Brainscape's Knowledge GenomeTM


Top Flashcards (Certified)
All Flashcards

Product Design > June 2021 Mock > Flashcards

June 2021 Mock Flashcards

1
Q

Any process where smaller pieces of material or separate parts are joined together to form a larger structure or assembly

A

Fabrication

a manufacturing process

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
2
Q

Any process by which a material’s shape is changed WITHOUT removing material

e.g. Pulling, stretching, folding, crushing

A

Deformation

a manufacturing process

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
3
Q

Any process by which materials are melted and liquified and poured into a mould or similar then left to cool in the shape of a new form

A

Redistribution

a manufacturing process

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
4
Q

Any process by which material is removed from a larger piece to arrive at the final shape.

A

Wasting

A manufacturing process

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
5
Q

Examples of Fabrication

A

MIG Welding,

Adhesive

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
6
Q

Examples of Deformation

A

Press Forming,
Rolling,
Spinning

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
7
Q

Examples of Redisribution

A

Sand Casting,

Injection Moulding

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
8
Q

Examples of Wasting

A 
Turning (Lathe),
Sawing,
CNC Router,
Routing,
Drilling
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
9
Q

What is Blow Moulding?

A

A moulding process where small plastic (polymer) granules are melted and squeezed into a mould. Since the system is under high pressure, the polymer forms around the edges of the mould creating a hollow object when ejected.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
10
Q

What is the full process of Blow Moulding?

5 Steps

A

1: The polymer is fed into the hopper.
2: An Archimedean screw pulls the polymer through a heated section, melting the polymer.
3: The melted polymer is extruded as a tube, which is called a ‘parison’.
4: the mould sides close around the paris on and air is injected into the mould forcing the polymer to the sides.
5: The polymer is allowed to cool for a few seconds, the mould opens and the finished bottle is ejected.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
11
Q

What are the advantages and disadvantages of Blow Moulding?

A

Advantages:

  • Suitable for mass production
  • Cheaper than injection moulding (in most cases)
  • doesn’t require moulds on each side of the part making more shapes possible and reducing mould costs
  • Allows one-piece construction of hollow shapes reducing manufacturing steps
  • Many materials to choose from

Disadvantages:

  • As the diameter increases, the corners and areas with the thinnest walls have the closest tolerance
  • Longer cooling times than injection moulding
  • Doesn’t allow for a high level of detail
  • Can result in large amounts of waste due to a lot of the extruded plastic not being used in the mould
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
12
Q

What type of Manufacturing Process is Blow Moulding?

A

A Redistribution Process

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
13
Q

Examples of products that use the Blow Molding

A
  • Kayaks
  • Mannequins
  • Bottles
  • Car seats
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
14
Q

What is a CNC Plotter (Vinyl) Cutter?

A

A CNC Plotter Cutter is a computerized cutter that allows for a CAD file to be cut onto vinyl.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
15
Q

What is Vacuum Forming?

A

Vacuum Forming is a manufacturing technique used to make 3D products out of moulds by melting a sheet of polymer and redistributing it by using a vacuum to pull the polymer tight onto the mould.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
16
Q

What is the Vacuum Forming process?

6 Steps

A

1: The mould is placed onto the bed of the machine, which is called the ‘platen’. The platen is lowered to the bottom of the machine.
2: Polymer sheet is clamped over the mould and a heater is pulled over the polymer sheet.
3: When the polymer sheet has softened, the platen is raised onto the polymer and the heat is removed.
4: The vacuum pump is switched on, which sucks the polymer onto the mould.
5: Once the polymer has cooled and returned to a solidified state, the platen is lowered and the vacuum is switched off.
6: The mould is removed from the moulding. Excess polymer is then trimmed off.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
17
Q

What type of manufacturing process is Vacuum Forming?

A

A Deformation Process

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
18
Q

What are the Advantages and Disadvantages of Vacuum Forming?

A

Advantages:

  • Durable moulds can be made allowing for mass production without deterioration of mould over time
  • Fairly cheap process
  • Moulds are very simple to make

Disadvantages:

  • Not cast effective for one-off manufacture (takes too much time to make a mould for the turnout)
  • Fairly slow compared to other moulding processes (e.g. injection moulding).
  • Normally limited to a small-scale batch.
  • Limited to shaping polymer sheets of up to about 6mm in thickness
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
19
Q

What can a Vacuum Formed part not do?

