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Y12 - Product Design

Revision and Test Material for Unit 2 of Edexcel A-Level Product Design
by

Mr Reynolds

on 2 January 2014

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Transcript of Y12 - Product Design

6th March 2013
Non this week
Homework
40% at AS
20% at A-Level
What percentage is it worth?
The Exam
Assessment:
What are you expected to know?
WARM & COOL Colours
Colours
Question
What do we have?
1 hour 30 minute examination, EXTERNALLY marked
Consists of short-answers and extended-writing
A knowledge and understanding of:

- a wide range of materials and processes used in the field of design and technology.

- materials and processes so that they can develop a greater understanding of how products can be designed and
manufactured.

- industrial and commercial practices, and the importance
of quality checks and the health and safety issues that have to be considered at all
times.
Content
Broken down in to 4 sections:
- Materials & Components,
- Industrial & Commercial Practice,
- Quality,
- Health and Safety
Content
Link to Prezi-tation:
http://prezi.com/y9oeocwijsrp/y12-product-design/?auth_key=08ed248e4109911a16c32c1f7eb529bd6b23a94f
Links
QR Codes:
Each section is then broke down in to sub-sections
(see specification sheet)
BBC Bite Size
Design & Technology
Student
Prezi-tation
Download QR Scanner App for your Phone or Computer

[i-nigma is a good free one]


Prezi App for smart phones
Answer ALL the questions. Write your answers in the spaces provided.
1. (a) 25 park benches are to be manufactured using hardwood rather than softwood.
(i) Give two advantages of using hardwood.
1 .............................................................................................................................
...............................................................................................................................
2 .............................................................................................................................
...............................................................................................................................(2)

(ii) Give one disadvantage of using hardwood.
...............................................................................................................................
...............................................................................................................................(1)

(b) Outline three health and safety risks that must be considered when manufacturing the
park benches and outline how each could be minimised.
1 ...................................................................................................................................
......................................................................................................................................
......................................................................................................................................
......................................................................................................................................
2 ...................................................................................................................................
......................................................................................................................................
......................................................................................................................................
......................................................................................................................................
3 ...................................................................................................................................
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......................................................................................................................................
......................................................................................................................................(6)
Question
3. Figure 1 below shows a jigsaw puzzle which has been manufactured from acrylic in a
school workshop.
[Figure 1 - see hand out]
(a) Give four advantages of using a laser cutter to produce the jigsaw.
1....................................................................................................................................................................................
2...................................................................................................................................................................................
3 ..................................................................................................................................................................................
4 ..................................................................................................................................................................................(4)

(b) The jigsaw is to be manufactured by a company in large quantities. The company
must have quality assurance systems in place.
(i) Describe what is meant by “quality assurance”.
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................(2)

(ii) Explain two ways in which quality assurance is used to ensure the product is
suitable for its intended market.
1 ............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................
2 ............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................
..............................................................................................................................................................................(4)
Answer ALL the questions. Write your answers in the spaces provided.
1. (a) 25 park benches are to be manufactured using hardwood rather than softwood.
(i) Give two advantages of using hardwood.

1 ........................................................................................................................................................................................................................................................

2 ........................................................................................................................................................................................................................................................

(ii) Give one disadvantage of using hardwood.

.............................................................................................................................................................................................................................................................

(b) Outline three health and safety risks that must be considered when manufacturing the
park benches and outline how each could be minimised.

1 .........................................................................................................................................................................................................................................................

........................................................................................................................................................................................................................................................

2 .........................................................................................................................................................................................................................................................

........................................................................................................................................................................................................................................................


3 .........................................................................................................................................................................................................................................................

........................................................................................................................................................................................................................................................
What do we have?
3. Figure 1 below shows a jigsaw puzzle which has been manufactured from acrylic in a
school workshop.
[Figure 1 - see hand out]
(a) Give four advantages of using a laser cutter to produce the jigsaw.

1....................................................................................................................................................................................

2...................................................................................................................................................................................

3...................................................................................................................................................................................

4..................................................................................................................................................................................(4)
What do we have?
(b) The jigsaw is to be manufactured by a company in large quantities. The company
must have quality assurance systems in place.
(i) Describe what is meant by “quality assurance”.

..............................................................................................................................................................................

..............................................................................................................................................................................

..............................................................................................................................................................................(2)

(ii) Explain two ways in which quality assurance is used to ensure the product is
suitable for its intended market.

1 ............................................................................................................................................................................

..............................................................................................................................................................................

..............................................................................................................................................................................

2 ............................................................................................................................................................................

..............................................................................................................................................................................

