Exam Preparation Your exam is NOT just remembering FACTS. It is a DESIGN EXAM The Final exam is worth 40% of the final GCSE It will be 2 hours and is marked.

Exam Preparation

Your exam is NOT just remembering FACTS. It is a DESIGN EXAM

• The Final exam is worth 40% of the final GCSE• It will be 2 hours and is marked out of 120marks• That works out to 1 minute per mark

• Your Unit 1 Final Exam is on Monday 22nd June

• Section A of the paper (the first bit you do) is a THEMED question.

• The Exam Board issues “Preliminary Material” that tells us what the theme of Section A will be. We can then Research & Prepare

Section A – What to expect

This year the Preliminary Material gives this information:

Context: Pattern and Structure found in nature can inspire the design and

manufacture of products.

That gives you TIME to research and prepare to answer a DESIGN QUESTION in Section A that will definitely be related to Pattern and Structure found in nature

Section A – Initial reaction

Context: Pattern and Structure found in nature can inspire the design and manufacture of products.What could this mean? What might you be expected to do?

Jot down (and sketch?!?) as many ideas as you can think of in the following 2 categories

Natural Patterns

Natural Structures

Section A – Practice Question: 30 mins

This question is about Designing a coffee table based on the natural form of a tree1 (a)Complete a 5 point Design Specificationfor things that such a coffee table MUST DO. One has been done for you:

1. The coffee table must safely hold hot drinks cups, remote controls and magazines securely, and safely to prevent accident or injury.

2. The coffee table must…3. The coffee table must…4. The coffee table must…5. The coffee table must…

(8 marks)

1 (b) On one side of plain A4 paper, Design a coffee table that is inspiredby the natural form of a tree

Marks will be given for:• A creative solution that shows clear inspiration from the natural

form of a tree• The construction of the coffee table to securely hold the cups,

magazines and remotes safely• The material used to make the coffee table• The surface finish of the coffee table to prevent the material

from being damaged• Ergonomics to ensure the coffee table’s ease of use.• Dimensions.

(15 marks)

Section A – Practice Question: 30 mins

1 (c) Evaluate how well your designPerforms the following functions:

• Securely and safely hold cups, magazines and remotes• Function ergonomically so that it is easy to use• Be durable to function without damage after continued

use.

(6 marks)

Section A – Practice Question: 30 mins

Technology Push

• Advances in technology are used to produce new products. • Inspiration for new products comes from research and

development labs. • An innovation based upon a new invention and a

perceived market need.

Market Pull

• Inspiration for new products often comes from the needs of society, market research improves products, brand loyalty, “have to have one” psychology.

• An innovation based upon market pull has been developed by the Research & Development function in response to an identified market need, fashion or trend.

Obsolescence

• A product is no longer working or useful. Obsolete

• Consumer demand leads to the production of new products

Planned Obsolescence

• A Manufacturer deliberately minimises the ‘life’ of a product to maintain sales of future products –

• Planned obsolescence = Built in obsolescence

Pull Push Analysis

Technology Push Market Pull

Technology Push Market Pull

Mobile Phones

Office Chair

What new technologies have been invented that have led to new products being released.

What features have been demanded by the Target Market, that have then had to be invented and led to new products

Product Evolution

• Products Naturally Change over time. • Small improvements can gradually adapt the

design of the product so that after a while it is very different to how it started but has never had a MAJOR redesign

• These small changes can be driven by: new technology, improved production methods, style and fashion, problems with the old model etc

You need to know what each of these mean…

Intellectual Property IP

Patents:

Ergonomics & Anthropometric DataAnd how it affects designers

Ergonomics is about the relationship of people with productsFrom how easy it is to open a jar to the discomfort of sitting on a bus to the positioning of the controls in a fighter jet, ergonomics is how a person interacts with a product.

As a designer we always need to consider how easy and comfortable any product will be to use. One of the ways to do this is to look at ANTHROPOMETRIC DATA.

