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design and manufacture > paper 2 revision > Flashcards

paper 2 revision Flashcards

1
Q

what are the 4 types of commercial manufacture?

A
  • one off manufacture
  • batch manufacture
  • mass manufacture
  • continuous manufacture
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2
Q

what is one-off manufacture?

A

when a single product is produced by a highly specialised craftsman

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3
Q

what is batch manufacture?

A

a small batch of identical products produced by highly skilled workers (e.g. chairs)

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4
Q

what is mass manufacture?

A

a large amount of identical products are made, highly automated with low-skill workers. maybe injection moulded parts

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5
Q

what is continuous manufacture?

A

extremely high volume 24 hour manufacturing process, highly automated with low skill workers, high demand consumer products (e.g. plastic bottles)

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6
Q

advantages of computer aided manufacture (CAM)

A
  • high volume high pace
  • costs are low when high volumes are produced
  • identical products
  • high level of detail
  • reduced waste
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7
Q

disadvantages of computer aided manufacture (CAM)

A
  • everything stops if a machine breaks

- reduction in employment opertunities

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8
Q

impact of emerging technologies

A
  • job availability for skilled workers
  • less labour intensive jobs
  • reduction in work related injuries
  • economic impact on the local area
  • unemployment in local area
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9
Q

advantages of manufacture in developing countries

A
  • cheap material costs
  • low cost labour
  • increase profits
  • skilled workforce (highly trained labour force)
  • low running costs (e.g. electricity)
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10
Q

advantages of 3D printing

A
  • high level of accuracy
  • repeatable process
  • no craft skills required
  • one off parts quickly made
  • no need for moulds
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11
Q

what is injection moulding?

A
  • a manufacturing process that allows parts to be produced in a high volume
  • it is most typically a mass manufacturing process
  • used for complex shapes like toys, remote controls, buckets, toothpaste caps, etc.
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13
Q

what is the process of injection moulding?

A
  • melt plastic pellets
  • inject into a 2 piece mould
  • wait until solidified
  • remove the mould
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15
Q

what is rotational moulding?

A

rotational moulding is a plastic manufacturing process which is ideal for making large hollow products, such as kayaks

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16
Q

what is the process of rotational moulding?

A
  • fill empty mould with material
  • heat and rotate mould
  • cool mould
  • unload mould
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17
Q

what type of plastic is used to rotational mould?

A

Polypropylene (PP)

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18
Q

how is rotational moulding identified?

A

hollow plastic product with mould split lines

19
Q

what is the process of vacuum forming?

A
  • heat thin sheet of plastic to forming temperature
  • stretch onto single-surface mould
  • force against mould by vacuum
  • eject product from mould
20
Q

what plastic is needed to vacuum form?

A

thermoplastic, such as:

  • polystyrene
  • ABS
  • acrylic
  • polypropylene
21
Q

what is vacuum forming typically used to make?

A

packaging

22
Q

properties of vacuum forming

A
  • easy to form with low forming temperature
  • needs round edges to form so material doesn’t split
  • high impact strength
  • low levels of shrinkage when cooling
23
Q

properties of laser cutting

A
  • use acrylic
  • can only print 2D flat parts
  • drawn on CAD
  • laser leaves a clean cut which doesn’t require a finish
24
Q

what is die-casting?

A

it’s a metal manufacturing process which is much like injecting moulding but with metal

25
Q

how can you tell if a product has been die casted?

A

solid metal product with intricate details or surface pattern and sprue marks it ejector pin marks

26
Q

what is sand casting

A

a metal manufacturing process in which a 2 part mould is made from sand

27
Q

disadvantages of sand casting

A
  • labour intensive
  • mould lines
  • parts can be brittle
28
Q

what materials are tools typically made from?

A

high carbon steel or tool steel

29
Q

why must tools be made from strong materials?

A

they must:

  • be able to withstand forces (pushing/twisting)
  • be resistant to wearing out
  • have a higher melting point than material of product being manufactured
30
Q

what type of plastic is needed to injection mould?

A

thermoplastic, but only ABS or polypropylene (PP)

31
Q

how can you know if a product has been injection moulded?

A

injection moulding can be identified by:

  • mould split lines
  • pin marks
  • tapered edges

design and manufacture (2 decks)

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