ENGINEERING & PRODUCT DESIGN



Table Example for Unit 2 AS Graphic Products Unit 2 Malleability – The ability to withstand deformation.Ductility – The ability to be drawn out.Toughness – The ability to withstand sudden impact.Elasticity – The ability to flex and bend.Plasticity – The ability to be shaped permanently.Hardness – The ability to resist wear, indentation or deformation.Durability – The ability to withstand wear and tear, weathering or deterioration.Strength – Tensile, Compressive, Bending, Shear and Torsional.MATERIALOR PROCESSPROCESSESADVANTAGESDISADVANTAGESPaper and board PULPS paper p30-31 Table P30Processing wood pulp mechanicallytimber is debarked (1)timber is ground/crushed to form a pulp (1)pulp is soaked for period of time in vast quantity ofwater (1)often pulp has to be bleached (1)pulp often contains impurities (1)steam used to aid pulping process (1)Provides a 90% yield from the pulpwood as it uses the whole of the log except for the bark.Can be bleached to produce higher value-added products.Well suited for ‘bulk’ grades of paper, i.e. newsprint and packaging boards.Lower strength characteristics than softwood chemical pulps.Paper can ‘yellow’ when exposed to bright lights due to lignin content.Processing wood pulp chemicallytimber is debarked (1)timber is chipped/cut into fragments (1)fragments are pounded (1)pulp is treated with chemicals (acid or alkaline) (1)this dissolves lignin (1)treated with steam (1)screened to ensure chips are correct size (1)Produces ‘chlorine-free’ disposable products.Higher quality wood pulp produced with longer, stronger fibres that contain fewer impurities.No chemical pulp is produced in the UK, therefore it must be imported.Lower yield than mechanical methods as the lignin is completely dissolved and separated from the fibres.Processing waste pulpRecyclable/old paper + card screened + shredded (1)shredded waste is pulped with water (1)ink is chemically removed (1)properties poor so chemicals/bonding agents added tostiffen (1)often added to new paper/mixed with virgin fibres (1)pigments added to change colour (1)Makes use of recycled papers, which are a sustainable resourceWell suited for ‘bulk grades’ of paperDoes not save any more energy in processing than other methods.Requires considerable processing and additives to produce good-quality paper Recycled paper and board is not as aesthetically pleasing as virgin fibres it also isn’t as strong.Fourdriner process4 sections make up this process:Wet endPress sectionDryer sectionCalendar sectionwet end/diluted pulp fed onto mesh where water is removed (1)press/pulp is squeezed to remove access water (1)drying/heated rollers/Dandy Roll used to flatten (1)roll paper into specific thickness (1)calendaring/highly polished rollers (calendars) produce final smoothgloss paper finish (1)paper rolled into large rolls to be transported (1)vibrating belt to help drain water (1)fibres interweave (1)suction box and rollers draw out more water (1)sizing agents added during drying process (1)Rollers can be adjusted for thickness grades of paperTime consuming processDESCRIPTIONAPPLICATIONAESTHETICSADVANTAGESDISADVANTAGESPICTURE Drawing Papers p32-33Layout PaperThin translucent paper with a smooth surfaceOutline sketchesSketching and developing ideasMarker renderings50 gsm Translucent propertyAccepts most drawing media (except paints)Semi-transparent/Translucent (1) so allows overlay and images to be traced/copy through pages. (1)Smooth surface finish (1) so accepts most drawingmedia. (1)expensive-68580-3175Tracing PaperThing transparent paper with smooth surface. Pale grey in appearanceSame as layout paper60-90 gsmAllows tracing through to another sheet in order to develop design ideasHeavier weights can be expensiveCopier PaperLightweight grade of quality paper. Good quality bleached surface.Black and white photocopying and printing from inker jet and laser printers80 gsmBright whiteAvailable in a range of coloursInexpensive when bought in bulkCartridge PaperCreamy-white paper. Smooth surface with a slight with a slight textureDrawing paper120-150 gsmCompletely opaqueAccepts most drawing mediaMore expensive than copiercommercial printing papers p32-33Bond PaperHigh-quality durable writing paper that often carries a watermark.LetterheadsStationary and as paper for electronic printers50+ gsmMade from rag pulp meaning it is stronger than wood pulpLong-wearing paperAvailable in wide range of coloursDurable/doesn’t rip easily (1)High quality surface finish/printing surface (1)Good quality paper(1)Coated PaperCovered with a suspension of china clay, pigment and adhesive to give a smooth surface finish.High-quality printer jobs70-300 gsmGives shiny/glossy finish. (1)? Enhances product impression of quality/moreattractive/ enhances printing.Impermeable toliquids/chemicals/waterproof/protects carton gettingsoggy. (1)Allows package to be wiped clean/improve hygieneEasily die cut. (1) Strengthens package. (1)Protects the graphicsCoating gives a good quality surface for printing on (1)Relatively expensivecommercial card and board p32-33mounting boardRelatively thick board with colour on one side only (white on backPresentations and displays1000-1500 micronsVery high qualityStrong boardAvailable in wide range of coloursExpensiveRecycled BoardCard made from varying percentages of recovered waste pulp.‘environmentally friendly’ productsDisposable items (trays etc.)220+ gsmCan be coloured for individual useLower quality than cards made with virgin pulpSurface finish of recycled board is poor (often grey) folding boxboardUsually consist of bleached virgin pulp top surface, unbleached pulp middle layers and a bleached pulp inside layerMajority of food packagingGeneral carton applicationsExcellent for scoring, bending and creasing without splittingExcellent printing surfaceRelatively inexpensive when purchased in bulkcorrugated boardConstructed form a fluted paper layer sandwiched between two paper liners.Protective packagingBox-making materialLow costRecyclableExcellent impact resistantGood strength/absorbs impact (1) so givesprotection to the product. (1)Rigid material (1) so allows stacking of boxes. (1)Relatively inexpensive (1) so doesn’t excessively addto the cost of the product. (1)Recyclable/ biodegradable (1) so reducesenvironmental impact. (1)Made from Natural materials (1) so is morallyacceptable to use. (1)Lightweight material (1) that doesn’t add undueweight to the package. (1)solid white boardMade entirely from pure bleached wood pulp.Packaging for frozen goods (ice-ream, pharmaceuticals and cosmetics)Very strong and rigidExcellent printing surfaceExpensivefoil-lined boardConsists of a laminated foil coating (can be used on all of the above boards). Foil available in matt or gloss finishCosmetic cartonsPre-packed food packagesVery srong visual impactFoil provides and excellent barrierRelatively expensive MetalsDESCRIPTIONAPPLICATIONAESTHETICSADVANTAGESDISADVANTAGESPICTURE Ferrous p34-35steelSteel is a ferrous metal so contains mainly ferrite, or iron. It is also does not have a huge amount of added substances. It is also magnetic.CutleryJewelleryCookwareSterile surgical instrumentsBuilding constructionStrong and rigidResistant to corrosion and wearing High quality surface finishLow maintenance100% recyclableRelatively expensiveRelatively hard to machineNon-ferrousAluminumAluminium is rarely used as a pure metal. It is mainly alloyed with copper to improve strength, eg. Duralumin which used in the production of aircraft parts.Aircraft and vehicle structuresPrecision toolsBicycle partsCar partsCar bodies, cookware, food wrapping foil, insulation, aircraft, boats, engine cylinder heads and window frames.Excellent strength to weight ratioExtremely hard and toughHigly resistant to stress-corrosion crackingMachines and casts wellHigh performance in extreme temperaturesIn Packaging :Acts as a barrier to light/odour/heat/gas/impurities (1)so preserves contents/ensures hygiene. (1)Adds to the strength of the card (1), so givesadditional protection to the contents againstcontamination. (1)Keeps the product cool once chilled/providesinsulating layer (1) adding to enjoyment ofbeverage. (1)Prevents UV/sunlight contamination (1) so stopscontents becoming spoiled/keeps fresh/longer shelf life.