ANTHROPOMETRY is the study of statistics that have been gathered and combined over many years of the sizes of the human body.As designers we can use this data to decide on the sizes, weights and proportions of our products so as to provide the best ergonomics for the end user.

Anthropometric Data Explained•Of course not all people are the same size. There will be huge differences between the heights, weights, and other dimensions due to: gender, age, diet, growth rate, genetic make up and other factors.

•Therefore the Anthropometric data needs to be organised in a specific way.•If we were to plot a graph with peoples heights along the bottom and how many people are at that height up the side we end up with a graph that looks like this.

•The shape is called a “Bell Curve”

•The percentage of people at each height (or weight or whatever) is called the percentile.

•The average (mean) size is therefore the 50th percentile. We sometimes use this as the best size to design for. However really we should design for everyone between the 5th and 95th percentile. The top and bottom 5% being just to big or too small to practically design for. Tough luck for them!

# Female Male

  5% 50% 95% 5% 50% 95%

A 690 743 795 739 795 850

B 181 226 266 188 235 274

C 406 439 479 447 482 520

D 438 478 525 458 499 544

E 540 585 637 569 616 665

F 352 388 428 395 434 476

G 474 513 558 515 559 605

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Ergonomics – Product Analysis

Find a Folding Chair on the internet and stick it in the middle of a blank page.Annotate the picture to make (full sentence) comments about the Ergonomics of: • the seat• the back support• the size & weight • the aesthetics

Add further annotations about Function, Materials, Construction & ManufactureMake good and bad comments and suggest improvements

COMPUTERS IN PRODUCT DESIGN

TASK: Write a description for how Computers can be used when Designing and Developing new products. Use

full Sentences and Explain HOW and WHY

2D CAD: 2 D_______ C________ A_______ D________ can be used to…

3D CAD: 3 D_______ C________ A_______ D________ can be used to…

CAD Modelling: Can be used to…

CAM: C________ A_______ M_________ can be used to…

CNC: C________ N_______ C_________ this is how CAM operates by a computer sending numerical information to a CAM machine to control what it does and what it makes.

How many mobile phones have you ever owned?

How many broke?

How many did you replace even though they still worked?

Product Analysis - BlackberryAnnotate in full sentences:• Materials• Construction• Manufacture• Ergonomics• Function• Cost• Target Market• End User• How long should it last Don’t just state facts – give your opinions

Say good things and Bad things

Name:_______________

Sustainability and the Environment

Starter: Try to think of 5 reasons we change our Mobile Phones so often.

(Hint: Think about the work we have covered and the key words we have learned)

Question: Write a paragraph, in full sentences, to describe how having a culture that throws

products away so often can be harmful to the environment.

You will be marked on the quality of your written EnglishWriting frame: “A culture that throws products away so often is harmful to the environment because…”

Use words like: because, therefore, furthermore, however, etc

Sustainability and the Environment

Sustainability is where products are designed in a way that aims to preserve the world's natural resources for future

generations.

A sustainable design can be made again and again without serious environmental problems.

The 6 Rs of Sustainability• Re-use: Take an existing product that has become waste

and use the material or parts of it for another purpose, without processing it.

• Repair: When a product breaks down or doesn’t function properly, try to fix it rather than throw it away.

• Recycle: Take an existing product that has become waste and reprocess the material to use in a new product.

• Reduce: Minimise the amount of energy and materials you use.

• Rethink: Ask whether we can sustain our current way of life and the way we design, make, use and dispose of products.

• Refuse: Don’t use a material or buy a product if you think you don’t need it or if it’s unsustainable.

