Sam Naylor

Organic

1

Sam Naylor GCSE Resistant MaterialsCandidate Number 5686

Organic – Contents Page

-Planning

-Problem analysis

-Design Brief and Major Specifications

-Research plan

-Market research

-Product analysis

-Mood board

-Initial ideas

-Size research

-Modelling – Diary of Manufacture

-Development- function

-Design proposal one

-Development- ergonomics

-Development- aesthetics

-Design proposal two

-Research- Materials and Finishes

3

4-5

6

7

8-11

12-15

16

17-25

26-27

28-30

31-32,34

33

34-35

36-37

38

39

-Construction techniques

-List of Specifications

-Final design

-Engineering drawing

-Manufacturing plan

-Diary of manufacture ensuring quality/ mistakes made

-Evaluation

40

41

42-44

45-46

47-48

49-53

54-61

Pages- Pages-

Sam Naylor | GCSE Resistant Materials | Organic2

Planning

Introduction Method

On this slide, I have presented the plan for my project in the form of a Gantt Chart. It is very important to plan your work well as it helps you to recognize all the important stages, to allocate an adequate amount of time to complete each stage, and keep your project up to date in all areas.

In order to construct the Gantt Chart, I first listed the tasks needed to complete the project. Once I listed each of the tasks, I was able to put them in to a logical order. I then estimated and assigned each with the necessary time frame to complete each task. I then linked these times together and as a result, was able to estimate the total time needed to complete my project. Finally I had to regulate the planning to fit into the desired time specified.

Planning Est. Duration (wks) 3 4 5 6 7 8 - 11 12 13 14 15 16 17 18 - 20 21 22 23 24 25 - 27 28 29 30 31 32 33 34 35 - 37 38 39-51 44 45Identify Problem 1 Project Outline 1 Research Plan 1 Market Research 3 Results of Research 3

Product Analysis 2 Competing Products 1 Mood Board 1 Initial Ideas 1 Research Size 1 Development - Modeling + Function 2 Modeling Evaluation 1 1st proposal 1 Ergonomics 2 Aesthetics 2 2nd proposal 1 Materials, finishes and testing 3 Construction techniques and testing 1 Manufacture - Prototype 2 Minimizing environmental impact 2 Detailed specification 1 Final proposal (full CAD illustration) 2 Engineering drawing 1 Manufacturing plan + list of tools and equipment 2 Cutting and Components Table 2 Manufacture - Finish Product 12 Diary of manufacture 2 Evaluation 2

ConclusionsIn conclusion, I am going to use this Gantt chart to make sure that I keep up to date with all of my work, ensuring that I complete every bit of work in on time.

Design ProcessPlanning is the act or process of drawing up plans or layouts for a project or enterprise and it is an industrial practice.

I used the design process model as illustrated below to help myself construct the Gantt Chart as shown on the right. I also used the Design process when attempting to identify all of the major stages of my project.

Gantt Chart


Design Problem and Problem AnalysisIntroduction

Design problem

On this slide, I have presented my design problem and problem analysis. In order to identify the problem I have looked at existing problems in products already in the market. Throughout the product analysis I hope to identify the design specifications that must satisfy my product in order to be successful. When boiling an egg, I discovered a number of problems. First of all, one has to be careful that they do not place their hands too close to the water or saucepan – in order to avoid burning. Also, one must be careful not to crack the egg when placing it into the saucepan, as this would ruin the egg. One must also be careful that they do not overcook their egg, as this may cause the egg to crack or be too hard.

Figure 1

Figure 2

Figure 1 shows me about to try to spoon out a boiled egg from a saucepan. This is a very awkward step when the water is boiling, as first of all, you have to be careful that you don’t burn yourself while placing the spoon in the saucepan, as the saucepan is very hot. You also have to be careful that you don’t place your hand to close to the boiling water, which adds to the difficulty.

It is also important that the egg is not overcooked – in which case, the egg would crack when boiling.

Conclusion

Through this problem analysis I have developed a number of major specifications that my product must satisfy these are as follows:

1) It must be able to provide easy means of removing an egg from a saucepan.

2) It must also be able to determine when an egg has boiled.

Figure 2 shows that it can be quite difficult to manage to balance an egg on a spoon when taking it out of the saucepan. This would be especially hard for an elderly person wishing to make themselves a boiled egg. As well as this, you also have to take each egg out one by one, which is not a very practical way of taking them all out. As well as this, it is very hard to be able to tell when an egg is cooked, but there are methods of doing so. Obviously, everyone knows that there is time, which can give a rough answer as to whether the egg has been cooked, by knowing how long it has been boiling for. However, another method is by taking the egg out, and watching for condensation around the egg, and if condensation does occur, then it is cooked, if not, then it is still undercooked. It is very hard to do this and balance the egg on the spoon in the meantime.


Design Problem and Problem AnalysisIntroductionOn this slide I have continued to analyse the design problem.

Conclusion

Now that I have completed identifying a problem in different products, I can now list any other specifications needed to be included in the making of my product.1) It should be able to hold at least 2 - 3

eggs.2) It must be able to provide an easy way of

removing an egg from a saucepan.

Figure 3

Figure 4

Figure 3 shows me trying to place the egg into an egg cup. This is made very awkward, as again, I am having to balance the egg on the spoon, and in the meantime, place the egg in the egg cup without it falling on the floor. I have to do so as once the egg is boiled, it is too hot to handle, and I would burn myself if touched.

Figure 5 shows an existing product already on the market. I found this image on the internet, and I found that yes, it does provide easy means of boiling your egg, however, I was able to think of a few flaws in the design. First of all, while all it does to help the consumer know how cooked the egg is, it doesn’t help the user to remove the egg from the saucepan. The time that it takes to take the egg out may be considered valuable by some as they may wish for there egg to be cooked for a very specific amount of time.