A
  • Have Overhands
  • Be a closed 3D shape (it must be hollow with one side open)
  • Have vertical faces
  • Have screwthreads or holes (holes can be drilled after though)
  • Have clips or fastening built-in
  • have strengthening ribs and supports
  • Have varying thickness over the part
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
20
Q

What are examples of Vacuum Formed Parts?

A
  • Plastic cups
  • Toys
  • Roofboxes
  • Coffee cup lids
  • Mudguards
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
21
Q

Explain Injection Moulding

A

Injection Moulding is an industrial process used to manufacture complex items made from thermoplastics.

(We did this in the computer room)

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
22
Q

What is the injection Moulding Process?

7 Steps

A

1: Thermoplastic granules are poured into the hopper.
2: A screw thread is rotated by a motor. This pulls the granules through the chamber and past electric heaters
3: The heaters melt the polymer
4: When a sufficient charge of polymer has melted and formed at the end of the screw, a hydraulic ram forces the screw thread forward. This injects the polymer into the mould.
5: The mould is water cooled, which enables the moltern polymer to harden quickly.
6: The mould opens and ejector pins push the moulding out.
7: Any excess polymer is trimmed off the moulding. Formers or jigs may be used to maintain the dimensional accuracy of the moulding while it cools and hardens completely.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
23
Q

What is a mould?

A

don’t be stupid you know what a fucking mould is…

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
24
Q

What is a moulding?

A

A moulding is a part that has been moulded (e.g. what gets ejected from the mould after injection moulding).

