test Flashcards
What are the physical characteristics to consider when selecting materials?
- malleability
- toughness
- hardness
- thermal conductivity
- electrical conductivity
- resistance to corrosion and degradation
- product function
- aesthetics
- cost
- manufacture and disposal.
Name the classifications of materials.
- metals (ferrous, non-ferrous, alloys)
- woods (hardwoods, softwoods, manufactured boards)
- polymers (thermoplastics, thermoset polymers, elastomers)
- papers and boards
- composites
- smart materials
- modern materials.
List the performance characteristics of papers and boards.
- ability to be scored
- cutting
- folding
- surface qualities for printing
- impact resistance
- recyclability and/or biodegradability.
Provide examples of different types of papers and their applications.
- layout paper: sketch pads
- cartridge paper: printing
- tracing paper: copying images
- bleed proof paper: marker rendering
- treated paper: photographic printing
- watercolour paper: painting
- corrugated card: packaging
- bleached card: greeting cards and high quality packaging
- mount board: modelling
- duplex card: food packaging
- foil backed and laminated card: drinks packaging
- metal effect card: gift packaging
- moulded paper pulp: eco-friendly packaging.
Identify the performance characteristics of polymer based sheet and film.
- ability to be scored
- cutting
- folding
- moulding
- transparency
- translucency
- flexibility
- recyclability and/or biodegradability.
What are the different stock forms of timber?
- rough sawn
- planed square edge (PSE)
- planed all round (PAR)
- natural timber
- manufactured boards
- mouldings.
List the performance characteristics of woods.
- grain pattern
- grain direction
- surface defects
- warpage
- shrinkage
- splitting
- joining
- forming
- steam bending
- laminating
- machining qualities
- resistance to decay
- moisture resistance
- toxicity.
Name examples of softwoods.
- pine
- spruce
- Douglas fir
- redwood
- cedar
- larch.
Name examples of hardwoods.
- oak
- ash
- mahogany
- teak
- birch
- beech.
What are the performance characteristics of metals?
- hardness
- toughness
- malleability
- elasticity
- tensile strength
- density
- resistance to corrosion
- thermal conductivity
- electrical conductivity
- melting points
- ability to be alloyed
- ability to be joined with heat processes
- ability to take applied coatings and finishes.
Identify examples of ferrous metals.
- low carbon steel
- stainless steel
- high speed steel (HSS)
- medium carbon steel
- cast iron.
Identify examples of non-ferrous metals.
- aluminium
- copper
- zinc
- silver
- gold
- titanium
- tin.
What are the stock forms of polymers?
- sheet
- film
- granules
- rod and other extruded forms
- foam
- powder.
List the performance characteristics of polymers.
- toughness
- elasticity
- insulation (thermal and electrical)
- UV resistance
- ability to be moulded
- resistance to chemicals and liquids
- melting points
- suitability for food packaging applications
- biodegradability
- recyclability
- self finishing
- ability to be combined with other polymers and/or additives.
What are examples of thermoplastic polymers?
- low density polyethylene (LDPE)
- high density polyethylene (HDPE)
- polypropylene (PP)
- high impact polystyrene (HIPS)
- acrylonitrile butadiene styrene (ABS)
- polymethylmethacrylate (PMMA)
- nylon
- rigid and flexible polyvinyl chloride (PVC)
- Polyethylene terephthalate (PET).
What are examples of thermoset polymers?
- urea formaldehyde (UF)
- melamine formaldehyde (MF)
- polyester resin
- epoxy resin.
What are elastomers?
- natural rubber
- polybutadiene
- neoprene
- silicone
- Thermoplastic Elastomer (TPE).
What are the characteristics of biodegradable polymers?
- ability to be moulded into 3D products or film
- ability to degrade with the action of UV rays (sunlight), water or enzymes present in soil.
List examples of biodegradable polymers.
- corn starch polymers
- potatopak
- biopol (bio-batch additive)
- polyactide (PLA)
- polyhydroxyalkanoate (PHA)
- water soluble: lactide, glycolide (Lactel and ecofilm).
What are composites?
Materials combined to make composites with enhanced properties.
List examples of composites.
- carbon fibre reinforced plastic (CFRP)
- glass reinforced plastic (GRP)
- tungsten carbide
- aluminium composite board
- concrete, including reinforced concrete
- fibre cement
- engineered wood, e.g. glulam (glued laminated timber).
Define smart materials.
Materials that respond to external stimuli.
What are examples of smart materials?
- shape memory alloys (SMA), e.g. Nitinol
- thermochromatic pigment
- phosphorescent pigment
- photochromic pigment
- electroluminescent wire
- piezoelectric material.
What are modern materials?
Materials developed recently with enhanced properties.
List examples of modern materials.
- kevlar
- precious metal clay (PMC)
- high density modelling foam
- polymorph.
What methods can be used to enhance materials?
Methods that improve properties for specific applications.
What is the purpose of UV stabilisers in polymers?
To prolong the life of polymers
UV stabilisers protect materials from degradation caused by ultraviolet light.
What are bio-batch materials used for?
To encourage biodegradability
Bio-batch materials help in the decomposition of plastics in the environment.
What is a method of enhancing wood properties?
Combining natural timber with resins and lamination
This process increases strength and stability of timber products.
Name a heat treatment method for enhancing metals.
Case hardening
Case hardening increases surface hardness while maintaining a tough interior.
List four paper and board forming processes.
- Die cutting
- Laser cutting
- Creasing
- Bending
What is vacuum forming used for?
To shape polymers into 3D products
Vacuum forming uses heat and vacuum to mold plastic sheets.