Figure 5

Figure 4 shows another existing product already on the market. However, despite it being similar to the product shown in Figure 5, it has a completely different function, in that it helps the user remove the eggs from the saucepan. This product solves the problem shown in figure 1 and 2, of having to remove the egg from the saucepan, without touching the water or saucepan. It solves this problem as when the consumer uses it, the first thing that they do is they place 1-3 eggs on the product, and then they place the product into the saucepan, whilst holding the top of the product. This helps the user, as this way, the user doesn’t need to get too close to either the saucepan or the boiling water. However, a problem with this solution is that the part of the product from which the user is meant to grip it from is very thin, and therefore would be quite difficult for some people to get a firm hold of.


Design Brief

Introduction

Brief

On this page, I have presented my Design Brief and Major Design Specifications. The design brief is the statement of intent which states the aim of the project. The design specifications are criteria which the product must satisfy.

To design and manufacture an egg holder that can support an egg whilst in a saucepan. The product must be able to hold the egg securely and be able to be removed with ease. It should also be able to hold at least two eggs.

Conclusions

I have now created my brief and my major specifications and therefore will be able to look back and use this page to direct me through my project. Next I will move onto my research plan.

Major Design Specifications

The product must:• Be able to be easily removed from the

saucepan once it has finished boiling, as otherwise it would defeat the object of why the product was made.

• Be able to hold at least 3 eggs so that if for example the consumer wishes to boil 6 eggs, they don’t have to boil 2 eggs on 3 occasions.

• Be able to be used in a range of different sized saucepans so that the consumer doesn’t have to have a specific sized saucepan when using the product.

• Be able to keep the consumer safe from burning themselves on either the saucepan, or the boiling water.

Figure 1

Figure 1 shows my drawings of my first initial ideas for my project. The drawing on the left hand side shows the side view of my product. The drawing on the right hand side shows a 3D drawing of my initial idea, along with annotation giving an explanation of the drawing. The handle must be heat-proof, so that the consumer won’t burn their hand when they want to remove the egg from the saucepan. It also gives an idea of how many eggs it will be able to fit inside it when in use. As well as this, it shows how the product will be able to attach itself to a saucepan. Finally, it explains that there would be small holes in the side of the product so that boiling water will be allowed in to the holder.


Research PlanIntroduction

Conclusions

From the analysis of my research I will develop a list of design specifications that my product must satisfy. These design specifications will provide me with a foundation upon which to base my initial design ideas. I will now start the research section with the market research and look to identify the consumers needs and wants.

Research Area

Question Data Source

Primary or secondary information

Qualitative or Quantitative

Method of Presentation

Size What width should the product be so that it will fit a normal sized saucepan?

Research sizes of saucepans

Primary and secondary

Quantitative Pie chart and images

Size Should the product only have to fit one size of saucepan?

Questionnaire

Primary Qualitative Graph and statements

Materials What material would be most suitable to manufacture the product?

Materials on the school database

Secondary and Primary

Qualitative Show comments from questionnaire

Aesthetics What aesthetic qualities should it have?

Questionnaire and existing products

Primary and Secondary

Qualitative Pie chart

Design How should it attach itself to the saucepan?

Practical testing

Primary Qualitative Sketches from other people

Existing Products

Are there any products that already exist in the market that deal with the same problem?

Do research on the internet or at shops

Primary Qualitative Photos and statements

Product life span

Would it be better as a cheap and disposable item or an expensive and long-lasting item?

Questionnaire

Primary Qualitative and Quantitative

Graph and statements

Durability How often would it be used? Questionnaire

Primary Qualitative and quantitative

Pie chart and statements

Maintenance Will it need to be washed regularly?

Questionnaire

Primary/Secondary

Qualitative Pie chart and statements

On this page, I have presented a research plan for my project. A research plan is important as it helps me to identify all of the areas of research I must investigate. This research plan contains 11 questions concerning my product. It gives me a question, the data source, what type of source the answer has come from and what kind of information this is (Qualitative/Quantitative). This plan aids me when identifying the areas that I will need to look into, but also provides a logical and original structure to follow.


Market ResearchIntroduction

Conclusions

On this slide, I have presented the questionnaire for my Market Research. Market Research looks specifically at what the consumer would desire from a product. One way of discovering this information is by using questionnaires and surveys. Google defines Market research as: Research that gathers and analyzes information about the moving of good or services from producer to consumer.

Producing and handing out a questionnaire is an industrial practise. I will start my Market Research by carrying out a survey using a questionnaire. It will consist of questions on the current methods of boiling an egg. Those asked to participate in the questionnaire will be people who have experienced boiling an egg, and be those who regularly come across the problem. At the bottom of the questionnaire, I will leave a space in which the person filling in the questionnaire may sketch any of their own ideas concerning the aesthetics and function of the product.

Method

On the following slides, I will present the results from the questionnaire using pie charts, graphs and any other methods that I deem necessary. It is hoped that through the analysis of the results, detailed design specifications will be formed.

Questionnaire


Results of Market ResearchIntroductionOn this page I have presented the results of my market research. For each question, I have tried to identify any emerging trends. To show my results, I have chosen to use pie charts and graphs as they provide easy means of presenting data. From this, I could then develop design specifications.

Pie chart to show whether or not the product should be aesthetically

pleasing

YesNo

Stainless steel

Plastic

Other

Pie Chart to show what type of material the product should be made from.

AnalysisThe majority of people chose stainless steel as the material that they believe would be best to manufacture the product from. I believe that this material was chosen because it is a hard and durable material, resistant to heat and is good aesthetically.

AnalysisThe majority of people thought that the product should be aesthetically pleasing, as they believe that the product must look good and function well. Also, kitchens now tend to be fashionable , and therefore must require kitchen utensils to complement their environment.

AnalysisThe majority of people also said that when they boil an egg, they usually use a saucepan with a diameter of about 6-7 inches. This is because they would rarely need a saucepan to fit more than around 5 eggs within it.

Analysis

Most of the people that took my questionnaire also said that they usually have boiled eggs about once a week.

Conclusions

I have now identified three more design specifications.