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
25
What are the advantages and disadvantages of Injection Moulding?
Advantages: - Mass production is easily accomplishable. Parts can be made just seconds apart thanks to the cooling in the moulds. - It is a fast method of production. - It is extremely scaleable for a production line. - Overhangs, strengthening ribs, projections, built-in screw threads, holes, slots, hinges, clips and screw bosses can be included in a mould. This means that once manufactured, a rapid assembly can take place reducing the need for extra binding parts (like screws, glue etc.). - Manufacturing is 100% repeatable. - The only process that can replicate injection moulding is 3D printing which takes WAY LONGER and produces weaker parts. Disadvantages: - Not suitable for one-off manufacture since moulds take far longer to make than parts. *Mass production ONLY* - Several factors make the process very EXPENSIVE: - Moulds have to be made from very hard materials which are very difficult to machine. - They must have a super polished, super hardened surface to survive the moulding process over millions of cycles. -
26
What type of manufacturing process is Injection Moulding?
Redistribution
27
What is 3D printing?
3D printing is a
28
What are the Advantages and Disadvantages of 3D printing?
Advantages: - Allows for rapid prototyping, designers can test one-off parts and make changes with a physical reference to what they are doing within hours. - Accurate dimensions and a fairly high-resolution finish can be achieved. Disadvantages - Very slow process therefore not ideal for mass production. - Only a select few polymers can be processed using this method.
29
What type of Manufacturing Process is 3D Printing?
Redistribution
30
What are examples of Injection Moulded Parts?
- TV Back - Car Bumper - Lego Brick - Lemon Squeezer - Pen Lid - Remote Controller
31
What's the difference between Injection Moulding and Blow Moulding?
Injection Moulding makes solid parts Blow Moulding makes Hollow parts
32
Define/Explain Softwood.
Softwood is a wood that comes from a Coniferous Tree (cone bearing tree). This type of wood is therefore generally fast growing, it doesn't lose its leaves in the winter
33
What are 3 examples of Softwood Timbers?
- Pine - Spruce - Douglas fir
34
Why are softwoods more desirable than man-made boards for furniture construction?
Because they have cosmetic characteristics in their grains which are more attractive than man-made boards.
35
Why are softwoods less desirable than Hardwoods?
Hardwoods are denser and therefore longer lasting than softwoods.
36
Why are softwoods more sustainable than hardwoods for manufacturing products?
Softwood trees grow much faster than hardwood trees meaning that you could create more softwood products over a timespan than hardwood products, using the same amount of space to grow the trees.
37
Define/Explain Hardwood.
Hardwood is timber from Broad-leaved (deciduous) trees. These are trees that lose their leaves in Autumn. This generally produces stronger, harder, and more durable timber at a sacrifice of growing far slower.
38
Name some Hardwoods.
- Oak - Beech - Walnut - Maple - Ash
39
What is Rough Sawn timber
Wood which comes directly from seasoning and has rough surfaces produced from initial conversion. Rough Sawn timber usually will have nominal sizes rather than accurate finished sizes.
40
What is P.S.E Timber (planed square edge)
Planed Square Edge wood has only one edge that is planed accurately; the rest are rough sawn. Planing removes about 3mm from the original nominal size.
41
What is the definition of a Smart Material? * - YOU NEED TO KNOW THIS - *
Smart Materials are materials whose physical properties change in response to an input or change in the environment, such as electricity, pressure, temperature or light. Many products utilize smart materials, often bringing benefits such as increased safety and/or ease of use.
42
Name three Smart Materials and Why they are smart, what they do, and typical applications for use * - there are others, these are good ones to know though - *
* * Shape Memory Alloy ** - - Changes shape in response to change in temperature or electrical input. - For example, nitinol wire in dental braces changes length in response to a change in temperature USES: - Dental Braces - Self-closing windows - Aeroplane wing flaps - bioengineering e.g. Stents - Bone plates and screws * * Photochromic Pigment (paint) ** - - Changes colour with light intensity USES: - Fire exit signs - Glow in the dark products e.g. adhesive stars - Masks - Night lights - Watch hands * * Thermochromic Pigment (Paint) ** - - Changes colour in response to temperature change USES: - Room thermometers - Medical thermometers for kids - Bathwater thermometers - Colour changing mugs and kettles - Battery charge indicator strips
43
What are the *GOOD* properties of aluminium as a material? AND How they make it suitable as a material?
Aluminium * Good Properties:* - Low density/weight for its strength - Corrosion-resistant (compared to other materials) because of the self-forming oxide layer (anodizing principle) - Readily available - a very common element (bauxite) - Highly recyclable and recycled - Low melting point - cheaper energy costs for casting etc. - easy to machine (softer than other metals) - Good thermal conductor (heat sinks, castings that need to dissipate heat e.g. engine blocks etc.) - Average electrical conductor (good copper substitute for cheaper items) - Highly polishable - Ductile & Malleable in certain forms. Used for: - Coke cans - Aluminium cooking foil - Car engine block - Bicycle rims - Cooking equipment - pots & pans - High-end computer/electrical cases/chassis (e.g. iPhone, surface pro) - Rivets
44
What are the *BAD* properties of aluminium as a material?
Aluminum * Bad Properties:* - Low hardness - not good for wearing surfaces/bearings, etc. - Low tensile strength compared to steel - Low toughness - tends to crack rather than bend under sudden impact - Low melting point (680C) - makes it unsuitable for some components (e.g. jet engines) - High initial extraction cost compared to other metals (requires large amounts of electricity) - Tricky to weld - needs annealing post welding to maintain strength or pre-heating before welding - Needs to be alloyed with other materials to make it useful - usually magnesium - *Raw aluminium is very brittle and a poor material* A good alloy would be Duralumin
45
Explain the process, Press forming.
1 - Metal *blank* is clamped over die 2 - *Punch* is pressed with hydraulic force downwards onto metal blank whilst blank is clamped securely in place with a *blank holder*. - Metal stretches over the punch and is pushed up into the *die*. 3 - Pressure is released and usually, air or ejector pins are used to push the finished part out of the die. (key words are starred)