What is a specific process used in metal shaping?
Forging
Forging involves shaping metal using compressive forces.
Identify a temporary joining method for metals.
Self tapping screws
Self tapping screws are used to join materials without pre-drilling.
What is the purpose of milling in wasting processes?
To remove material from a workpiece
Milling creates precise shapes and features on metal and wood.
What is a dovetail joint?
A traditional wood jointing method
Dovetail joints are known for their resistance to being pulled apart.
Name a type of adhesive used in product design.
PVA
PVA (Polyvinyl Acetate) is commonly used for wood bonding.
What are some specific finishes for paper and board?
- Laminating
- Embossing
- Debossing
- Varnishing
What is the function of electro-plating in metal finishing?
To enhance appearance and prevent corrosion
Electro-plating deposits a layer of metal on the surface.
Identify a scale of production.
Batch production
Batch production involves producing a set quantity of items.
What is Just In Time (JIT) manufacturing?
A strategy to increase efficiency by reducing inventory
JIT aims to produce only what is needed, when it is needed.
What are computer-aided design (CAD) advantages?
- Speed
- Precision
- Easy modifications
What is rapid prototyping?
A process of quickly creating a scale model of a physical part
Rapid prototyping is often done using 3D printing techniques.
What does electronic data interchange (EDI) facilitate?
The electronic exchange of business documents
EDI streamlines processes like ordering and invoicing.
What is the role of Production, Planning and Control (PPC) systems?
To manage manufacturing logistics and scheduling
PPC ensures materials and resources are available when needed.
Define inclusive design.
Design that accommodates a wide range of users
Inclusive design considers accessibility for disabled, elderly, and children.
What is inclusive design?
Design that can be used by a wide range of users including the disabled, children, and the elderly.
What does the Health and Safety at Work Act (1974) influence?
The safe manufacture of products.
What is COSHH?
Control of Substances Hazardous to Health.
Name one piece of legislation used to protect consumers.
Consumer Rights Act (2015).
What does the British Standards Institute (BSI) do?
Tests specific products to meet safety standards.
What is a trademark?
A sign capable of distinguishing the goods or services of one enterprise from those of others.
What is ‘open design’?
Development of products for the common good of society.
What are the six Rs of sustainability?
- Reduce
- Reuse
- Rethink
- Recycle
- Repair
- Replace
What is the purpose of a feasibility study?
To assess the practicality for production of proposed designs.
What should students interpret in market research?
Market research data, calculating costs and profit.
What is the iterative design process?
A design process that involves continuous refinement based on feedback.
Name a key historical design movement.
Bauhaus.
What is the impact of socio-economic influences on product design?
They help shape product design and manufacture.
What is the significance of new materials in product design?
They influence the development and manufacturing processes.
What are some ethical considerations in design?
- Sustainable materials
- Ethical production methods
- Cultural acceptability
What does the product life cycle include?
Introduction, evolution, growth, maturity, decline, and replacement.
What is the role of feedback in product testing and evaluation?
Informs future modification and development.
What is the importance of accuracy in design and manufacture?
Ensures consistency of accuracy and reduces possible human error.
Fill in the blank: The _______ is a measure of how well a product meets user needs.
[design specification]
True or False: The use of ergonomic data is not important in product design.
False.
What is the role of geometry in design?
Geometry is used to create templates for design drawings.
Geometry helps in ensuring accuracy and consistency in design processes.
How can testing eliminate errors in design?
Testing can eliminate errors by ensuring accuracy in design drawings.
It provides a means to verify that designs meet specifications.
What are some measuring aids used in design?
Measuring aids include:
* Templates
* Jigs
* Fixtures
These tools help in ensuring consistency of accuracy and reducing human error.
What are the responsibilities of designers in terms of environmental issues?
Designers are responsible for ensuring products are made from sustainable materials and components.
This includes considering the environmental impact of packaging.
What is the concept of a circular economy?
A circular economy involves designing products to conserve energy, materials, and components.
It emphasizes minimal environmental impact throughout a product’s lifecycle.
What are some aspects of sustainable manufacturing?
Sustainable manufacturing includes:
* Use of alternative energy
* Methods to minimize waste
It focuses on reducing the environmental impact of manufacturing processes.
What are the implications of waste in manufacturing?
Waste impacts include:
* Cost implications of dealing with waste
* Creation of surplus and by-products
* Reuse of material off-cuts, chemicals, heat, and water
Addressing these issues is crucial for sustainable practices.
What is the importance of planning for accuracy in production?
Planning for accuracy is essential when making prototypes and for production at all scales.
It helps in optimizing efficiency and reducing errors.
What is Total Quality Management (TQM)?
Total Quality Management (TQM) is a quality assurance system aimed at reducing waste and ensuring accurate production.
It involves continuous improvement in processes and products.
What are some quality control methods?
Quality control methods include:
* Monitoring and checking of materials
* ‘Go-no go’ gauges
* Laser or probe scanning
* Use of digital measuring devices
* Non-destructive testing
These methods ensure products conform to acceptable tolerances.
What are some national and international standards in product design?
Standards include:
* British Standards Institute (BSI)
* International Organisation for Standardisation (ISO)
* Restriction of Hazardous Substances (ROHS) directive
* WEEE directives
* Energy ratings of products
* Eco-labelling
These standards guide product safety and sustainability.
What is eco-labelling?
Eco-labelling includes:
* The Mobius Loop
* The European Eco-label
* The EC energy label
* The Energy Efficient label and logo
These labels indicate the environmental performance of products.