The product must be:• able to withstand regular use • manufactured from stainless

steel • designed to fit into a saucepan

with a diameter of around 6-7 inches

• aesthetically pleasing

Once a week

Every two weeks

More than once a month

Pie chart to show the amount of times people boil an egg

6 inches 7 inches 8 inches0%

10%20%30%40%50%60%70%

Approximate diameter of saucepans


Results of Market Research - Sketches

Introduction

On this page I have presented the design ideas people who answered my questionnaire gave me.

Conclusions

The eggs would be placed in a vertical rack.

Figure 1

Figure 1 shows a basket like product, with holes in that would simply aid the user place and remove about 4 eggs into and out of a saucepan.

Figure 2

This design is certainly the more complex of the two. This first of all is because it would have a rack that rests on top of the saucepan whilst supporting about three eggs.

Conclusions

Now that I have a good idea about what people would want my product to look like, I can now start to think of things that I could include in my designs. There is not that much from either of these two design ideas that I would wish to incorporate with my final design. However, I will be considering some of the aspects of the design idea shown in figure 2. For example, I may consider having two parallel strips which would rest on the saucepan.


Market Research – Competing ProductsIntroduction

On this slide, I have presented my analysis of competing products already on the market. Analysing existing products is an important exercise as it will help me form design specifications that may help focus my design ideas. Also it may allow me to identify design faults with products so that I can design a new improved product. Finally, it will also provide me with good design ideas and design elements that I may try to incorporate in my design.

Conclusions

Figure 2

Figure 2 shows a product that enables the consumer to boil an egg without having to use a saucepan, which can be helpful in many ways. First of all, it is helpful as usually, when one boils an egg, waste is left on the inside of the saucepan, which can be hard to remove. So by using this product, the consumer will not come across this problem.Also, depending on the size of the saucepan, there is a limit to the amount of eggs that you can place in the saucepan, however this product allows a maximum of 7 eggs into it at once. This is useful as the consumer may boil quite a few eggs at one time. However, this product could be very inefficient, as if the consumer only needs to boil 1 egg, then the product will still boil as if it is boiling 7 eggs, which would waste a lot of energy. This product is also not very compact, and would therefore take up a lot of space when not in use.

Figure 1

Figure 1 shows a very small and compact product, which is very useful, as it provides the consumer with easy means of storage when the product is not in use. However this means it does not hold very many eggs at a time, and can actually only hold a maximum of 3 eggs at any one time, which would be very impractical if the consumer needed to boil more than three eggs at once.

Figure 3

Figure 3 shows a sieve that would probably be found in any kitchen. This product is very useful to have as it can be used to undergo many different functions. One of which is that it can be used to boil eggs. It could hold about 3-4 eggs, which again is not always large enough if the consumer needs to boil eggs for a host of people. It is also not a very compact product, as its long handle would take up quite a lot of precious space in one’s cupboard. Despite this, it does have quite a unique look and is quite aesthetically pleasing.

I have now completed my market research, and I will now be able to move on to my product analysis. From this slide, I have come up with a number of different design specifications.

The product must be:

• able to allow water to flow feely within it

• able to hold at least three eggs

• small enough to fit into a regular sized saucepan


http://upload.wikimedia.org/wikipedia/commons/0/00/Sieve.jpg

Product AnalysisIntroduction

On this slide, I have presented the product analysis of a colander. Product Analysis is vital for all designers because it helps you practise thinking about design and it helps develop your understanding of manufacturing methods. As well as this, it helps develops one’s use of different materials. It also gives you ideas for use in your own designs and encourages you to evaluate examples of good design and manufacture. Finally, it allows you to make better judgements about the products and services we buy and how they are marketed.

ConclusionsNext, I will move on to the analysis of the product, starting with the materials that the product is made from and how it was made.

Figure 1

Focus Area Question

Materials What materials were used and why?

Manufacture How has the product been manufactured and why has it been made that way?

Performance How well does the product perform?

Ergonomics How easy is it to use?

Aesthetics What are the aesthetic qualities of the product, looking at colour, texture and shape

Figure 1 shows the product I have chosen to study. I chose this product as it is one kind of product that can be used to help someone boil an egg. It is made out of stainless steel, which is very heat resistant and aesthetically complements the kitchen environment.

The table above will be very useful for me as I progress in the product analysis stage of my project. It will be very helpful for me as it offers a wide range of different focus areas of the colander, which I can cover and look back to.


Conclusions

Product Analysis – Materials and ManufactureIntroduction

On this slide I have presented the analysis of the materials the product has been made from. I will also look into why the materials were used and whether or not they are appropriate. I will also analyse the manufacturing process of the product and assess whether it is a suitable way to make my product.

ConclusionsOn the next few slides I will be

continuing with the product analysis section and will be looking at the aesthetics of the colander.

From this slide, I have been able to come up with a major specification:

1) I would benefit from making the product out of stainless steel.

Analysis of Figures 1, 2 and 3The material used to make this product was stainless steel. This material was used to make he product as first of all, it is very malleable, and can be formed into a very complex shape without fracturing. As well as this, it is a very tough material, and would be able to stay in one piece if it were to be dropped, or if a large amount of pressure was exerted on it. Another thing about stainless steel is that it doesn’t corrode, so acidic substances would not effect it in any way if they were to make contact with the product.`

Manufacture of the productTo manufacture this product, two manufacturing process’ could have been used – the first one would have been presswork. Presswork would have been used so that there were holes made for water to be able to flow into the product. A pre-cut blank of stainless steel would have been profile cut, punched and crack raised in one power press operation. The next manufacturing process could have been CNC spinning, to form the actual shape of the product. The pre-cut blank would have been spun around a mould, in order for it to form into the final shape desired by the manufacturers.

Figure 1 Figure 2

Two different stages of the CNC spinning process

Figure 3

Three different stages of the presswork manufacturing process


Product Analysis - Aesthetics

IntroductionOn this slide have analysed the aesthetic qualities of my colander. Aesthetics are ultimately to do with how easy a product is on the human eye, and whether or not the product looks good. Essentials of aesthetics may include; color, shape, texture, form or other features of the product. Also on this slide I have analysed the finish of the product.