..............................................................................................................................................................................(4)
Do expect homework in the up and coming weeks
UNIT 2 - Design & Technology in Practice
METALS
POLYMERS
ferrous
non-ferrous
alloys
thermoplastics
thermosetting plastics
WOOD
hardwood
softwood
COMPOSITES
carbon fibre
glass reinforced
plastic (GRP)
medium density fibreboard (MDF)
chipboard
LAMINATES
plywood
block-board
MODERN MATERIALS & PRODUCTS
thermo-ceramics
tinted glass
solar panels
liquid crystal displays (LCD)
electroluminescent
(EL) lighting
NEW & SMART MATERIALS
shape memory alloy (SMA)
reactive glass
photochromic paint
quantum tunneling composites (QTC)
Materials
BEARINGS
GEARS
ball
journal
plain
rack & pinion
simple gear trains
CAMS
circular
pear shaped
COMPOSITES
carbon fibre
glass reinforced
plastic (GRP)
medium density fibreboard (MDF)
chipboard
RIVETS
snap
pop
FOLLOWERS
flat-foot
knife-edge
roller
electroluminescent
(EL) lighting
Components
compound gear trains
worm and wheel
bevel & mitre gears
spur gears
bushes
eccentric
heart shaped
snail
METAL
POLYMERS
ferrous
non-ferrous
alloys
thermoplastics
thermosetting plastics
WOOD
hardwood
softwood
COMPOSITES
carbon fibre
glass reinforced
plastic (GRP)
medium density fibreboard (MDF)
chipboard
LAMINATES
plywood
block-board
MODERN MATERIALS & PRODUCTS
thermo-ceramics
tinted glass
solar panels
liquid crystal displays (LCD)
electroluminescent
(EL) lighting
NEW & SMART MATERIALS
shape memory alloy (SMA)
reactive glass
photochromic paint
quantum tunneling composites (QTC)
Industrial and commercial practice
Cast Iron
Mild Steel
Carbon Steel
Zinc
Stainless Steel
Aluminium
Copper
Duralumin
White Cast
Grey Cast
Heavy machinery
Cannot be Machined
Brittle
Very hard
Components
for machines
Can be machined
Easily cast
Corrosion resistant
Cast iron cookware
Disk brakes
Can crack under stress and requires constant annealing when worked
When worked
will become brittle
Danger of electrolysis if
joined to iron pipes in
water systems
Harder than mild steel but less
ductile and less malleable
0.15% - 0.30%
Nuts and bolts
General engineering
Has high tensile strength
Ductile, tough, malleable
Cutting tools
Drills
Hammer heads
Properties can be improved
by heat treating
0.70-1.40%
High carbon steel
Medium carbon
steel
0.30 - 0.70%
Springs
Garden tools
Engine components
Castings
Aircraft industry
Does not withstand
great loads
Good conductor
Lightweight
650
Corrosion resistant
420
Galvanising
Batteries
Castings
Corrosion
resistant
Printed circuits
Central heating
When worked requires
constant annealing
Electrical cables
Corrosion resistant
1100
Good conductor of
heat and electricity
Copper & Zinc
Brass
Addition of copper has
given rise to some
corrosion issues
Ships
propellers
Electrical
components
Central heating valves
Needs to be
constantly annealed
Susceptible to cracking
when cold worked
Good conductor of heat
and electricity
Easily to machine
Casts well
Chemical and
nuclear industries
Medical tools
Kitchen utensils
pipes
Hard to cut
Expensive
Corrosion resistant
Chromium
& Nickel
Strong
Lightweight
Aluminium, Copper & Manganese
Automobile industry
Aviation industry
UV light causes degradation
Stiff, hard, durable, can
be easily scratched,
High density
polyethylene (HDPE)
Good electrical insulator
Polyethylene
terephthalate (PET)
Weather resistant
Light, hard, impact resistant
Expanded: Buoyant,
lightweight, good insulator
Polyvinyl chloride (PVC)
Good chemical resistance
Floor covering
Pipes and guttering
Electrical wiring insulation
Ultraviolet light causes brittleness
Can become
brittle over time
Stiff, tough, hard, lightweight
Ignites easily
Polystyrene (PS) Compressed:
low impact strength
light
hard
stiff
brittle
Easily ignites
Crumbles and breaks
Weak
Polypropylene (PP)
Kitchenware
Carpets
Medical syringes
Oxidation can be a problem
during manufacturing processes
Ultraviolet light causes degradation
Chemical resistant.
Brittle and can break
Scratches easily
Splinters easily
Lighting
CD cases
Car light
Baths
Acrylic
good electrical insulator
Acrylonitrile
butadiene
styrene (ABS)
Chemical resistant
Hard
Tough
Fizzy drinks bottles
When used in containers for foodstuffs needs to be treated to prevent taste problems
Can discolour
High tensile strength
High impact resistance
Chemical resistant
Good alcohol and oil barrier
Bowls
Buckets
Water pipes
Water tanks
Can break under stress
Colour tends to fade over time
Flexible
Impact resistant
Chemical resistant
Good electrical insulator
Low density
polyethylene (LDPE)
Packaging film
Cable insulation
Dustbin sacks
Washing up liquid bottles
Can break under stress
Colour tends to fade over time
Flexible
Chemical resistant
• Corrosion resistant
Epoxy resins
• Strong, hard, brittle
• Good electrical
insulator
• Electronics
• Paints and coatings
• Adhesives
• Suspected of health problems
• Can cause allergic reactions
• Good bond qualities
• Electrical resistant
Polyester resin
Urea formaldehyde
• Domestic appliance
components
• Electrical fittings
• Can emit toxic vapours during
manufacturing process
• Heat resistant
• Glass reinforced boats
• Can crack
• Brittle
• Heat resistant
• High class furniture
• Tough
• Easy to work
Mahogany
• Durable
• Finishes well
• Prone to warping
• Physical hardness varies
• Floor boards
• Veneers
• Furniture
• Grain can be variable
Oak
• Strong, durable, hard, tough
• Works well,
• Finishes well
• Expensive
• Heavy
• Prone to splitting
• Can be physically hard
• Garden furniture
• Construction
Beech
• Physically hard
• Furniture
• School desks
• Workshop benches
• Can be difficult to work
• Not suitable for
outside applications
• Can be prone
to warping
• Turns well
• Straight grain
Pine
• Furniture
• Floorboards
• Roof joists
• Construction
• Knots can make
working difficult
• Easy to work
Full transcript