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Product Design > Smoethattestk > Flashcards

Smoethattestk Flashcards

1
Q

What is PTFE and why is it used for non-stick saucepans?

A

PTFE (Polytetrafluoroethylene) is a polymer with non-stick properties, high heat resistance, and chemical inertness, making it ideal for durable and easy-to-clean non-stick cookware.

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2
Q

What makes polypropylene suitable for seating?

A

Polypropylene is a flexible, lightweight thermoplastic with high impact resistance and durability, making it ideal for chairs, especially in high-use areas.

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3
Q

What is ergonomics, and how is it applied in chair design?

A

Ergonomics is the study of designing products to fit the user comfortably and reduce strain. In chair design, it ensures proper posture support and comfort.

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4
Q

What is anthropometric data, and why is it important in design?

A

Anthropometric data refers to measurements of human body dimensions, used by designers to ensure products fit the target audience for safety and usability.

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5
Q

What are modern materials?

A

Modern materials, like carbon fiber composites, are advanced materials engineered for specific properties, such as strength-to-weight ratio and corrosion resistance.

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6
Q

What are smart materials?

A

Smart materials, such as shape memory alloys, respond to environmental changes (e.g., heat or stress) and can adapt their properties, like returning to a pre-set shape.

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7
Q

What is Polymorph, and why is it useful?

A

Polymorph is a low-temperature thermoplastic that becomes pliable at 62°C, ideal for prototyping and creating custom shapes due to its reusability and ease of molding.

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8
Q

What are the advantages of shape memory alloys?

A

Shape memory alloys, like Nitinol, can return to a pre-set shape after deformation when heated, making them useful in medical devices and responsive mechanisms.

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9
Q

What drives the development of sustainable products?

A

Key drivers include reducing environmental impact, meeting consumer demand for eco-friendly solutions, and ensuring economic viability through efficient production processes.

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10
Q

What is the product life cycle?

A

The product life cycle covers all stages of a product, from raw material extraction through manufacturing, usage, and end-of-life disposal or recycling.

Process: The product is designed and developed (concept and prototyping).

Manufacture: Mass production of the product takes place to meet demand.

Move Item - Distribute: The product is distributed to retailers or customers.

Sell/Purchase: Customers buy the product, and it enters the market.

Sell Used Item/Recoup Money: The product is resold or traded, and its value may decrease over time.

Dispose: The product reaches the end of its life, and it is disposed of or recycled.

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11
Q

What are the 6Rs of sustainability?

A

Reduce – Minimize the amount of materials and energy used to lower waste and consumption.

Reuse – Use items again, either for the same purpose or repurpose them to extend their life.

Recycle – Convert waste into reusable materials to prevent depletion of resources.

Rethink – Consider alternative ways to design or use products to make them more sustainable.

Refuse – Avoid products that are harmful to the environment or unnecessary.

Repair – Fix broken items instead of replacing them to reduce waste.

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12
Q

What are the key properties of UPVC?

A

UPVC is rigid, weather-resistant, and low-maintenance, ideal for windows and pipes, though it becomes brittle in extreme cold.

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13
Q

Why compare traditional and modern materials?

A

Comparing helps evaluate suitability. For instance, carbon fiber is lightweight and strong, while wood offers natural aesthetics and sustainability.

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14
Q

How do sustainable design principles influence product development?

A

Designers prioritize renewable materials, waste reduction, durability, and recyclability to minimize environmental impact.

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15
Q

Why are functional qualities important in material selection?

A

Functional qualities, such as strength or heat resistance, determine a material’s performance in specific applications and its suitability for the product.

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16
Q

How does ergonomic design enhance product usability?

A

Ergonomic design reduces strain, improves comfort, and enhances efficiency, making products safer and easier to use for a wider audience.

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17
Q

What are the main uses of polypropylene?

A

Polypropylene is used in storage containers, seating, and automotive components due to its durability, flexibility, and impact resistance.

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18
Q

What is injection molding, and what is it used for?

A

Injection molding is a manufacturing process where molten plastic is injected into a metal mold under high pressure.

Applications: Used for creating high-volume products like bottle caps, toys, and electronic casings.