Shape and form

The shape of the colander is bowl-shaped. This design could be quite practical for boiling things with as the product has many small holes in it (with a diameter of approximately 4mm). However, it is quite difficult to clean the colander in some places. The edges of the product are curved so that the consumer is in no danger of being cut by the product. From an aesthetics point of view it is quite a good-looking product.. The handles of the colander are curved and rounded, however are not comfortable to use as the edge of the colander digs into ones hands when being held. Also the circular base provides stability when placed on a flat surface.

Texture

The texture of the colander is smooth, however, the small holes on the colander slightly affect the feel of it. However it is quite tricky to hold the colander by its handles, as if one has sweaty or wet hands, then they may find it difficult to grasp a firm grip of it. A benefit of its smooth texture, is that it is

Size

The size of this colander means that it is slightly awkward to store when not in use. This means that the consumer of the product must have an adequate amount of storage space available to them, which in some cases would be a down side of the product.

Colour

It has a shiny, reflective, silver colour, and has a fairly modern look about it

Conclusions

From my product analysis, I have come up with a number of design specifications:

1. The egg holder must have small holes – to allow boiling water to enter within holder.

2. There must be no sharp edges on the egg holder, so that the user of the product does not manage to cut or harm themselves.

3. The egg holder must be aesthetically pleasing in shape, colour and texture.

4. The product must be well finished, and be durable.

Figure 1 Figure2


Product Analysis Ergonomics and Function

Introduction

On this slide I have presented the analysis of function and ergonomics of the colander. I will try to discover any problems that one may come across when using the product. I will also try to discover how the product fits in with the environment that it will be in. I will therefore investigate why the colander has been shaped in the way it has.

ConclusionsFrom my product analysis, I have come up with a number of specifications.The product must: 1) Not have many, if any corners. 2) Be easy to clean after use. 3) Be easy to hold, (with one hand if necessary).4) Allow water to flow through it with ease.

Function

The function of the colander is quite easy to understand. It works by providing a large bowl-shaped structure in which the user may place whatever they wish inside. The small holes within the colander allow for water to flow in and out of the colander with little delay. The colander has two handles, however, when the colander is being used, it is not possible to use them both if the user wishes to hold something within the colander (Figure 4). The flat base attached to the bottom of the colander allows for it to be placed on a flat surface without tipping from side to side.

Ergonomics

The colander has been specifically shaped and modified so that once the user doesn’t need water within it, the water drains to the bottom of the colander and through the small circular holes. However, in many cases, the water does not drain through the holes at the base of the colander, as shown in Figure 2. It has also been made in the shape of a bowl so that it is easy to clean after use, as if the product had corners, then it would be difficult to access them (Figure 1). Nevertheless, it does have some corners and they are very difficult to get in to with a standard washing-up brush (Figure 5). The handles on both sides of the colander are relatively difficult get a good, firm grip of, and from my experience of using it, they are not comfortable to hold (Figure 3).

Figure 3 Figure 4 Figure 5

Figure 1 Figure 2


Mood Board

Introduction

On this slide I have presented the Mood Board for my project. A Mood Board is a selection of images of products that relate to the problem in some way. These products may give oneself inspiration in the design of their product.

Conclusions

I based my decision when choosing which images to use on quality, shape and relativity to my product. I like the idea of kitchen utensils being made out of stainless steel, as I believe that it gives the product a more aesthetically pleasing look, and they always are made to a high quality finish.


http://images.google.co.uk/imgres?imgurl=http://www.foodutensils.com.au/images/485N70338_Egg%20Cup_SS.jpg&imgrefurl=http://www.foodutensils.com.au/serving-table-crockery-c-40_212.html&usg=__EvENFs8Vuktu_A3SHk3HKxz58jQ=&h=393&w=530&sz=39&hl=en&start=10&tbnid=FYdE9uWK_UVIvM:&tbnh=98&tbnw=132&prev=/images?q=egg+cup&gbv=2&hl=en

http://images.google.co.uk/imgres?imgurl=http://aka.weightwatchers.com.au/images/3081/dynamic/articles/2008/03/Tefal_n_lg.jpg&imgrefurl=http://www.weightwatchers.com.au/util/art/index_art.aspx?tabnum=1&art_id=39441&usg=__p_bwX9cGnXOqrYbKw1pANJ7Gzmk=&h=216&w=216&sz=6&hl=en&start=7&tbnid=0cHddzqMaqddnM:&tbnh=107&tbnw=107&prev=/images?q=tefal+logo&gbv=2&hl=en

http://images.google.co.uk/imgres?imgurl=http://www.onlinekitchenware.co.uk/prodimages/prod-574.jpg&imgrefurl=http://www.onlinekitchenware.co.uk/Anolon-Advanced-Nylon-Head-Suregrip-Utensil---Slotted-Turner&usg=__ZtnmbT1ppnrCq1DBz448ffQ9OaM=&h=400&w=392&sz=9&hl=en&start=8&tbnid=_-MkWsh7UcdDBM:&tbnh=124&tbnw=122&prev=/images?q=heat+proof+utensil&gbv=2&hl=en&sa=X

http://images.google.co.uk/imgres?imgurl=http://z.about.com/d/swimming/1/0/5/A/pool_outside_night_79359512.jpg&imgrefurl=http://swimming.about.com/od/olympicswimming/ig/Swimming-Action-Image-Gallery/Beijing-Water-Cube-Outside.htm&usg=__cqL6ODSmDDoq_rmcvCTZGUgAFf8=&h=333&w=500&sz=99&hl=en&start=1&tbnid=QRx1dMrsAEX_wM:&tbnh=87&tbnw=130&prev=/images?q=beijing+swimming+building&gbv=2&hl=en

Initial Ideas – Buzz PageIntroduction

On this page, I have presented my Buzz page of initial ideas. To produce this page, I worked with my class-mates, explained the design brief to them then asked them to draw an initial idea of their own, in order to solve my design problem. This process is an industrial practice. Figure 1

Conclusion

This page of designs enabled me to get a wider perspective on possible design solution for my product. This buzz page is the basis of ideas for the final product. More detailed designs will be drawn, which will be accompanied by CAD drawings. From the ideas that some of my classmates proposed, I may choose to develop the ideas shown in figures 3,5 and 8 further. However, I will not be developing any of the other ideas proposed any further.