Quality Assurance…does not check the quality of the final product but the quality of all systems on the production line, staff training and quality monitoring.• Quality of Materials• Equipment• Manufacturing Processes• Staff Training

Quality Control… checks the quality of the final product though TESTING• Drop Test• HALT (Highly Accelerated Life Testing)• Mechanical Testing• Sound Testing

Quality Assurance Systems

• BSI Kitemark– British Standards Institute symbol– Recognised symbol of quality and safety– Companies Pay to be checked by BSI to see if their

product conforms to the standard for quality/safety• CE Symbol

– Shows that the product meets the requirements of the applicable directives in Europe

– Legally required on certain types of product to be sold in the European Economic Area (EEA) e.g. products that use an electrical voltage

– Companies Produce a Legal Declaration of Conformity to show that their product meets the requirements

Say what each of these means and where you might find them

Product Packaging - Labelling:

Product miles:

Carbon footprint:

Safety: Risk Assessment• When doing any practical activity in a workshop or factory, someone should

always do a risk assessment• It is usually in the form of a table like this:

Task Risk How Likely Control measures

What tools & processes are going to be used?

What might happen?

Red/Amber Green? 1-10?

What will you do to minimise the risk?

e.g. Drilling holes in pine using pillar drill

Trapping fingers, cuts, dust, flying objects

AmberOr 6/10

Apron, Googles, clamp work securely, ensure guard is in position

Or e.g.Cutting Acrylic on the laser cutter

Inhaling toxic fumes, burns to skin or eyes

Unlikley Ensure extractor fan is switched on, ensure lid is closed. Ensure that the machine has been regularly serviced (filters changed)

One off / Prototype Production:• Where only one of a product is made. This could be to make a test product to see if it’s

any good (prototype) or it could be a unique or “BESPOKE” product which is the only one of it’s kind

• e.g. wedding dress, bespoke furniture, new innovative product

Batch Production:• Where a set number (perhaps 10 to 1000) of a product are made in a set production

run. Batch production techniques can be used to make sure they are all the same (quality)

• E.g. wooden toys, designer furniture

Mass Production:• Where millions of identical products are made using large scale inductrial processes

(e.g. injection moulding) Setup costs are high but once set up each product can be made quickly and cheaply

• e.g. coke cans, school chairs, iphones,

Just in Time (JIT) Production:• Materials, components and Parts to arrive from other factories ‘just in time’ for

production. Finished products are despatched immediately they are made. This system reduces any storage of stock and allows for changes to the product to be made quickly without the need to use up stock items first.

Scales of Production

• Template: a tool that is used to mark out accurately every time e.g. draw around, mark out where to drill etc

• Jig: a tool that is used to cut or drill in the correct place every time (not just mark out but actually cut or drill)

• Former: A tool that material can be shaped around to make it the same shape every time e.g. vacuum forming or line bending

• Mould: A tool that liquid material can be poured into & then sete.g. Casting Pewter jewellery

• Computer Aided Manufacture (CAM): A specific Computer Numerically Controlled (CNC) machine that makes parts from CAD filese.g. “Laser Cutter”, “3D Printer” or “CNC Plotter/ Cutter”

Manufacturing techniques that will make sure a product is good quality every time

Batch Production Techniques:

Quality Control!

JIGS

Used to cut or drill in an exact place every time

TEMPLATES

Used to mark out to an exact size/shape every time

FORMERS

Used to shape a material into an exact form the same every time

• Cartridge Paper: Good surface for sketching and rendering with coloured pencils. More expensive than copier paper. Heavier papers are more versatile, less prone to yellowing with age.

• Layout Paper: Used by designers- particularly advertisers. It has partial transparency so designers can trace through previous design ideas to adapt and develop

• Tracing Paper: Semi transparent for accurately tracing outlines to make working drawings or templates

• Grid Paper: Used for schematic diagrams and technical graphics.• Properties of Paper:

– BRIGHTNESS (degree to which they reflect light)– COLOUR– OPACITY (how transparent they are: Opaque = shows nothing

through)– GLOSS (how shiny they are)– STRENGTH (determined by length of fibres (recycled is less strong))

Paper

• Carton Board: – The type of card commonly used in cereal/shoe boxes. – Can be bleached white or left unbleached– Thin versions have a printable white side– Can also be LAMINATED with a sealing layer of plastic to make it

watertight

• Corrugated card: 2 layers of carton board with a third fluted in between to improve; stiffness, protection and insulation

• Duplex board: Duplex board is stronger and better quality than carton board

• Solid white board: Strong and high quality with good printing surfaces on both sides

• Foam core board: Multi-layer board made up of two outer layers of high gloss card and a middle layer of foam. Used for mounting photographs &3D modelling.