(1)Stops leaks/waterproof (1) so allows boxboard to lastlonger. (1)Pure aluminium is very soft so it is alloyed to make it stronger. Soft, difficult to weld due to oxide film on the surface. Can crack under stress. Requires constant annealing when worked. Does not withstand great loads.Can suffer from corrosionBecomes brittle through fatigueTinSoft solder, alloys (a major part of pewter). . Tin is very soft (only slightly harder than lead) and malleable; it can be rolled, pressed, or hammered into extremely thin sheets (tin foil). When iron or sheet steel is dipped into molten tin (tinplate), a layer of tin is deposited on the surface. A tin coating may also be applied by electroplating, which uses less tin. The tin serves to prevent rusting as it is barely affected by moisture. Used in alloys such as bronze and pewter. Very low melting point makes it good for casting prototypes. Very malleable.Very soft, indentation marks left in it easily. Not very strongVery soft, low melting point, high density Commercial usefulnessDoesn’t corrode easily.Alloys p27-28stainless steelUsed for kitchen utensils, medical tools and in the chemical and nuclear industries. Building constructionSink units, kitchenware, pipes and aircraft.Stainless steel has a high tensile strength and resists abrasion and corrosion because of its high chromium content. Corrosion resistant?Strong and rigid?Resistant to corrosion and wearing ?High quality surface finish?Low maintenance?100% recyclableStainless steel is hardwearing/strong/durable/scratch resistant(1)? Resistant to corrosion/staining/doesn’t rust(1)? Rigid/impact resistant and therefore means themechanism within is not affected in any way (1)? High quality finish (1)? fashionable/stylish/modern (1)? Low maintenance/easy to clean (1)? Colour/finish ‘fits’ style of the watch i.e. tough, sporty (1)? Black/silver colour scheme is masculine (1)? Gives feeling of quality (1)? Heavy/weight gives feeling of value for money (1)? Not affected by magnets? surface scratches can effect overall visual appeal (1)Expensive.Very hard and difficult to cut or file.Alloy of steel, chromium and nickel.?Relatively expensive?Relatively hard to machineDuraluminDuralumin (Aluminium and copper)Aluminium is rarely used as a pure metal. It is mainly alloyed with copper to improve strength, eg. Duralumin which used in the aviation and automobile industries.High performance in extreme temperaturesMachines and casts well Lightweight, strong, ductile, malleable, excellent machining characteristics.Age hardens over time becoming brittle after timeAlloy of copper, aluminium and manganese.Polymers: Thermoplastics p36-38 Table P37DESCRIPTIONAPPLICATIONAESTHETICSADVANTAGESDISADVANTAGESPICTURE Polythenehigh density polyethylene (HDPE)A linear polymer, High Density Polyethylene (HDPE) is?prepared from ethylene by a catalytic process. The absence of branching results in a more closely packed structure with a higher density and somewhat higher chemical resistance than LDPE.?HDPE is?also somewhat harder and more opaque and it can withstand rather higher temperatures (120° Celsius for short periods, 110° Celsius continuously).?Bottles, pipes, bowls, milk crates and buckets.low density polyethylene (LDPE)It is opaque, but only thin layers of it can be transparent. It naturally is a white colour, but if pigmented it can come in a range of colours. It can be welded, foamed, blow moulded, injection moulded and also extruded.Packaging film, carrier bags, TV cable, toys, detergent 'squeezy' bottles and dip coating.polyethylene terepathelate (PET)Polyethylene terepathelate is a thermoplastic polymer resin of the polyester family and is used in synthetic fibres; beverage, food and other liquid containers; thermoforming applications; and engineering resins often in combination with glass fibre.Bottles for food and beverages up to 2 litres in capacity.? Transparent (1)? Tough/durable/does not break when dropped (1)? inert/does not affect the liquid (taste/safety) (1)? impermeable(1)? recyclable (1)? lightweight/does not add weight to product (1)polyvinyl chloride (PVC)Medical equipment (e.g. blood bags), window and door frames, domestic piping.RIGIDRainwater goods, pipes to carry air and water, window frames, chemical tanks, floor and wall coverings, shoe soles, shrink and blister packagingPLASTICISEDLeathercloth, suitcases, dip coating, hose pipes, electrical wiring insulation, vinyl wallpaper, floor tiles, toys, dolls, footballs and cushioning (when foamed).Environmental concerns; dioxins produces when it is incinerated.The effect on the environment of the production of, and decomposition of additives is negative.Changes depending on additives, e.g. uPVC (used for window and door frames) is harder and less flexible than plasticised PVC. RIGID PLASTICISEDpolypropylene (PP)is a thermoplastic polymer used in a wide variety of applications including packaging, textiles (e.g., ropes, thermal underwear and carpets), stationery, plastic parts and reusable containers of various types, laboratory equipment, loudspeakers, automotive components. Polypropylene is most commonly used for plastic mouldings, wherein it is injected into a mold while molten, forming complex shapes at relatively low cost and high volume; examples include bottle tops, bottles, and fittings.Chemical resistant containers, hinges, bottle crates, medical equipment (can be sterilized), syringes, food containers (microwave), nets, animal feed hoppers and storage boxes with integral hinges.? A range of colours are available (1)? It takes a range of surface finishes well (1)? It is a durable/strong material which is suitable for purpose (1)? It has flexibility (1)? It can be cleaned easily (1)? Resistance to chemicals/liquids/water (1)? Good impact resistance (1)? Suitable for mass production – injection moulding/rotational moulding(1) Do not award a mark for vacuum forming or blowmoulding? Lightweight (1)? Can be recycled when finished with (1)? Self finished material (1)polystyrene (PS), rigid (high density polystyrene) and expandedlimited flexibility. It can be cast into moulds with fine detail. Polystyrene can be transparent or EXPANDED Packaging, ceiling tiles and insulation. High Impact (HIPS)can be made to take on various colours.Good for Vacuum formingLow cost and disposable items produced by vacuum forming or injection moulding, internal secondary glazing, toys, model kits and refrigerator linings.Excellent impact resistance/absorb energy/protects the product (1)Lightweight (1)Easily formed ? (1)Relatively inexpensive (1) expanded high density polystyrene. styrofoamStyrofoam is an extruded polystyrene foam material developed by Dow and is more than an effective thermal insolent. It has a unique combination of physical and chemical characteristics that make it a key component within a wide variety of today's high performance composite structures. Styrofoam is lightweight, yet exceptionally strong, safe in use and capable of being precision - engineered. It is used in floors, basements, flat and pitched roofing applications on both new build and refurbishment projects. insulating buildings, modelling use,blue or pink extruded polystyrene foamGreat rigidity High compressive strengthEasily cutEasily shaped Can be sanded for smooth surface finish Weak Surface breaks breaks away very easily and therefore it is unsuitable for high detailed modellingSurface can become dented when a file is used on it acrylicAcrylic is the common name for polymethyl methacrylate. Usually cast as a sheets but can also come in rods and tubes and is self finished. Trade names: Perspex, Plexiglass.point of scale displays to shop signage, Shop signs in the display industry, baths, machine guards, furniture, roof lights, glazing and car light lenses.usual a sheets but can also come in rods and tubes and is self finished which can be any thickness and comes in huge variety of coloursAble to withstand extreme weatherconditions/waterproof/ weatherproof. (1)? Available in variety of colours/visualappeal/aesthetically pleasing. (1)? Tough/ durable/hard wearing. (1)? Available in variety of surface finishes/opacity/selffinishing/ good surface finish / shiny surface finish.