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19
Q

What are the steps involved in injection molding?

A
  1. Plastic pellets are melted in a heated barrel.
  2. The molten plastic is injected into a mold cavity.
  3. The material cools and solidifies into the shape of the mold.
  4. The mold is opened, and the part is ejected.
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20
Q

What is blow molding, and what products are made using this method?

A

Blow molding is a process for making hollow plastic objects.

Applications: Used for bottles, fuel tanks, and containers.

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21
Q

What are the steps involved in blow molding?

A
  1. Plastic is melted and extruded as a tube (parison).
  2. The parison is clamped inside a mold.
  3. Compressed air inflates the plastic to fill the mold cavity.
  4. The part cools, solidifies, and is ejected.
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22
Q

What is vacuum forming, and when is it used?

A

Vacuum forming shapes a heated plastic sheet over a mold using suction.

Applications: Commonly used for packaging, trays, and product casings.

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23
Q

What are the steps involved in vacuum forming?

A
  1. The plastic sheet is clamped and heated until pliable.
  2. It is draped over the mold.
  3. A vacuum removes air, pulling the sheet tightly against the mold.
  4. The plastic is cooled and trimmed.
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24
Q

What is 3D printing, and what are its applications?

A

3D printing builds objects layer by layer from a digital file.

Applications: Prototyping, custom parts, and complex designs for industries like healthcare and aerospace.

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25
Q

What are the steps involved in 3D printing?

A
  1. A 3D model is sliced into layers using software.
  2. Material is deposited or solidified layer by layer.
  3. The final object is removed and post-processed.
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26
Q

What is CNC machining, and why is it important?

A

CNC machining uses computer-controlled tools to precisely cut or shape materials.

Applications: Used for intricate metal and plastic parts in automotive and aerospace industries.

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27
Q

What are the steps involved in CNC machining?

A
  1. A design is inputted into the CNC machine.
  2. The machine uses tools (e.g., drills, mills) to shape the material.
  3. Excess material is removed to create the desired part.
28
Q

What is die casting, and what materials are used?

A

Die casting involves injecting molten metal into a mold under high pressure.

Applications: Used for aluminum, zinc, and magnesium parts like engine components and housings.

29
Q

What are the steps involved in die casting?

A
  1. The metal is melted and injected into a steel mold.
  2. The mold cools and solidifies the part.
  3. The mold is opened, and the part is trimmed.
30
Q

What is sand casting, and what are its typical applications?

A

Sand casting forms metal parts using sand molds.

Applications: Used for large, complex shapes like engine blocks and industrial machinery.

31
Q

What are the steps involved in sand casting?

A
  1. A pattern is created and placed in sand to form a mold cavity.
  2. Molten metal is poured into the cavity.
  3. The metal cools and solidifies.
  4. The sand mold is broken to remove the part.
32
Q

What is laser cutting, and what materials can it process?

A

Laser cutting uses a focused laser to cut or engrave materials.

Applications: Suitable for wood, acrylic, and metals in prototyping and detailed designs.

33
Q

What are the steps involved in laser cutting?

A
  1. A design is programmed into the laser cutter.
  2. The laser melts, burns, or vaporizes the material along the design path.
  3. Excess material is removed, leaving a clean edge.
34
Q

What is rotational molding, and what products are made with it?

A

Rotational molding creates hollow plastic parts by rotating a mold filled with polymer powder.

Applications: Used for tanks, kayaks, and playground equipment.

35
Q

What are the steps involved in rotational molding?

A
  1. Polymer powder is placed into a mold.
  2. The mold rotates while being heated to evenly distribute the material.
  3. The mold is cooled, and the part solidifies.
  4. The part is removed.
36
Q

What is extrusion, and what are its applications?

A

Extrusion forces material through a die to create continuous profiles.

Applications: Pipes, window frames, and tubing.

37
Q

What are the steps involved in extrusion?

A
  1. Material (e.g., plastic or metal) is melted.
  2. It is forced through a shaped die.
  3. The extruded product is cooled and cut to length.
38
Q

What is press forming, and what materials are used?

A

Press forming shapes sheet metal into specific forms using a press.

Applications: Used for car body panels and metal casings.