46
What are the properties of stainless steel?
Stainless Steel: - Germicidal (germs won't stick to its surface because of its smoothness) - Non-corroding - good thermal conductor - self finishing - easily polished and maintains a shine - hard and high tensile strength/toughness relative to other metals
47
Examples of products made from Press Forming?
Press formed products: - Saucepans - Baking trays, - Car body panels - Sinks - Army helmets
48
What are the benefits of press forming?
- Mass production (can be a very fast process) - Greater accuracy in terms of tolerances within 0.01 to 0.02 inch. - Dies used in press forging have less draft, therefore more complicated shapes can be forged with better dimensional accuracy.
49
What is a die?
- A die is a specialized machine tool used in manufacturing industries to cut and/or form material to a desired shape or profile. - Stamping dies are used with a press, as opposed to drawing dies and casting dies which are not.
50
Explain the Spinning Process.
The Spinning Process involves spinning a sheet material (blank) and pushing/easing it into a shape using a roller tool. Similar to a Die, a mandrel is found underneath the spinning sheet material which the material is pushed against to gain the desired shape.
51
What kind of products/shapes are made with the Spinning Process?
Anything dome shaped with a hollow inside e.g.: - Bells - Bullets - Aeroplane nose - Satellite dishes - Gas cylinders - Brass instruments - Stainless steel bowls
52
Explain the steps of the Spinning Process
1 - A former called a 'mandrel' is put into the chuck. The sheet metal blank is held in place between the mandrel and the tail stock. 2 - The roller tool is moved into the blank and is rotated with the mandrel. This starts to stretch the metal over the mandrel 3 - The roller tool is moved along the mandrel as pressure is maintained against the rotating blank (sheet material) 4 - The roller tool is moved to the end of the mandrel, while still maintaining contact with the blank. This finishes the shape of the product. 5 - The finished product is removed from the mandrel 6 - Excess material is trimmed off following the spinning process.
53
In what instances of production is the Spinning Process best used?
Spinning is typically used in mass production, and can be set up using computer controlled machines so that thousands of identical products can be made. However, as the formers are relatively simple, it can be used in batch production, particularly where dome-shaped items need to be made but the quantity required does not justify the costs associated with press forming.
54
Define Ergonomics.
the scientific study of people and their working conditions
55
Define Aesthetics.
the features of a product that make it visually appealing
56
Define Inclusive Design.
The concept of designing products that will allow the maximum number of possible users to successfully use their product without discomfort.
57
How are ergonomics considered or applied to products that require constant human interaction/handling? You need to be able to justify these design ques in a product.
Ergonomics are considered to make a user experience more pleasant, increasing the quality of the working environment which one interacts with when using a product. An example would be a handle of a kettle, how the handle allows for a natural upright grip that is better suited for pouring and suited for someone who may struggle with something like arthritis.
58
What is Anodising?
Anodising is a finishing process commonly used for aluminium products which enhances the natural oxide layer, resulting in the aluminium having increased hardness and toughness. Anodising can also provide colour to the product
59
Give examples of products which use Anodising.
- Outer casings of torches - External hard drive covers - Casings for mobile phones or digital music players - Aircraft parts - Car engine components - Mountain bike parts - **ANY ALUMINIUM COMPONENT USED OUTSIDE**
60
What is so great about Anodising?
- Provides colouring for a surface (mainly for cosmetic reasonings) - Provides a barrier against corrosion (hardens the surface against wear and tear) - Hard finish compared to spray paint - Fairly easy to automate in a factory setting - Can anodize hard to reach areas that paint may not get to - The surface becomes very smooth (ideal for something like a carabiner)
61
Explain the Anodising process.
- Aluminium is cleaned, either mechanically, or with an acid chemical bath process. When cleaned, it is placed in an electrolyte solution *as the ANODE part of the circuit.* - Current is passed through it, with a carbon Cathode. - The current causes an electrolysis effect where aluminium oxide (basically aluminium 'rust') forms on the part. - After some time spent in the electrolyte solution, the part is removed and placed into a dye where it absorbs the colour through its pours. - The part is then placed into a bath of boiling hot water which closes up the pours.
62
What are the downsides of Anodising?
- Chemicals involved in manufacture - Limited range of colours/shades - can be time consuming
63
Tensile Strength is?
The ability to withstand the forces in tension without damage or permanent deformation
64
Compressive Strength is?
The ability to withstand forces in compression without damage of permanent deformation
65
Torsional Strength is?
The ability to withstand forces in twisting without damage or permanent deformation
66
Bending Strength is?
The ability to withstand forces in bending without damage or permanent deformation
67
Shear Strength is?
The ability to withstand forces in slicing without damage or permanent deformation
68
Malleability is?
The ability to deform (from being compressed, squashed, hammered, dented, rolled) without breaking
69
Ductility is?
Ability to be deformed (stretched) without breaking
70
Plasticity is?
The ease with which a material can be moulded/deformed/squeezed
71
Hardness is?
The ability to withstand indentation and scratching
72
Toughness is?
The ability to withstand sudden impacts without fracture
73
Elasticity is?
The ability to be deformed (stretched) and return back to its original form
74
Thermal Conductivity is?
The property of a material to allow thermal energy to flow through it, measured in W/m-k 0 (watts per meter-kelvin)
75
Electrical Conductivity is?
The property of a material that allows it to pass an electrical current

Product Design (1 decks)

Brainscape helps you reach your goals faster, through stronger study habits.
© 2025 Bold Learning Solutions. Terms and Conditions