(1)? Ease of laser cutting/ machining/joining/shaping/forming. (1)? Able to be backlit. (1)? Easy to clean/wipe clean. (1)? Recyclable (1It can be polished to a high finish. Comes in a huge variety of coloursCan be ordered in ay thicknessSelf-finishedLow costLightweight Breakage resistance is 6-17 times greater than glass.Its brittle Acrylic scratches easily and tends to splinter.Low scratch resistanceCracks easily form and spreads through the acrylic Woods p38-39 Table P39hardwoods (Deciduous)Hardwoods have grains that are closer together because the trees that they come from take more time to grow than softwood trees.A deciduous tree loses its leaves in winter. Hardwood comes from deciduous trees.JelutongIt is a hardwood from Indonesi. Pattern making, model making, carving, matchsticks and clogs.Low densityStraight grainFine textureMechanical: any one from the following:? Lightweight (1)? Straight grain (1)? Fine grain/texture/short fibres (1)Functional: any one from the following:? Easy to cut and work (1)? Glues well (1)? Good finish can be achieved due to fine grain (1)? Takes paint easily (1)BalsaModel making, buoyancy in rafts, floats, water sports equipment, heat, sound and vibration insulation.Balsa has a high strength to weight ratio.Extremely buoyantVery soft and lightLow density with high strengthExpensiveSoftwoods (Coniferous) p30Softwoods are woods that come from coniferous trees. All softwoods come from coniferous trees.Coniferous trees are those which do not lose their leaves in winter, i.e. they are evergreen trees.PineFurniture making, joinery, building construction, telegraph poles and plywood.Hard, straight grainFairly strong, durable and easy to workSmooth finish ? Natural wood (1) so gives realistic impression. (1)? Easy to cut/join/work (1) with good naturalfinish/range of finishes can be applied. (1)? Readily available (1) and relatively low price incomparison to hardwood.(1)Composites p39-41 Table P41Carbon FibreHigh performance structural applications that require greater tensile strength than GRP. For example, aircraft, sports cars (body panels) and very lightweight bicycles (instead of aluminium).Carbon fibre is a filament material incorporating thousands of filaments that are woven to form a fabric. Sports equipmentTennis racquetsFishing rodBicycle framesWheelsAircraftVehicle componentsExcellent strength to weight ratioBetter tensile strength than steel alloysCan be engineered to be anisotropicCan be formed into complex shapes Lighter with greater tensile strength than GRP, lighter than alumini um with comparable strength, corrosion resistant.? Extremely strong/durable/tough/impact resistant (1)? Light weight (1)? Good strength to weight ratio (1)? Gives good protection for the rider (1)? Easily mouldable (1)? A uniform strength can be achieved all over the helmet (1)? The surface is suitable for the application of various decorativeoptions e.g. decals/paint (1)? Has good elastic properties deflecting some of the impact (1)? Doesn’t degrade e.g. in sunlight/water (1)? Aesthetic appeal / range of colours (1)Cannot be recycled like aluminium or other metals, since the polymer used is often a thermoset. Cannot be reshaped once cured and expensive due to the cost of carbon fibre, mould, and autoclave (if required).? High cost of material (1)? High wastage (1)? Time consuming/skilled process to manufacture (1)? Relatively high cost of production method (1)? Accident/impact means the helmet is no longer serviceable/safe touse (1)High tensile and compressive strength, lightweight, not very malleable or ductile.Can be polished to a shiny or matte appearance. Usually dark grey colour due to the colour of the carbon fibres. Clear polymer makes the weave visible, often considered desirable and is polished rather then painted.Glass Reinforced Polymer (GRP)Applications where lightweight yet strong material is need for the structure of a product, e.g. small aircraft, boats and car body panels.Hand lay up where the fibreglass matting is placed inside a mould coated with release agent and resin/hardener mix. A roller is used to compress matting layers together and remove air bubbles.Spray lay up where strands of fibre are sprayed into the mould or the outside of the structure to be supported (e.g. bath tub) with a hose.Glass-reinforced plastic, composite is made of a polyester or epoxy resin reinforced by fine fibres of glass in the form of a woven mattingMould/highly polished mould (1)? Mould covered with release agent to ensure it can be releasedfrom GRP when finished (1)? First layer is gel coat, coloured polyester resin (1)? Polyester resin and catalyst/hardener is mixed to ensure resin ‘sets’(1)? Chop strand mat/glass fibres or woven wordings used (1)? Layers of polyester resin and chopped strand mat/wovenwrovings layered on mould (1)? air rolled out of polyester resin, CSM layers (1)? Can be hand rolled or use resin/CSM spray gun (1)? Edges need to be trimmed after lay up (1)? Mould is removed leaving shell structure (1)Rotor blades of wind turbinesCanoesFish pondsVehicle bodiesFairground ridesExcellent weight to strength ratioResistant to corrosionWater resistantCan be repaired easily High tensile and compressive strength comparable to steel while being lightweight.Easy enough to use for amateurs to do repairs with it.Expensive materialSpecialised manufacturing process High-quality mould needed Can delaminate in water.not very malleable or ductileSmooth, shiny finish on the side that has been against the inside of the mould, but rough with the texture of fibres on the other sideCannot be recycled like aluminium or other metals, since the polymer used is often a thermoset. Cannot be reshaped once cured.Health risks associated with inhaling fumes from the resin and hardener during curing and glass dust from cutting, sand and grinding operations.167005-1270 Density Fibreboard (MDF)Kitchen worktops, cheap furniture and moulds/patterns.MDF is commonly made by wood waste in the form of wood chips, which are subjected to heat and pressure in order to soften the fibres and produce a fin, fluffy and lightweight pulp. This pulp is then mixed with a synthetic resin adhesive to bond the fibres and produce a uniform structure and heat pressed to form a fine textured surface.Flat pack furnitureGeneral joinery work Moulds for forming processesModerate tensile and compressive strength, inexpensive, no grain, no knots, no warping, made mostly from waste wood.The resins used to bond particles together give off toxic fumes and can be inhaled during cutting and sanding operations. MDF is not completely made from waste, some softwood trees are specially grown for the purpose.Less expensive than natural timbersAvailable in large sheet sizes and range of thicknessesIsotropic, so no tendency to splitConsistent strength in all directionsNo grain, so no tendency to split (1)? Range of thicknesses / large sheets (1)? Less expensive than ‘natural’ timber (1)? flat/rigid surface (1)? stable/dense/supportive surface for model (1)? surface takes paint/other modeling features (1)? smooth surface (1)Moderate tensile and compressive strength, inexpensive, no grain, no knots, no warping, made mostly from waste wood.? Cheaper (1) as it is manufactured from low gradetimber / off-cuts / for making low cost furniture/increasing profits. (1)? Available in wide boards (1) so easy to cut to sizesneeded for furniture panels / so no edge jointingneeded / not limited to tree width. (1)? Has no grain (1) so is stable / will not warp / twist/ split / move as much as solid timber. (1)? Smooth finish (1) so less surface preparation isneeded before a finish is applied. (1)? No natural faults / knots (1) so it is easily worked/that cause problems during manufacturing. (1)? Uniform strength in all directions (1) so noconsideration has to be given to the graindirection. (1)Yellowish, light brown colour with some larger particles visible. Can be given coatings such as Formica and paint. Can be stained.HeavierRequires appropriate finishes to seal surface fibresSwells and breaks when waterloggedWarps or expands if not sealed Dulls blades more quickly than many woodsModern materials and products p42-43DESCRIPTIONAPPLICATIONAESTHETICSADVANTAGESDISADVANTAGESPICTURE liquid crystal displayLiquidcrystals are organic, carbon-based compounds that can exhibit both liquid and solid crystal characteristics.Used to produce electricity for isolated areas a long distance from mains electricity, satellites and space craft. Increasingly used to produce domestic electricity.Require small currents and voltages can produce colour images (in the case of LCD monitors) and make for small, lightweight components in products.?Not a lot of current is needed to make it work?Ideal for electronic devices like mobile phones?Slim/lightweight/suitable for portable devices (1)?Quick response to data input (1)?? Range of colours on display(1)?Can be used to display photos/ moving images/web/email(1)?Low power so very little battery use (1)?Clear to see/high resolution (1)Colour LCD televisions only show the correct colours when viewed from the correct angle, whereas CRT screens can be viewed from any angle.