39
Q

What are the steps involved in press forming?

A
  1. A metal sheet is placed between a die and a punch.
  2. Pressure is applied to shape the sheet.
  3. The formed part is trimmed and finished.
40
Q

What is powder coating, and what are its advantages?

A

Powder coating applies a durable finish to metal parts.

Applications: Metal furniture, car parts, and appliances.

41
Q

What are the steps involved in powder coating?

A
  1. Dry powder is sprayed onto a part using an electrostatic gun.
  2. The part is heated in an oven to cure the powder.
  3. The result is a smooth, hard finish.
42
Q

What is forging, and where is it used?

A

Forging shapes metal through compressive forces.

Applications: Tools, bolts, and engine parts.

43
Q

What are the steps involved in forging?

A
  1. Metal is heated to a malleable state.
  2. It is hammered or pressed into a die.
  3. The shaped part is cooled and finished.
44
Q

What is lamination, and why is it used?

A

Lamination bonds layers of material to improve strength or aesthetics.

Applications: Plywood, laminated glass, and decorative finishes.

45
Q

What are the steps involved in lamination?

A
  1. Layers of material are coated with adhesive.
  2. They are pressed together under heat and pressure.
  3. The laminated product is trimmed to size.
46
Q

What is thermoforming, and how is it different from vacuum forming?

A

Thermoforming involves heating plastic sheets and forming them over a mold.

Applications: Used for packaging and enclosures.

47
Q

What are the steps involved in thermoforming?

A
  1. The plastic sheet is clamped and heated until soft.
  2. It is pressed into or over a mold using vacuum, pressure, or both.
  3. The plastic is cooled and trimmed.
48
Q

What are the properties and examples of hardwoods?

A

Properties: Dense, durable, and typically slow-growing. Often more expensive than softwoods.

Examples:
Oak (strong, durable, resistant to wear).
Mahogany (aesthetic, good workability, but prone to warping).
Beech (tough, resistant to impact, easy to finish).

49
Q

What are the properties and examples of softwoods?

A

Properties: Lighter, less dense, and faster-growing than hardwoods. Often more sustainable.

Examples:
Pine (lightweight, easy to work with, prone to knots).
Cedar (naturally resistant to moisture and decay).
Spruce (lightweight, strong, used for construction).

50
Q

What are ferrous metals and their properties?

A

Metals containing iron, usually magnetic, prone to rust (unless alloyed).

Examples and Uses:
Mild Steel (tough, ductile, used in construction).
Stainless Steel (corrosion-resistant, aesthetic, used in kitchenware).
Cast Iron (brittle, strong under compression, used in machine parts).

51
Q

What are non-ferrous metals and their properties?

A

Metals without iron, usually resistant to corrosion and non-magnetic.

Examples and Uses:
Aluminium (lightweight, corrosion-resistant, used in cans).
Copper (excellent conductor, malleable, used in wiring).
Brass (alloy of copper and zinc, aesthetic, used in musical instruments).

52
Q

What are thermoplastics and their characteristics?

A

Plastics that can be reheated and reshaped multiple times.

Examples and Properties:
Acrylic (rigid, clear, weather-resistant).
Polypropylene (flexible, chemical-resistant, used in containers).
ABS (tough, impact-resistant, used in car parts).
Polyvinyl Chloride (PVC): Tough, durable, resistant to chemicals and weathering. Used in pipes, window frames, and flooring.
Polyethylene (HDPE/LDPE): Lightweight, impact-resistant. HDPE is used for bottles; LDPE is used for plastic bags.

53
Q

What are thermosetting plastics and their characteristics?

A

Plastics that harden permanently after heating and cannot be reshaped.

Examples and Properties:
Epoxy Resin (strong adhesive, chemical-resistant).
Melamine Formaldehyde (heat-resistant, used in kitchenware).
Polyester Resin (rigid, used in fiberglass).

54
Q

What are composite materials and their uses?

A

Materials made by combining two or more materials to enhance properties.

Examples and Properties:
Carbon Fiber (lightweight, strong, used in aerospace).
Glass Reinforced Plastic (tough, corrosion-resistant, used in boats).
Concrete (strong in compression, weak in tension, used in buildings).