Figure 5 Figure 6 Figure 7Figure 8

Figure 9


Introduction

On this slide, I have presented my first initial idea. My first initial idea is a shape similar to that of an up-side-down umbrella, with five slots each capable of holding one egg each. It has a rubber handle, in order to prevent the user getting burnt, whilst the main body and shaft is made out of stainless steel. The product is designed to fit into a regular sized saucepan.

Initial Idea 1

Figure 1

AnalysisPros:1. It is a unique design2. It would hold a sufficient amount of

eggs for a family of five.3. It has a modern, and slick look.4. Due to it having a unique method

of gripping it, when it is lifted, the centre of gravity of the product is in the centre of it, so it doesn’t tip to the sides.

Cons:5. The eggs may get pushed out of

the slots by bubbles when they are being boiled, and therefore defeat the object of the product.

6. The eggs may not boil quickly, as the product may insulate the bottom of them.

7. Water may not drain through the slots for the eggs.


Initial Idea 1 (continued)

Introduction

On this slide I have continued to present my first initial idea. As you can see, I have presented it using CAD, in order to give a better representation of what it would look like if it were to be manufactured from stainless steel.

Figure 4Figure 2

Figure 3

ConclusionsI have decided that I will be modelling this initial idea, as I believe it has some very unique characteristics, and is very aesthetically pleasing. I will model it using CAD, and then using the CNC miller in order to machine it.

There are five slots, which would all be capable of holding one egg each.

The handle of the product would be made out of rubber, to prevent the user from burning themselves.

The diameter of the product at its widest point would be small enough to fit into a saucepan with a diameter of 170mm or more.


Initial Idea 2

IntroductionOn this slide, I have presented my second initial idea. My second initial idea is a shape similar to that of my first initial idea, however, there were some features which I decided to change. A different shaped handle has been used to try and help improve grip and control of the product. I also changed the way in which the product holds the eggs, by getting rid of the individual slots for the eggs.

Figure 1

Analysis

Pros:1. It is a unique design2. It would hold a sufficient amount

of eggs for a family of five.3. It has a modern, and slick look.4. It is capable of holding at least 3

eggs, which satisfies one of my major specifications previously mentioned.

Cons:5. If the user is only boiling one or

two eggs, then the product would not balance well.

6. The eggs may not boil at the same heat throughout them, as the product may insulate the bottom of them.

7. Water may not drain through the slots for the eggs.


Initial Idea 2 (continued)IntroductionOn this slide I have continued presenting my second initial idea. However, as you can see, I have done so using CAD.

Figure 1

Figure 2

Figure 3

ConclusionsI have decided that I will be modelling this initial idea. I will be doing so as I would like to test and compare the different features of my first and my second initial ideas due to them being quite similar in terms of size and shape. I will model it using CAD, and then using the CNC miller in order to machine it.

In figure 1, you can see the height of the shaft relative to the base of the model. You can also see from the orange part of the model that the handle of the product would be made out of rubber.

Figure 2 shows the plan view of my second initial idea. From this view, you can see that their would be sufficient space for at least 5 eggs. You can also see that the shaft of the model is based right in the centre of the model, in order to give the user as much balance possible when they hold the product.

Figure 3 shows the 3D view of my second initial idea. The arrow below Figure 3 demonstrates the diameter of my second model, which is 140mm wide. This means that it would be able to fit into any saucepan with a diameter larger than 140mm.


Initial Idea 3

Introduction

On this slide, I have presented my fourth initial idea. My fourth initial idea is an egg holder with a rack which would hold a maximum of four eggs, and a long z-shaped handle which would provide the user with sufficient leverage to lift the holder. When placed on a flat surface, the egg holder would be able to balance well without the aid of any support. The slots which would be used to hold the eggs would have very smooth edges, so that the eggs inside would be in no danger of cracking. This idea also has a rubber grip attached near the handle, which would allow the product to stay secure when in the saucepan.Analysis

Pros:1. The egg holder would be able

to balance on a flat surface without any support

2. The egg holder would be able to firmly attach itself to the rim of a wide range of sizes

3. It would securely hold four eggs

Cons:4. It would not be able to fit

comfortably in a saucepan with a diameter of less than 190mm.

Figure 1



Introduction

On this slide, I have presented my third initial idea. To do so, I used CAD, as shown below in figures 1,2,3 and 4.


Conclusions

I have decided that I will not be modeling this initial idea. This is for several reasons

Figure 4

Figure 1 shows my third initial idea from a front on perspective. As you can see, it has 4 slots, each capable of holding one egg each.

In figure 2, you can see that there would be a rubber grip which would be capable of holding the product firmly onto a saucepan.

The user of the product would be able to comfortably hold the product, due to the handle being made out of rubber. Also, the shape of the handle would suit the user well, as the user would be able to easily grip it using their thumb, index and middle fingers.


Initial Idea 4

Introduction

On this slide, I have presented my fourth initial idea. My fourth initial idea is similar to that of a basket, except there are small holes on the sides of it (each 10mm wide) which allow water to easily flow within it. When placed on a flat surface, the egg holder would be able to balance well without the aid of any support. The main frame of the product would have a very slick interior and exterior, and very smooth edges so that the eggs inside would be in no danger of being damaged prematurely. Due to the rest of the product being made out of stainless steel, the handle would be made out of rubber, in order to prevent the user from being burnt.

Figure 1

AnalysisPros:1. The egg holder would be able


2. Once within a saucepan, there would be no issues, concerning balancing the product within the saucepan.

Cons:3. It would not be able to fit

easily in a saucepan with a diameter of less than 175mm.