-68580635phosphorescent pigmentsThese materails absorb energy or ‘charcge’ in normal daylight conditions and are capable of storing that energy for some time, then releasing it relatively slowly in form of light.Used in products where little current is available e.eg. battery powered devices such as mobile phones and calculators. Laptop screensLCD televisionsModern domestic appliancesLiquidcrystals are organic, carbon-based compounds that can exhibit both liquid and solid crystal characteristics.Non-radioactiveMakes things to be seen in the dark6351905electroluminescent (el) lightingUsed in applications where areas of a product need to be illuminated with the minimum amount of electricity, e.g. wristwatches, posters and mobile phones.electroluminescent (el) lighting converts electrical energy ito light by applying a voltage across electrodes.? Coverts electrical energy into light (1)? Power is applied across electrodes (1)? Organic phosphor sandwiched between the electrodeconductors (1)? When electrical charge is applied phosphor crystals arecharged (1)? Phosphor crystals emit radiation which is seen as light (1)PostersBus sheltersbillboards Consume very small amounts of electricity while producing a lot of light. Very lightweight, weather resistant, very small (come in the form of thin wires and sheets) and so can be incorporated into products with minimal affect on size.waterproofvisibleextremely reliable? different organic compounds emit different colour light/green/yellow(1)? Extremely low current/very high voltage (1)? Low energy consumption (1)? Can be ‘packaged’ in variety of panels/wires/strips fordifferent applications (1)The phosphor that is used in EL lighting has a short life span.Different wires/sheets can produce light of different colours.New and smart materials p43-45DESCRIPTIONAPPLICATIONAESTHETICSADVANTAGESDISADVANTAGESPICTURE thermochromic liquid crystal/filmChanges state when temperature is changed or used as a stimulusForehead thermometersBattery test panelsSpecial printing effectsThin and portable so it easy to use and handleNo chemicals involved meaning it is good and safe for kids under 5Good for decoration (1)Gimmick effect (1)?The temperatures are measured only where the sensors are basedpiezoelectric crystalsExpands and contracts when electrical current is applied. It converts this mechanical stress or vibration into electrical signals and vice versa.Musical greeting cardsElectronic drum kitCrystals that are placed near a electric charge that when turned on vibrates.radio frequency identification tags (RFID)Method of identification that uses tags stuck on it a product to store data that can be retrieved by a reader.Security systemsMade up of a transmitter (reader) and a transponder (tag)Advantages? Passive (receive only) and active (transmit and receive) tagscan be inbuilt into labels and products (1)? Auto price checking (1)? Telemetry (remote measurement and recording of info) (1)? Stock levels can be measured automatically/Auto reorderingwhen low (1)? Don’t have to scan products so reduces queue time whenpurchasing goods (1)? Anti theft properties/alarm trigger as products tags can holdunique info (1)? Marketing information can be made available/tracking productsales (1)? Tracking product use can provide information to manufacturers(1)? Tracking product during use can be used for guaranteeinformation and warrantee info/product identity (1)? Disposal for recycling information (1)? simple to install in products for tracking (1)? Not easy to replicate information held (1)? Do not require direct line of sight to work (1)? Can assist emergency services in tracking products (1)? Range can be greater distance: Active (1)?Prevents books being stolen.? Potential loss of privacy (1)? 1984/Big brother is watching you scenario (1)? Interference can hinder reception/affected by certainmaterials (1)? Range can be short: Passive (1)? Reliability still not known as RFID is relatively new (1)? Could be used by non-emergency services/ non-official servicesto monitor (1)? Adds cost (1)?Batteries have a limited battery lifetimeStrength of power doesn’t last longsmart inkMimics the appearance of ordinary ink on paper. Electronic paper was developed in order to overcome some of the limitations of computer monitorsElectronic booksStoring digital versions of booksElectronic newspapersTiny pit containing a small number of black and white beads?The pixels have an inherently stable ‘memory effect’ that requires no power to maintain an image.56327322616700shape memory alloys (small)sA shape-memory alloy (SMA, smart metal, memory metal, memory alloy, muscle wire, smart alloy) is an alloy that "remembers" its original, cold-forged shape: returning the pre-deformed shape by heating. This material is a lightweight, solid-state alternative to conventional actuators such as hydraulic, pneumatic, and motor-based systems. Shape-memory alloys have applications in industries including medical and aerospace.?high level of recoverable plastic strain that can be inducedBinding p46APPLICATIONADVANTAGESDISADVANTAGESPICTUREsaddle-wire stitchingbrochuresweekly magazinescomicsideal for signature feed processesprinted materials can be laid flat to readrelatively inexpensive when produced commerciallylower-quality, visual appearancenot durable as centre pages can esily fall apart-660400side-wire stitchingInformation bookletsRevision materialsUsed when the document is too thickIdeal for binding multiples of single sheets of papers without foldsCannot lay printed materials flat to read as it causes damage to spineLower-quality visual appearance2540635perfect bindingPaperback booksGlossy magazinesCatalougesBetter qualityBetter presentations and visual appeal with printable spine rather than staplesGlued spine provides longevity for a monthly magazineExpensive commercial process2540-1905hard-bound or case-boundHardback booksQuality presentationsSchool yearbooks Sewn-in pagesStiff board is used in the cover to protect the pagesHigh quality, professional binding methodExtremely durableStiff card covers protect pages (1)Extremely durable/hardwearing (1)Impression of professional quality/value for money impression(1)Sewn-in pages do not fall out (1)Generally lasts longer than other bound book types (1)Very expensive commercial processTime consuming to produce (1)Expensive in materials compared to perfect/other binding (1)Expensive for machines compared to perfect/other binding (1)Books often heavier/bigger (1)Spiral or comb binding.Business reportsdocumentsrelatively inexpensivefairly good-quality visual appearanceprinted materials can be laid flat to read? Temporary binding (1) and functional (1)? Easy to fit after training (1) and punch paper (1)? Inexpensive (only if qualified) (1) in terms of comb price and runningcosts/suitable for personal documentation (1)? Allows pages to open flat (1) provides easy viewing / don’t have tohold open(1)? Pages can be added/removed (1) in-house using low-cost specialistmachine (1)not durable as document can easily fall apart or tear down perforations? Bulky (1) so reduces space in document folder (1)? Paper can tear (1) binder can open when pulled (1)? Not very strong/durable (1)not suitable for large documents as pagescan easily fall out (1)? Need specialist machine to fit binder (1) so cannot be used unlessspecialist equipment obtained (1)? Does not look aesthetically pleasing (1) giving low quality impression(1)Drawing p50-51APPLICATIONADVANTAGESDISADVANTAGESMarks forPHOTOSisometricIdeal for sketching design ides and illustrating product designAccurate to show three faced objectCircles appear slightly distorted3175571502-point perspectiveWidely used method for illustrating product designs, architecture and inferior designsCan see an object from three views :Worms eye-viewStreet eye-viewBirds eye-viewCannot see behind object from one drawingPerspective construction lines (1)? accurate representation of object outline (1)? Correct proportion/reasonable proportions (1)? Radii corners (1)? Top toast slot detail (1)? End slider details (1)3rd angle orthographic projection to BSI standardsEngineering drawings, planning for models and prototypes Represents 3D object in 2D by using multiple views f the object. nets developmentsStructural packaging designMakes 3D shapes when foldedIf measurements are wrong it will ruin the whole netPROCESSESADVANTAGESDISADVANTAGES9Computer-aided design(CAD) p43-452D design to create and modify designsa wide range of hatching styles and fonts availablethe ability to easily modify an existing drawingAble to see 3D view (1) so saves money on costly realmodels. (1)Easy to manipulate/alter/edit (1) to allowalterations/redrawing/rendering. (1)Library of components/nets (1) makes it easier toconstruct/draw package. (1)Drawings can embed cut lines/score lines/folds (1)leading to accuracy in manufacturing/speed inmanufacturing. (1)It allows for collaborative working (1) with differentdesigners producing parts remotely. (1)? Range of fonts/grids/tools/zoom/measurements (1)that all leads to increased accuracy. (1)? Integrated process (1) which can be linked to testingand QC software. (1)? Digital image can be saved (1) so can beused/altered/adjusted later. (1)? Can email to manufacturer (1) allowing direct link toCAM machining/output to printer. (1)Costly computers and software3D modelling for creating ‘virtual’ products.great for the designer to see their design in 3D without making a modelreduces development times and coststhey are used alongside models to aid visualizationcan be easily changedHelps visualise the product/givesaccurate/scale/realistic impression. (1)Product can be seen from 3600/all angles. (1)Clear un-technical view so you don’t have tounderstand 2D orthographic/2d views. (1)Can automatically modify sizes and dimensions. (1)Surface textures/lighting detail/colour/rendering canbe added. (1)Helps designer where improvements/faults could be.