55
Q

What are manufactured boards?

A

Engineered wood products made by bonding layers or particles of wood.

Examples:
MDF (smooth, easy to machine, prone to moisture damage).
Plywood (strong, stable, made from layers glued at 90°).
Chipboard (cheap, not durable, often veneered).

56
Q

What are the different types of finishes applied to materials?

A

Wood Finishes:
Varnish (protects against moisture, enhances grain).
Wax (provides a natural look and slight protection).
Oil (e.g., Danish oil, nourishes wood, protects).
Paint (adds color, protects from moisture).

Metal Finishes:
Powder Coating (durable, aesthetic finish).
Galvanizing (zinc coating to prevent rust).
Anodizing (enhances corrosion resistance for aluminium).

Plastic Finishes:
Acrylic Spray Paints (Enhances appearances, UV protection).
Thermoplastic Elastomer (TPE) Overmoulding (soft, rubber-like grip to rigid plastics, improving ergonomics and slip resistance).

57
Q

Why are finishes applied to materials?

A

Protect against wear, moisture, and corrosion.
Enhance aesthetics (e.g., paint, varnish).
Improve functionality (e.g., non-slip surfaces).
Extend product life and durability.

58
Q

What is a physical property?

A

A physical property refers to a material’s inherent characteristics that are not related to force or deformation.

Examples:
Density: Mass per unit volume.
Thermal Conductivity: Ability to transfer heat.
Electrical Conductivity: Ability to conduct electricity.
Optical Properties: Transparency, translucency, or opacity.
Melting Point: Temperature at which a material changes from solid to liquid.

59
Q

What is a mechanical property?

A

A mechanical property refers to how a material reacts to physical forces.

Examples:
Strength: Ability to withstand force without breaking.
Hardness: Resistance to scratching or indentation.
Toughness: Ability to absorb energy and resist fracture.
Elasticity: Ability to return to original shape after deformation.
Ductility: Ability to be stretched into a wire without breaking.

60
Q

What are composite materials?

A

Composite materials are made by combining two or more different materials to enhance specific properties.

Examples and Uses:
Carbon Fiber Reinforced Polymer (CFRP): High strength-to-weight ratio, used in aerospace and sports equipment.
Glass Reinforced Plastic (GRP): Durable, used in boat hulls.
Concrete: Strong in compression, used in construction.

61
Q

What is pewter casting, and where is it used?

A

Pewter casting is a low-temperature casting process used to shape pewter, a soft alloy of tin with small amounts of other metals (e.g., copper).

Uses: Jewelry, decorative items, keychains, and small-scale production.

Advantages: Easy to work with due to its low melting point (~230°C), detailed finishes, and suitability for small-scale production.

62
Q

What is the process of pewter casting?

A

Create a Mold: Use materials like MDF, silicone, or metal to form a mold.

Heat Pewter: Melt pewter in a crucible until it becomes liquid.

Pour the Pewter: Carefully pour the molten pewter into the mold.

Cool and Solidify: Allow the pewter to cool and harden inside the mold.

Remove and Finish: Extract the casting from the mold and clean it by filing or polishing to achieve a smooth finish.

63
Q

What is die casting, and where is it used?

A

Die casting is a high-pressure metal casting process where molten metal is injected into a steel mold (die) to create precise, complex shapes.

Uses: Automotive parts, appliance components, and consumer electronics.

Advantages: High dimensional accuracy, smooth surface finish, and efficient for mass production.

64
Q

What is the process of die casting?

A

Prepare the Mold: Steel dies are preheated and coated with a release agent to prevent sticking.

Melt the Metal: Metals like aluminium, zinc, or magnesium are heated until molten.

Inject the Metal: Molten metal is injected into the mold under high pressure.

Cool and Solidify: Allow the metal to cool and solidify in the mold.

Eject and Finish: Eject the casting from the die and perform secondary processes such as trimming, polishing, or machining if necessary.

65
Q

RIDDOR

A

Reporting
Incidents
Diseases
Dangerous
Occurrences
Regulations

66
Q

COSHH

A

Control
Of
Substances
Hazardous To
Health

Product Design (3 decks)

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