

used in automatic night lights

168
Q

how do pressure sensors function?

A

depending on the type of pressure sensor, resistance can be increased or decreased
used in equipment where gases or liquids are monitored.

169
Q

what are integrated circuits?

A

tiny self contained circuits, they simplify a circuit and make a circuit cheaper, smaller and use less power

170
Q

name advantages and disadvantages of a micro controller

A

+they can do the job of multiple ICs
+they can be reprogrammed
- more expensive than other ICs

171
Q

How are timers and counters different?

A

timers add a a time delay to a process and generate a pulse after a certain amount of time. counters count the pulses made by an input device

172
Q

how does a microcontroller use a timer?

A

microcontrollers controlling flashing lights like car indicators use timers to set how long the light is on/ off
microcontroller controlling microwave uses a timer

173
Q

what does a mechanical system do?

A

changes the magnitude and direction of a force

174
Q

what do levers do?

A

make it easier to lift loads

175
Q

What is in the middle in a first order leaver?

A

The pivot between the effort and the load.

picture it like a seesaw

176
Q

What is in the middle in a second order leaver?

A

the load, like a wheelbarrow. the closer together the load and the pivot, the easier it is to lift

177
Q

What is in the middle of a third order leaver?

A

the effort, like a fishing rod and garden spade. moving the effort and the pivot further apart makes it easier to lift

178
Q

name 2 types of linkage

A

bell crank, push/pull linkages

179
Q

what does a bell crank linkage do?

A

changes the direction of a force through 90 degrees

180
Q

what do gear trains do?

A

transmit or change rotary motion

181
Q

How do you make gears turn in the same direction?

A

use a third gear called an idler

182
Q

How do you half the force needed to lift a load?

A

use one fixed pulley and one moving pulley (a block and tackle)

183
Q

what do belt drives do?

A

transfer movement. They are used in things like pillar drills and washing machines. they are made up of a driver (motor), belt and the driven shaft.

184
Q

what do cams do and what can they be used for?

A

they change rotary motion to reciprocating motion

changing the size and shape of the cam can be used to change the magnitude of the output motion

185
Q

name 4 basic cam shapes

A

pear, circular, snail and four-lobed

186
Q

name properties of metal foam

A

contain many gas filled spaces so are lightweight

stiff, tough and strong under compression. used in lightweight car parts and in bone implants

187
Q

name properties of titanium

A

corrosion resistant, high strength: weight, used in aerospace, difficult to machine

188
Q

name properties of liquid crystal displays

A

when an electric current is applied, the crystals change shape so the image changes. used in flat screen displays and calculators

189
Q

name properties of coated metals

A

galvanising and electroplating can prevent rust, anodised aluminium is harder and resistant to corrosion, coating with PVC makes it corrosion resistant and can be coloured

190
Q

name properties of carbon nanotubes

A

very high strength : weight, are good conductors of heat and electricity. can strengthen materials. used in electronics and tennis racquets

191
Q

name properties of self cleaning fabrics

A

they have a nanoparticle coating that removes odours and stains upon exposure to light

192
Q

name properties of antibacterial fabrics

A

use nanoparticles of silver to kill bacteria. they have medical uses like face masks and dressings.

193
Q

name some smart materials

A

shape memory alloys (nitinol), photochromic pigments, thermochromic pigments

194
Q

what are technical textiles?

A

made to just be functional

195
Q

what does batch production do?

A

makes a certain amount of products.
batches can be repeated
one process is done on the whole batch and then another
the machinery and workforce need to be flexible so they can be quickly changed
down time wastes money

196
Q

what does mass production do?

A

making loads of the same product
used for mass-market products each worker does a small part of the process
uses CAD/CAM

197
Q

how does continuous differ from mass production?

A

it runs all the time as it would be too expensive to keep stopping
almost entirely automated
makes huge amounts of only one thing
cost per item is cheap

198
Q

name some quality control tests

A

go/no go fixtures, registration marks, checking against original

199
Q

what do registration marks do?

A

they check that the printing plates are aligned

200
Q

name ways to achieve consistency during manufacture

A

depth stops, laser cutters, PCBs

201
Q

what do depth stops do?

A

create exact depths, they are long rods clamped close to the drill bit

product design (4 decks)

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