(1)Enables client feedback. (1)Ergonomic/aesthetic testing can occur. (1)Saves physical model being made. (1)Surface model can be used as a promotionalimpression. (1)Can be linked to RPT. (1)Easier to work with than 2D modelling. (1)Can simulate ‘in use’/walk round capability/virtualfeel. (1)Ability to edit/modify on screen. (1)Costly computers and software10. Modelling andPrototyping p54-56block modelling? A block model can be used to test ergonomic properties (1) whichcannot be done on CAD models (1)? A block model can be shown to/tested by potential customers (1)to gain feed back (1)? Block models can be made much more cheaply (1) than producingthe final product (1)? A 3d block model allows the scale/proportions of the product tobe evaluated (1) so that it can be evaluated within its intendedenvironment/use (1) all design features have been considered andare correct/altered before costly production starts (1)?rapid prototyping using CAD/CAMThe creation of 3D objects using laser technology to solidify liquid plastic polymers or resins in a process called stereolithography and othersreduces development time and therefore saves moneyaccurate testingproduces very complex and intricate shapes directly from CAD data ? RPT can be done extremely quickly compared to traditionalmethods (1) therefore saving lead time/money (1)? RPT models can be made extremely accurately (1) with out theneed for highly skilled craftsmen (1)? RPT models can be made as hollow formings (1) due to tool-lesstechnology (1)? RPT models can be made with intricate detail (1) allowing morerealistic prototypes to be produced (1)computer modelling renders for creating photo realistic imagesWire frame models can be rendered using the computer, they wrap a ‘skin’ around the wire frame to give a photo-realistic image.Designer can select materials/colours (1)Designer can simulate lighting and atmospheric effects to seeproduct in ‘real life’/virtual view (1)Product can be viewed from any angle/zoom in/zoom out/3D (1)Alterations can be made on screen (1)Images used in marketing materials (1)Images can be used by the designer to evaluate design withusers (1)Images can assist in production process (1)Technique part of manufacturing process (1)Can be electronically sent to clients/manufacturers (1)Integral tools allows sizing/dimensions (1)Visualise before time/money spent on modelling (1) (mustclarify time modelling)Wire frame modelling3D animations starts with a wire frame model being created on-screen that can be viewed in all directions using built-in camera angles in the computer softwarerelatively simple and fast to calculate on a computerable to review changes or rotate the object without long delayswell suited and widely used in computer numerically controlled programminglacking in detaildifficult to read or interpret as all hidden lines are also in viewsolid modellingThe production of a full digital representation of an object complete with the properties of the solid formclear communication – no confusionphotorealistic image produced sing rendering techniques to apply shading, surface pattern and texturecomplex data required, therefore slow to date and render objectssurface modellingA surface is added to the wire frame model, making it a more realistic picture of the 3D objectgreater definition of contours and surfaceshidden lines can be removed to give a more solid feelblending between surfaces is improveddoes not give any information about surface finishes or textures Joining Techniques p57CHARACTERISTICSPREPARATIONPROCESSESADVANTAGESDISADVANTAGESPICTUREcontact adhesiveUsed for metals and polymers; unlike materials, e.g. plastic to wood; general purpose; fabric to most materialsAdhesives require clean and thoroughly prepared surfaces an order for the joint to fully bond.Able to bond unlike materialBond forms very quickly so less need for clampingIdeal for gluing large sheet materialsSold in metal tubes for easy applicationRelatively expensiveContains harmful chemicalsMust be applied to both surface and held in place for a long time which make the job longerProduces toxic fumes. Once the two surfaces have been pressed together, there is no “open time” to re-position the two materials being bonded because adhesion takes effect on contact between the two coated surfaces.acrylic cement/ ( Tensol cement)Used for acrylicsA solvent that melts thermoplastics allowing two surfaces to fuse together. A permanent bond is formed once the solvent evaporates. The two surfaces become chemically joined.Polymers should firstly be a smooth and shiny surface finish, they should firstly be cleaned and roughened with an abrasive paper before bondingLid fitted securely/sealed container/solvent correctlylabelled. (1)? Store in cool/dry/well ventilated area. (1)? Store away from heat/sun/flame. (1)? Store in metal cupboard/locked cupboard/yellowcupboard. (1)? Cupboard must have safety signage. (1)? Staff to be briefed as to how to store adhesives. (1)? Regular checks need to be made bytechnician/monitoring log. (1)Rapid bonding of acrylicsThe use of Tensol cement results in a strong bond.You get a few seconds/minutes of “open time” to adjust the position of the surfaces being bonded relative to each other until it is correct.Relatively expensiveContains harmful volatile organic compoundsCan be difficult to apply and give a neat joint Only works on thermoplastics.Gives off harmful fumes when drying. Takes 24 hours to dry fully.polystyrene cementUsed for high-impact polystyrene (not expanded polystyrene)Important that the two surfaces are held in place securely so that they do not slip as this process can take several minutes or hoursStrong bonAble to use a brush to apply and absorbed into joint by capillary actionRelatively expensiveContains harmful volatile organic compoundsepoxy resinCan be used on most materials including expanded polystyreneMetal surfaces should also be degreased and roughened with an abrasive paper.Chemical reaction hardens immediately Versatile – can be made flexible or rigid, transparent or opaque/coloured, rapid or slow settingExcellent heat and chemical resistanceExcellent heat and chemical resistance Creates a strong, permanent bond on many materials.You can alter the proportions of hardener and resin to have control of how long you want it to take to cure, e.g. you can put slightly more hardener than resin with it if you want it to harden faster, or put more resin than hardener in the mixture to give you more “open time”.Bonds are watertight.ExpensiveReaders full strength only after a few daysOften requires manual mixing of resin and hardener, which can be messyTakes 24 hours to fully cure, so work piece has to be held under pressure until the epoxy resin has cured.Doesn’t bond certain materials with non-porous, smooth surfaces such as some plastics, metal and glass.Produces toxic fumes as it cures.If you don’t mix it correctly or in the right proportions, you won’t get the best bond.Mixing the two components is time consuming.Irritant to skin.polyvinyl acetate (PVA)Can only be used on wood ( and porous materials)Viscous white liquid that dries clear. Viscosity can vary depending on the manufacturer or intended purpose. Primarily used to glue woods.Woods are porous so the adhesive will ‘soak’ into it’s surface.Surfaces must be clean and fit together without gaps.Gives a strong jointRelatively inexpensiveInexpensive (1)? Strong joint (1)? Easy to use (no mixing- straight from