4. It is moderately aesthetically pleasing.



IntroductionOn this slide, I have presented my fourth initial idea. To do so, I used CAD, as shown below in figures 1,2,3 and 4.Figure 1 Figure 2 Figure 3

ConclusionsAlthough my fourth initial idea has many useful and interesting characteristics, I have

decided that I willnot model this design.

Figure 4

Figure 1 shows my fourth initial idea from a 3-D perspective. As you can see, it has many small holes on the sides of the basket. These have been placed where they are, so that water can easily flow into the product when it is placed in a saucepan containing water.

Again figure 2 shows my fourth initial idea, however it does so from a side-on view. It gives a very clear idea of how large the handle is, compared to the basket in which eggs would be placed.

The user of the product would be able to comfortably hold the product, due to the handle being made out of rubber. I designed the handle specifically so that the user of the product would be able to easily remove it from a saucepan, as it provides itself with a lot of leverage.Sam Naylor | GCSE Resistant Materials | Organic

25

Research - Size

Introduction

On this slide, I have presented the size research concerning anything which may influence the size of my project. I will look into the size of eggs, saucepans and the size different types of handles, due to it being a hand held product. It is important that I can out some research on the size of my product, as it has a big effect on how my product will perform when used.Method

I took the measurements using a ruler, a vernier, a tape measurer when attempting to acquire the most accurate results possible.

Figure 3 Figure 4

Conclusion

From carrying out this research, I am now able to come up with some more specifications:1. The handle must be at least 13mm wide. 2. The handle must be no wider than 42mm.

Figure 2Figure 1

Figures 1 and 2 are of myself measuring the dimensions of a handle on a cupboard, in my house. I looked at measuring how wide and how thick the handle was, at the points where the user is meant to grip the handle. It was 42mm wide, and had a thickness of 24mm. I do not believe that the handle which I will use for my product would need to be any wider than that of the handle on this cupboard, as I believe that the majority of people would be able to grip this handle with ease.

Figure 3 shows an image of myself using a ladle. I chose to look at the size of this ladle as I thought that it would be useful to know how small and thin some kitchen utensils are. Although it is a different type of handle to the one I would be looking to use, I think it is useful to look at how it can be held according to its size.

Figure 4 however shows myself measuring the width of the handle. I discovered that it has a width of 13mm, and it has a thickness of 6mm. I think that this is the bare minimum amount of material which could be used for this products particular function, because if it were to be any smaller, it would be too awkward for the user to grip.


Research - Size

Introduction

On this slide, I have continued to research size in order to help me with my project. I will research the size of chicken eggs and saucepans, as these are both significant features relating to my project.

To discover what the average size of chicken eggs was, I decided to take 5 different measurement from 3 different eggs. I chose these eggs, by determining which 3 eggs, within a box of 12 I deemed to be the smallest, the largest, and the most average size in length and width.

Smallest Medium Largest

Width 1 2.6cm 2.5cm 2.2cm




Length 5cm 5.7cm 5.9cm

The table below shows my results, after carrying out some measurements concerning the different sizes of eggs.

Size of Eggs

Width 1 Width 2 Width 3 Width 4 Length

I also decided to take dimensions of how much space 2, 4 and 6 eggs would all occupy if they were all placed within the closest possible proximity of each other. I discovered that the maximum amount of eggs that one could place on the base of a saucepan with a diameter of 18.5cm was 8.2 Eggs 4 Eggs 6 Eggs

Size of SaucepansI also decided to research the size of saucepans. I took measurements of the height of the saucepan, and also the width. I have demonstrated doing so, within figures 1 and 2. After carrying out some research, I discovered that the diameter of the saucepan was 18.5cm and that the height was 10cm.Figure 1 Figure 2

ConclusionFrom carrying out this research, I am now able to come up with some more specifications:1. If I decide to place slots in the products, designed to hold an egg each,

they must be at least 45mm wide.2. The product must be no wider than 18.5cm and at least 16cm tall.


Modelling - Diary of Manufacture

ConclusionsNext I will continue with the diary of manufacture for my two models and evaluate each model against my major specifications.


Figure 5Figure 4 Figure 6

Figure 1 shows the block of modelling plaster that I started off with.

Figure 2 is an image of me when I am measuring the correct thickness that my modelling plaster will need to be, for when it gets CNC machined.

Figure 3 shows the planer thicknesser that was used in order to cut my piece of modelling plaster down to the correct thickness.

Figure 4 shows me cutting my piece of modelling plaster to the correct length, using the band saw.

In order to machine the shaft and handle of my first model, I needed to export them on to an IGES file. Once I had exported my CAD onto an IGES file, I was then ready to CNC mill the handle and shaft of my first model. The result of this is shown above in Figure 5

Once I had machined both halves of my handle and shaft, I glued them together, and they were then ready to put together with the base of my first model. Superglue, a contact adhesive was used to ensure a secure bond.

IntroductionOn this slide, I have presented the diary of manufacture for the production of the models of my first and second initial ideas. Modelling is the act of representing something, however it is usually done on a smaller scale. Modelling is important for many different reasons. It is important as by doing so, one has the opportunity to test for:• Function• Durability/strength• Weaknesses• Suitable materials• Proportion• AestheticsI am also able take the model to a third party, so that they could be given an opinion on the model from another perspective.Finally, it helps when suggesting any other possible improvements that could be made to the product.I used modelling Plaster to model my first initial idea as it is:1.Very easily cut2.Relatively strong3.Its density is reasonably similar to the materials that I have already thought about using for the manufacture of my final product.


Modelling - Diary of Manufacture (continued)

Introduction

On this slide, I have continued to present my diary of manufacture for my two models.

ConclusionsThis has helped me to learn about how I will build my project. I will use the CNC miller to machine my final product as I now have sufficient experience using it.

Figure 1 shows the base of my first model which I exported into the MDX3P software. As you can see, I machined the base of my first model without the handle and shaft.

Figure 2 also shows the base of my first model, however I have presented it from a side elevation. To cut the base, I used the CNC miller. However, to round the edges at the bottom, I used the table router, as it gave me a reasonably accurate result, and it provided a very easy means of dong so.