Card

Offset Lithography: A common commercial printing method for paper and card Video: http://youtu.be/pNZb7CXUjs0

Flexography: A technique used to print onto flexible plastic film not just flat card e.g. carrier bagsVideo: http://youtu.be/vuGptR330VU

Screen Printing: Where coloured ink is forced through a fine mesh screen by hand.Video: http://youtu.be/es6iwTjMLhQ

Block Printing:A hand printing process used to create repeating patterns using a kind of big stampVideo: http://youtu.be/8De221tJt-w

Dye Sublimation: Uses a heat & is suitable for printing on materials like acrylic & fabric in short print runsVideo: http://youtu.be/kwV9IAGbYvo

Embossing: A way to decorate paper/card by pushing it in or out to make 3D patternsVideo: http://youtu.be/zPnKul79eGk

Laminating: Where at least 2 layers of material are fixed together to combine the properties of bothe.g. plastic and cardboard or foil and cardboard for food packaging

Packaging & Printing Processes

What is Packaging?

When designing packaging you MUST consider these 3 things…

Protect:

Display:

Inform:

Task: Write a sentence or two for each of the 3 key words to explain what packaging must be able to do.

What needs to be included on Good

Packaging???•Information about the product:

– What is it?– Symbols

•Instructions for use•Pricing information•Pictures: Make them Colourful and simple•Company Name, Logos, slogans Guarantee, Barcode, •Window

Packaging - Nets

Die Cutting

In industry companies need to manufacture packaging in large quantities. In order to create the packaging, nets or cutter guides have to be designed accurately so that the final product can be cut out after it had been printed

Many of the products you use everyday have been die cut: tissue boxes, stickers, cereal boxes, birthday cards, file dividers etc

Stage 1• The first stage is creating a cutter

guide or net for your packaging on Pro Desktop or an other CAD programmes.

The Die Cutting ProcessStage 2• The electronic file is then put into a

computerised laser cutter which burns the design directly on to a wooden board, it is accurate to 100th of a millimetre.

Stage 3

The Die Cutting Process

The operator uses the design to see where the die board (the lasered wood) should use a cutting metal rule (for cutting lines) or a blunt metal rule (for fold lines).

Metal rules are bent by hand and fitted into the wooden board where the laser cuts were made.

The operator then uses rubber to cover the blades, this helps to protect anyone handling the die board and stops the specialist machinery from getting damaged.

Stage 4

The Die Cutting Process

The dieboards are inserted into a machine called a Heidleberg Cylinder.

The paper or card is fed into the machine, the cylinder makes one rotation and the dieboard makes its cut.

These automatic machines can even separate the waste and stack the cut outs, saving time and money in the finishing process of making packaging.

Plastic Forming TechniquesForming Method

Common Plastic Used

Products Scale of Production

Diagram

Vacuum forming

High Impact Polystyrene

Prototypes,Yoghurt Pots, Shower Trays

One off & Batch Production

Line bending Acrylic Restaurant menu holder, Desk tidy

One off & Batch Production

Injectionmoulding

ABS Remote controls, mobile phones, wing mirrors

Mass & Continuous Production

Blow moulding

PolyPropylene (PPE)

Drinks Bottles, Barrels

Mass & Continuous Production

Compression moulding

Foam PVC, Urea Formaldehyde

Electrical Fittings, Hard Hats

One-off, Batch and Mass Production

Extrusion PVC Plastic window frames, Pipes

Batch and Mass Production

Life Cycle Analysis

Product Manufacture

Disposal

Raw Material Extraction

Material Manufacture

UseBy the End User of the

product

Re Use

Re Make

Recycle

Plastics Life Cycle Analysis

Oil Pumped out of

the ground

RefinedMade into

Plastic Granules

Made Into a product

and sent to shops

UsedBy the End User of the

product

Thrown outFor landfill or

recycling