tin) (1)? Can be reversed/soaking in water (1)? Can be used for range of woods/cards used in modeling (1)? Odourless/non-toxic (1)Surfaces need to be securely clamped together for a long timeGenerally not waterproof (although some brands are)Work needs to be clamped (1)? Takes time to dry/not instant (1)? does not stick “non-like” materials (1)? may come unstuck when in contact with water (1)? stains/marks wood (1)designing and creating nets using hand-drawn and CADmethodsThe accuracy of the drawing is extremely important when constructing nets. When drawing nets, technical drawing equipment or CAD programmes should offer accuracy and consistencyMaking die form for die cutting and creasing processCut linesFold linesUse tabsThe closure systemannotationVery accurate using CADOffers accuracy and consistency when using CADcommercial automated production of packaging nets using die-cutting, folding, scoring and spot gluing.The commercial production of packaging nets often requires large-scale production processes involving theuse of automated machineryPre-pass making four colour printing-platesPurchase of cartonboard, printing inks and adhesivesCut and shape hardened steel rulesMatrix strips cut or crease the cartonboard on the die-cutting machineEjector rubbers are added to the cutting rulers to push the cartonboard away from the rulers after a cut has been madeThe die-form is then mounted on thedie-cutting machineThe making of the die-form is the major cost in the setting up of the carton-making jobVery fast and can be used in large-scale productionCan be relatively expensive especially on a larger scaleForming Techniques p60-61CHARACTERISTICSPROCESSESADVANTAGESDISADVANTAGESblow mouldingPlastics bottles and containers of all sizes and shapes e.g. fizzy drinks bottles and shampoo bottlesPolymers used:HDPE, LDPE, PET, PP, PS, PVCHollow thermoplastic tube is extruded between a split mould and clamped at both endsHot air is blown to the parison which expands it to take the shape of the mouldOnce cooled product is ejected by opening the split mouldIntricate shapes can be formedIdeal for mass productionHigh initial set- up cost because the mould is expensiveinjection mouldingCasings for electrical products, containers for storage and packagingPolymers used:Nylon, ABS, PS, HDPE, PPGranulated polymer is placed into the hopperPolymer is heated to a LiquidThe screw is forcedforward underhydraulic highpressure and injects the liquid plastic into the mouldThe mould is cooled for quick to let out the productIdeal for mass productionPrecision mouldingHigh initial set-up cost as the mould is expensivevacuum formingChocolate box trays, yogurt pots, bliter packs etcPolymers used:Acrylic, HIPS,PVCMold info? Draft angle/tapers (1)? Rounded/radiused corners/edges (1)? Vent holes (1)? Depth of draw (1)? Internal draws must have vent holes (1)? Positioning of features to avoid webbing (1)? No undercuts (1)? High quality surface finish (1)? Resistance to heat (1)? Durable mould (1)Thermoplastic sheet is clamped and heated, blown and stretchedAir is sucked out of the vacuum forming machines to pull the softened sheet over a mould pushed up form belowOnce polymer is cooled it solidifies and cold air is blown between the mould Then it is releasedIdeal for batch productionInexpensiveRelatively easy to make moulds that ca be modifiedMould needs to be accurateLarge amounts of waste material produced? Mould? Clamp? Heater? Platform movement? Air blown in? Air drawn out? Forming removed? Mould is placed on platform and lowered (1)? Plastic sheet is placed into machine and clamped (1)? Plastic is heated (1)? Platform is raised (1)? Air is blown in to raise plastic from mould (1)? Air is drawn out to form plastic over mould (1)? Allowed to cool (1)Finishingprocesses p62-64 enhancing the format of paper and boardPROCESSESAPPLICATIONADVANTAGESDISADVANTAGESPICTURElaminatingA transparent plastic film to the surface of paper and boardFilm is glued to the paper as it is fed through a heating wedge under high pressureUsed all over the printing spectrumGood finishGood gloss and strengthinexpensiveCan curl at the edges during the processencapsulationlamination pouch is coated with a heat-activated film that sticks to the paper as it runs through the laminatorinside the laminater paper passes through a heater to activate the adhesive and then through rollers under pressureensure that all adhesive layers bond to one another and that the edge is sealedMenus for restaurantsID cardsKeeps things cleaninexpensivecan also be seen as useless if the paper is creasedvarnishingfine varnish is sprayed on to the surfacewhen dry this gives a gloss finishGlossy magazinesMakes a good finishing process ? Enhance the aesthetics/colours (1)? Make the product look more expensive/High Quality appearance (1)? Make the card stiffer/stronger/more durable (1)? Make the card moisture/liquid proof (1)? Protect against smell/impregnation of food (1)? Add protective layer to make surface more durable (1)? Protects from fading (1)Can only take place after the colour printing is completedhot foil blockingA roll of foil with a polyester backing sheet is continuously fed over the paper or board and a heated die presses the foil on to the surfaceGreeting cardsSignsBeing a dry process there are no problems with fumes or solvent vapoursThe print image is 100% opaqueIt can be very economic in short-run printingUsed to enhance and add value to conventionally printed materialsimprove aesthetic appeal/enhances the cover (1)Reflective metal used a gimmick on cover (1)gives impression of ‘luxury’ (1)adds perception of value (1) can be used to highlight areas (1)draws attention to the cover as marketing issue(1)traditional use for hardback book titles (1)dry process/so no fumes emitted (1)Image can ‘spread’ a little under the heatCan’t reproduce tints and halftonesRange of colour is wide but limited embossingA heated metal die and a counter die that fit together undrepressure and actually squeeze the fibres of the paper into the desired shapeThis pressure and a combination of heat actually ‘irons’ while raisingsurface decoration for signage using CAD/CAM p61-62 Table P61PROCESSESAPPLICATIONADVANTAGESDISADVANTAGESPICTURElaser cutting and engravingThe laser enters from the side of the sheet and cuts it through the axis of the beam.A peirece is made before every cutPiercing usually involves a high-power pulsed laser beam that slowly makes a hole in the materialideal for manufacturing signage for example, from sheet acrylicLack of physical contact with the material produces a clean edgeSome material or features are very difficult or impossible to cut by more traditional means.Very precise as the is no wearing on the laser like other methodsAutomated process meaning it can be replicated (1)No physical contact produces clean edge / no sharpswarf/neater finish. (1)Less mistakes/removes human error. (1)Low heat so less distortion /tool/laser wear/ lesschance of acrylic breaking. (1)more accurate/better quality due to computerprecision (1)Very complex cuts / acute shapes that are difficult toreplicate by hand. (1)Faster process than by hand. (1)Reduces labour costs. (1)Very expensive machineryHigh energy consumption required to power lasersCAD/CAM General? Files can be down loaded from a CAD package (1)? Items can be produced accurately/precisely (1)? Items can be produced quickly? Items can be replicated quickly/the same (1)? Curved surfaces can be machined with ease (1)? Files can be stored and re-loaded to match user demand (1)? Remote manufacturing due to electronic data transfer (1)? Reduced amount of waste material (1)? An automated production line can be used (1)? Automated inspection can be used (1)? Less direct contact therefore safer (1)? Simulations can be run to check operations (1)? They can run 24/continuous production/mass production (1)? Several machines can be operated by one operator / lower labourcosts (1)? Reduced human error (1)? Fast method of production. (1)? Can cut complex profiles.(1)? The machine works very accurately. (1)? High level of repetitive accuracy achieved / no humanerror / less waste. (1)? Minimal labour needed / minimal labour costs. (1)? Safe method of production. (1)? Shape is easily programmed (1)? Data is easily saved / retrieved for future batches.? The initial set-up costs for the machinery is high (1)? Training is required as software gets updated (1)? Trained technicians are needed to set up software/hardware (1)vinyl cutting.Image designed on CAD and sent to vinyl cutter tocut out (both points needed for one mark). (1)? peel off /remove/ weeding background leaving requiredimage.