Figure 1 Figure 2 Figure 3 Figure 4

Figure 6Figure 5 Figure 7

Figure 3 shows myself sanding the base of my first model, using P120 sandpaper, then P240 sandpaper. These were the first few steps taken in order to give my model a quality finish.

Figure 4 shows myself sanding the handle and shaft of my first model, to give a quality finish.

Figure 5 shows my final outcome after constructing my first model. I have presented it in context, demonstrating its purpose in the process.

Figure 6 shows the base of my second model which I presented, in the MDX3P software. As you can see, I machined the base of my first model without the handle and shaft.

Figure 7 shows the handle and shaft of my second model split into 4 parts on an IGES file. In order to machine these different parts, I had to place them onto an IGES file. Once I had machined the parts, I glued them together.

Figure 8

Figure 8 shows the base of my first model in MDX3P format. The cut the top of my base, I used the CNC miller, however in order to cut the bottom side of the base, I used the router.


Modelling - Evaluation

IntroductionOn this slide I have presented my Evaluation of my models. Having tested the models, I am now ready to look at any areas for improvement, or any especially weak areas of the models. Using the search engine ‘Google’, I discovered that the definition of Evaluation is: The act of gaining an understanding or fixing the value or worth of something. I will evaluate my models using many different methods.I will evaluate them by :1. Test against my major specifications2. Use a 3rd party3. Discovering the positive and negative points of my models, so that I have a good understanding of what I should and shouldn’t change.

ConclusionsAs both my models are quite similar, they share positive and negative points. Next, I will look to develop the design on the development of function.


By developing this model, I was able to discover all of the positive and negative points to do with my model, using a hands on approach.Pros:1. The model can securely hold the five medium-sized eggs that it is

required to hold, as said in my major specifications2. The handle functions well, and the user can easily grip the product.Cons:3. I discovered that when I placed the model in a saucepan full of

water, it was not possible for the water to drain through the slots in the model for the eggs once the eggs were boiled, and the model was removed from the saucepan (as demonstrated in figure 4).

Figure 5 Figure 6 Figure 7 Figure 8

By making a second model, I was able to give myself an accurate insight as to what positive and negative points there were to take from this design idea.

Pros: 1. The model can securely hold the five medium sized eggs 2. The user can grip the product relatively easily. Cons: 1. When I attempted to hold the model in mid-air, the model tipped

slightly to the side, due to the handle being vaguely off of the centre of gravity.

2. When I placed only 3 eggs within the model, they were not held securely within it, and this resulted in one of the eggs cracking prematurely.

Figure 4Water deposited within the slots designated for the eggs, after being taken out of a saucepan with water within it.


Development - Function

Introduction

On this slide, I have presented the first stage of development which I carried out on my 1st initial idea. The function of any product is a very important factor which must always be considered, as it determines how efficiently the product does what it is designed to do. Once I had modelled my 1st initial idea, I was able to put it in to practice and discover any problems concerning the function of the design.

Problems Identified

• There was no drainage system within the egg slots.

• Eggs could not be easily removed from their slots.

• The model could not be easily removed from a saucepan.

Solutions

• Incorporate small holes within the slots for the eggs.

Previous Design

CAD Accompaniment of proposed design

Proposed Design

Conclusion

On the next slide, I will continue to look at developing the function of my 1st initial idea, whilst I also start to look at the ergonomics of my 1st initial idea.

The holes which have been incorporated into the egg slots allow for drainage of water when the product is removed from the saucepan. In the meantime they would also reduce the amount of water resistance when the product is placed in and out of the saucepan, as the water would be able to flow through the saucepan slightly.


Development – Function (continued)Introduction

On this slide, I have continued to present the function development of my design.

I am looking at the possibility of having a slightly different design, in that there would not be individual slots for the eggs to sit in.

Problems Identified

• The model which I manufactured was very heavy

• There was a lot of waste material.

• There was no drainage system within the egg slots.

• The eggs were insulated slightly due to there being so much material around them.

Solutions

• Do not have individual slots for the eggs to sit within.

• Reduce as much waste material as possible without jeopardising the quality of the products function.

3-D View

Side elevation

Plan view (above)

Conclusion

On the next slide, I will continue to look at developing the function of my 1st initial idea, before I start to develop the ergonomics of my idea.

By having a cradle-shaped design, there are many benefits that come with it. First of all, there is obviously a large reduction in waste material, so there would be less of an environmental impact should the design by manufactured. This also makes the product lighter, and therefore easier to handle. Also, water can flow in and out of the product very quickly and efficiently. Another benefit although perhaps being more minor, is that more eggs could be place within the product than the previous design, as there is no fixed limit concerning how many eggs can be placed inside, due to there being no egg slots.Sam Naylor | GCSE Resistant Materials | Organic 32

1st Design Proposal

On this slide I have presented my First Design Proposal. I have made several improvements to my initial idea through modeling one of my initial ideas and developing its function. My major changes which I have made to my initial idea are presented on this slide. Figure 1 Figure 2 Figure 3

Figure 1 shows the trimetric view of my first proposal. The base of the product is a cradle-like shape, which allows for water to flow easily around the eggs. It would be capable of holding approximately 4 eggs.

Figure 2 demonstrates the plan view of my first proposal. The holes within the base of the product would 25mm wide, so there would be no issues concerning eggs falling through the base of the product. 25mm is plenty of space as far as allowing water to flow through the product is concerned. However, in the meantime it doesn’t allow eggs to fall through.

Figure 3 is the side-on view of my first proposal. While designing my first proposal, I tried to make sure that the handle of the product was long enough so that the user would not be in danger of burning themselves. The shaft of the handle would be placed right in the centre of the product, so that when the user holds the product in the air, it is relatively balanced.

AnalysisPros:1. The egg holder would be able to balance on a flat surface without any support2. Once within a saucepan, there would be no issues concerning balancing the product within

the saucepan.Cons:3. The edges on the product could easily crack eggs within the product4. The eggs would not be firmly held within the product, so they could crack when being

boiled.