(1)? Low tack film/ application tape/transfertape/masking tape applied over lettering. (1)? Mark out surface. (1)? Remove image from backing paper with lowtack/application tape.(1)? Apply image to surface and ’firm’ down removing air(both points needed for one mark). (1)? Remove low tack. (1)ideal for one-off or batch production, from an individual sign for a shop or restaurant frontage to a series of movie adverts covering the backs of buses Gives letters a soft flexible quality that allows stuck to variety of surfacesVery simple process to understandIt is affordable and cheapYou can change the lettering any time you like since the product is designed to be removable.It sometimes is hard to remove vinyl from back coatingPrinting processes p66-69 Table P69PROCESSESAPPLICATIONADVANTAGESDISADVANTAGESPICTUREoffset lithographyWhile the press is in operation, the engraved cylinder is partially immersed in the ink fountain, filling the recessed cells. As the cylinder rotates, it draws ink out of the fountain with it. Business stationary, brochure, posters. Magazines, newspapersHigh printing speedsWidely availableInexpensive printing processRequires a good-quality surfaceCan only be used on flat materialsPaper can stretch due to dampening-444501905flexographyA flexographic print is made by creating a positive mirrored master of the required image as a 3D relief in a rubber or polymer material. Flexographic plates can be created with analogy and digital plate making processes. Packaging, less-expensive magazines, paperbacks, newspaperFast-drying inksCan print on same presses as letterpressCan be used to print on uneven surfaces (1) asPrinting plates are flexible with raised ink pattern.(1)Use of fast drying water based inks (1) so card doesn’t absorb excess moistureand doesn’twarp. (1)Low viscosity inks used (1) so flow into rippledsurface (1)Horizontal printing (1) method so corrugated boarddoes not get bent. (1)Least expensive and simplest printing (1) so doesn’tadd to cost of product. (1)Low pressure from rollers (1) so printing doesn’tbend/ crush card. (1)Difficult to reproduce fine detailColour may not be consistent-444503810screen-printingThe original image is placed on a transparent overlay The overlay is placed over the emulsion-coated screen and then exposed with a strong lightThe areas that aren’t opaque in the overlay allow light to reach the emulsion, which hardens and sticks to the screen.The screen is washed off thoroughly. The areas that weren’t exposed to light dissolve and wash away, leaving a negative stencil a negative stencil of the image attached to the screenT-shirts, posters, plastic and mental signage, pens and glassesVersatileStencils easy to produce using photo emulsionEconomical for short-hand produced runscan be used to print directly on any surface/material (1)? economical for short runs(1)? can be used for a range of production methods (1)? relatively easy to do (1)? stencils can be hand cut or photo-emulsion(1)? can be fully automated production printing (1)? produces identical/replica images (1)? stencils can be easy to produce/reusable(1)? can be used to print on flat/curved surfaces (1)Print requires long drying timesGenerally difficult to achieve finedifficult to achieve details (1)? printing ink can take long periods to dry (1)? time consuming process (1)? adds to product unit cost (1)? expensive on long runs (1)? specialist process (UV) needed to dry ink fast (1)1587545085gravure.Gravure printing is an intaglio printing technique, where the image to be printed is made up of small depressions in the surface of the printing plate. The cells are filled with ink and the excess is scraped off the surface with a doctor blade, then a rubber-covered roller presses paper onto the surface of the plate and into contact with the ink in the cells. The printing plates are usually made from copper and may be produced by digital engraving or laser etching.high quality are and photographic books, postage stamps, packaging, expensive magazines High-speed printing processInk dries upon evaporationOnly efficient for long prints runsCONCEPTCHARACTERISTICSAPPLICATIONADVANTAGESPICTUREQuality control during a final print run They contain a whole range of test some are visual and some can be done electronically usual using a densitometer.Quality Checks during Print Preparation:? Check lithographic plates (1)? Print test pages (1)? Check ink quality (1)? Check paper quality (1)? Check guillotine/die cutter (1)? Check humidity suitable (1)Quality Checks during Print Processing:? Check colour density during print run (1)? Check colour registration during print run (1)? Check guillotine/die cut during process-ensure registration (1)? Visual Check during print run/Hickies/Halios/Smudging (1)Quality Checks during Assembly:? Check paper insert for fit to DVD box (1)? Samples are finally checked for alignment and print quality (1)? Check alignment within box (spine etc) (1)When there is a problem with the printing it is used maybe when picture is blurry or not registered wellComes in a wide range can fix most nearly all printing problems if the right corrections are madecolour bars for colour consistency/densityProvide vital information about the performance of both the printing press and the inks being used.Density is measured using a densitometer which can be visual bars or a digital devise it monitors the thickness of the ink printed on the colour bar to ensure that it is of a consistent quality throughout the run.Colour qualityvaries throughoutthe printrun/densityincorrect.(1)? Colours do notmatch theproof/inconsistentcolour. (1)If the colour variation is off then the printer does not maintain consistent colour throughout the run.Used when there is colour variation registration marks for aligning printing platesThey help to align the four process colours (CMYK) to form the full colour range.incorrect registration of one of the printing plates. This results in low quality image where one colour is printed slightly ‘off-centre’ causing blurring ? Image will look outoffocus/blurred/notaligned. (1)? Colours/printingwill not becorrectly lined up.(1)? Colours/printingwill overlap andprotrude. (1)Colours protrude beyond the edge of the four colour separations, making the image look out of focusUsed hen image or whatever is being printed is badly registered or greyscale for monochrome consistencyCHARACTERISTICSPROCEDURESADVANTAGESDISADVANTAGESPICTURECE Mark? CE Mark is administered by the European Union. ? By placing the CE mark on products, the manufacturer is warranting that the product meets the minimum EU standards set down for that product.Quality Sectors that benefitBenefits of good qualityCustomers and usersReceive products that conform to the requirementsReceive products that are dependable and reliableAvailable when neededEasily maintainedPeople in the organisationBetter working conditionsIncreased job satisfactionImproved health and safetyImproved moraleOwners and investorsIncreased return on investmentImproved operational resultsIncreased market shareIncreased profitsSocietyFulfilment of legal and regulatory requirementsImproved health and safetyReduced environmental impactIncreased securityBSI (British Standards Institute) for PackagingPerformance requirements laid out for materials. (1)? Information is made readily available for productsizes/packaging sizes. (1)to beused/non offensive language. (1)? Performance/hygiene requirements laid out for thepackaging /inks during use/ recycling/after use/nontoxic.(1)? BSI ISO 9001ISO 9001 accreditation By the BSI gives an organisation the quality systems that will provide the foundation to better customer satisfaction, staff motivation and continual improvement.Analysis and improvement of efficiency of all company procedures for both the product e.g. testing and staff procedures making them safer and of higher quality followed by regular monitoring to keep the standards anization Benefits? organizations receives accreditation/BSI logo for producingconsistently high quality products (1)? organizations have a culture for quality (1)? international standard that strives to improve quality (1)Employers Benefits? employers/whole organization effected from cradle to grave (1)? employers/organization returns better profits (1)? employers/whole organization improve their reputation (1)? employers/organizations improves its environmental impact(1)? employers have increased profits/operational results/marketshare (1)Employees Benefits? employees have better working conditions/morale/health andsafety (1)? employees have better job satisfaction (1)? employees have greater input/better training/are more valued(1)Customers Benefits? customers receive products that are higher standard/reliable(1)? customer satisfaction with service/product improved as lessbreakages/better service (1)? customer reassured by quality of organization (1)Needs rigorous analysis to achieve accreditation (1)? Time consuming for employers and employees(1)? Accreditation costs that can be transferred to product cost/customers (1)? Regular monitoring to keep up standards/re-accreditation (1)? Some employees resistant to change (1)Quality Controlmonitor/check/test product at specific points.Testing to Destruction:Force is applied in one form or another till the products breaks? Product is tested in controlled conditions (1)? Force is applied until the product breaks(1)? Information is gathered on how much protection is gained (1)? Information is gathered on how much force is needed/limitsof force at point of destruction (1)? Information is gathered on how the productbehaves/breaks upon breaking (1)Non-Destructive testing:Force is applied in one form or another till the products deformsCrack testing is another form of Non-Destructive testing: were cracks are detected on the surfaceby e.g. changes in density with ultrasound or changes in magnetic flowProduct is tested in controlled conditions (1)? Force is applied until deformation occurs (1)? Information is gathered on materials and construction (1)? Information is gathered on how the productbehaves/deforms/protects under pressure(1)Quality AssuranceQA monitors all stages from design throughmanufacture to after sales. (1)? QA ensures customer satisfaction. (1)? QA ensures the product is fit for purpose/safethrough testing. (1)? Ensures the product is the highest standards/quality.(1)? Uses Quality Control to monitor/check/test product at specific points. (1)TQM Total Quality Management? Commitment to continuous improvement (1) with Record at everystage to improve production and process/application for ISO 9000 (1)? Control over raw materials, records of every stage of production (1) toassist with quality of the complete product (1)? Covers complete lifestyle of product (1) with Working to reducewaste (1)? Quality built in with monitoring (1) in order to get the product rightfirst time/within tolerance (1)? Works to customer satisfaction (1) reputation of company enhanced(1)? Encourages a strategic, team building approach (1) increasinghigher/efficient levels of productivity/higher quality products (1)? Provides a high return on investment (1)by improving efficiency (1)? Continually improves process, products(1) and overall culture inwhich employees work (1)Positives? Staff feel more valued / listened too / stafffeedback accepted. (1)? Better working conditions / culture. (1)? Staff more highly motivated. (1)? Team mentality will be developed. (1)? Less staff absentees. (1)? Staff has increased job satisfaction / morale. (1)? Staff fully trained / has frequent trainingopportunities. (1)? Fair rates of pay. (1)? Improving health and safety. (1)? Each department treated as a client. (1)? Improved product quality / less failure productsand components. (1)? Improved company reputation. (1)? Develop an ethos of continuous improvement. (1)? Increased sales / market share. (1)? Improved productivity /profits. (1)? Gain BSI/ISO 9000 mark / trade with ISO.9000companies. (1)Negatives? Additional costs of developing new ways ofworking. (1)? Additional costs of training staff. (1)? On-going costs of responding to workforceproposals. (1)? Benefits will take time to filter through. (1)? Some staff may be reluctant to embracechange.(1)procedures of safety by employersEquipment must be maintained/ stored properly. (1)? Employees must be trained to use the equipmentcorrectly/use emergency evacuation procedurescorrectly. (1)? Employer to provide PPE. (1)? Display signage/warning symbols. (1)? Carry out risk assessments. (1)? Provide ventilation/extraction/guards. (1)Health and SafetyRisk AssessmentRiskControl MeasureAcrylic Cement Control MeasuresControl MeasureLid fitted securely/sealed container/solvent correctlylabelled. (1)? Store in cool/dry/well ventilated area. (1)? Store away from heat/sun/flame. (1)? Store in metal cupboard/locked cupboard/yellowcupboard. (1)? Cupboard must have safety signage. (1)? Staff to be briefed as to how to store adhesives. (1)? Regular checks need to be made bytechnician/monitoring log. (1)Scrol Saw risk assessment Risk ? Damage to eyes fromflying material/dust (1)? Cuts from material/blade(1)? Inhalation of dust (1)? Amputation (1)? Entanglement (1)Control MeasureUse PPE/tie hair back/masketc. (1)? Use machine guards/heightrestrainer (1)? Ensure extraction/use scrollsaw dust blower (1)? Have proper training for useof machine (1)? keep fingers away fromblade (1)? have proper supervision(1)? other students behindyellow line/1m away (1)? controlled cutting (1)? one person to use themachine (1)? clear work area (1)CHARACTERISTICSPROCEDURESPROCEDURES 2COSHHCOSHH is the law that requires employers to control substances that are hazardous to health.e.g.? Maximum safe exposure / controlling exposure e.g.extraction.(1)? Maintenance of protective equipment. (1)? Training in safe working / handling of hazardousmaterials. (1)? Frequency of monitoring / surveillance exercises.(1)? Safe methods of storing the materials. (1)? First aid measures in the event of accident /exposure.(1)? Safe methods of disposing of waste. (1)? Essential signage required. (1)What you need to doIdentifying hazard and assessing riskExposure limitsSafety data sheetsControl measuresPersonal protective equipmentMonitoringHealth surveillanceTrainingEmergencies? Employers must liaise with HSE (1)? HSE, H&S at work act and COSHH regulations applied (1)? Reduce exposure for employees (1)? Provide Control measures such as local ventilation (1)? Monitoring substances and levels of harmful substances (1)? Provide employees with information about substances (1)? Protect employees with PPE/use of PPE (1)? Provide first aid/showers and hygienic facilities (1)? Record incidents using accident book etc (1)? Undertake risk assessments (1)? Provide the safe storage and disposal of substances (1)? Warning material must be marked/labelled (1)? Warning/Safety signs provided (1)? Provide chemical spill facilities/accident procedures (1)? Provided training (1)Die Cutting ? Automated / machine process for cutting/suitable for massproduction (1)? Cutter for nets and ‘odd’ shapes (1)? Cutting and scoring achieved at the same time (1)? Multiple/identical sheets can be cut at the same time (1)? Accuracy/cuts cleanly/better quality finish (1)? Allows lay planning/tessellation (1)? Removes the human error when cutting (1)? Cost effective on large runs (1)? Die can be reused on another production run (1)? High speed process (1)NET partsA= glue flap (1) accept glue tabB= upper tuck (1) accept tuckC= Dust flap (1) accept dust panelModellingA scale model (1) allows designer to see proportion ofthe building/features (1)? Allows the designer/client to realise the 2D design (1) into3D (1)? Allows designers to solve problems at the design stage(1) rather than at the more expensive building stage (1)? Allows testing (1) to ensure environmental problems aresolved (1)? Allows materials/colours (1) to be experimented with prior tofinal build to ensure it ‘fits’ environment (1)? allows 3D model to be transported (1) so clients can have afirst hand input (1)Prohibition SignsMandatory SignsCircular signs are a command /mandatory /prohibition signs. wear gogglesWarning Sign(Triangular are warning signs).warning personnel about flammablesubstances / firewarning personnel about highvoltage / electricity / risk of electric shock.A reference to warning personnel about lasers.Safe Condition Signs First Aid Emergency stopFire Equipment Signs Fire extinguisherWarning Symbols Harmful irritant Toxic or poisonMass ProductionAny one from the following:? Products produced on assembly/production line (1) so less skilledlabour/workforce is needed (1)? Production broken into repetitive tasks (1) suitable for unskilledlabour (1)? Bulk purchase of materials at lower prices (1) leads to lowerfinished unit costs (1)? large volume/quantities produced (1), so reducing individuality ofproducts/standardised products (1)? automated process (1) can lead to reduced time to market (1)? Due to economies of scale product unit cost is low(1) Howeverinitial set up cost is high (1) ................
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