ConclusionI will now move on to developing the function of my product.


Development – Function and ErgonomicsIntroduction

On this slide, I have continued to present the development of my 1st Initial Idea. However, as well as continuing to focus on the function of my 1st Initial Idea, I have also started to look into developing the ergonomics of my 1st Initial Idea. The ergonomics of any product are very important, as they determine how well the product functions, relative to the user and his/her environment.

Problems identified

• The handle could not be gripped with ease for people with small or weak hands, due to it being so wide.

• The eggs could easily crack when placed within my model for my first design proposal as there were a lot of sharp edges.

Solutions

• Re-incorporate slots for the eggs within the design, however reducing the amount of waste material as much as possible.

• The handle size would be reduced.

Sketch work

The removal of waste material will dramatically reduce the weight of the product, making it easier to handle.

All of the edges on the product would be rounded, making the product easier to clean after use.


Development – Ergonomics

Introduction

On this slide, I have continued to present the development of my 1st Initial Idea once more. I have looked more thoroughly into developing the ergonomics of the product, in order to give for a excellent quality outcome.

Problems identified

• The eggs could not be removed from their slots easily enough

• The water did not drain out of the product fast enough, therefore wasting time for the user.

Solutions

• Small finger grooves have been incorporated into the sides of the egg slots.

• Larger diameter holes have been included within the egg slots

Conclusion

On the next slide, I will be presenting the aesthetic development of my product, demonstrating all of the ideas that I came up with in the meantime that I believed would make the product more pleasing on the eye.

Figure 2

Figure 1

Figure 2 shows the sketches that I have done to show one of the ideas I had concerning how I could develop the ergonomics of the product further. I have decided that I will incorporate small finger grooves on the edges of the egg slots. This will ease the removal of the eggs from the product dramatically, whilst in the meantime reducing the amount of waste material on the product.

Sam Naylor | GCSE Resistant Materials | Organic

Figure 1 shows my proposed alteration of the diameter of the holes within the egg slots. The holes would be 14mm, rather than 5mm, which would allow for faster drainage.

35

Development - Aesthetics

Introduction

On this slide I am going to develop the aesthetic assets of the egg holder in an attempt to make it engaging to the consumer market. I will mainly be looking at the designs that will be featured on the egg holder.

Using my mood board which I created earlier in my project, I looked at designs from kitchen utensils and other products which relate to my project to influence any aesthetic developments to do with my project.

I decided to look first of all at the design and shape of the handle.


Figure 1 Figure 2 Figure 3 Figure 4 Figure 5

Figure 1 shows my original design idea for the handle of my product. I quite like this idea due to the simplicity that it possesses. I also believe that is very important for the handle to have a shape similar to that of an egg, as the user can then start to understand its purpose in a much clearer manner.

In figures 2 – 5, I attempted to design a more diverse handle, so I chose to alter the original handle that I came up with, however keeping its ‘egg’ shape in the meantime. Figure 2 shows a ‘banana’ shaped hole which goes through one side of the handle, which I believe makes the handle look modern and slick. Figure 3 shows a more simple design, which a ovular shaped hole going through the centre of the handle. However figure 4 is a slightly different idea, in that it is a concaved ring which goes through the lower half of the handle. And finally, figure 5 shows 5 small holes within the handle, which give for a ‘bubbly’ and more diverse look.

ConclusionBy sketching such a vast range of ideas for the handle of my product, I now have a very clear idea of what I would like it to look like. However I will have to take into account the ergonomic impact that each of the designs possess, which may prevent me from developing some of the ideas further.

On the next slide I will continue to present the aesthetic development for my product.

36

Development - Aesthetics

Introduction

On this slide I am going to develop the aesthetic assets of the egg holder in an attempt to make it engaging to the consumer market. I will mainly be looking at colour and designs that will be featured on the egg holder.

Using my mood board which I created earlier in my project, I looked at designs from kitchen utensils and other products which relate to my project to influence any aesthetic developments to do with my project.


Figure 1 Figure 2

Figure 1 shows the first idea that I came up with concerning the aesthetic development of the base. As you can see, I have just added a small 2mm deep curved ring around the base of the shaft. I quite like this simple design, as although it is very straightforward design, I feel that it gives for a much more distinctive and unique design than when there is no ring.

In figure two, you can see that I have come up with a slightly different design than the one shown in figure 1. This design would simply just have three curved holes which go right through the base. Not only would this design have aesthetic benefits, but also functional benefits. These three holes would allow for air to easily pass from the air pocket underneath the base and through the base. What I like as far as the aesthetics are concerned about this design is that the three holes do not stand out too much in the design, however they do provide the product with a slightly more complex visual image.

Conclusion

Next I will present my 2nd design proposal, pointing out any major changes that I have made in the meantime.

Problems identified:• The centre of the base looks

quite plain.

Solutions:• Place a small ring around

the base of the handle.• Cut three semi-circular holes

around the base of the handle.

37

2nd Design Proposal

Introduction

On this slide I have presented my second design proposal. I have made several improvements to my initial idea through developing some of the function, ergonomics and the aesthetics and later modeling my initial idea. My major changes which I have made to my initial idea are presented on this slide. Figure 1 Figure 3 Figure 4

Figure 2 Figure 1 shows the trimetric view of my second proposal. The base of the product has six circular slots in which eggs can be placed. There has been a lot of waste material removed from the underside of the base, compared to the idea that I came up with when coming up with my initial ideas. Figure 2 shows a close up view of one of the egg slots. As you can see, I have incorporated a small hole within the slot in order to allow for drainage to occur.

Figure 3 shows the plan view of my 2nd design proposal. The shaft of the product is based in the very centre of the base, in order to allow for balance and stability during use. Figure 4 shows a side-on view of my 2nd design proposal. This image demonstrates the amount of material that has been removed from the under-side of the base. It also gives an idea of how far the users hand will be away from the saucepan when they grip the handle of the product.

Analysis

Pros:1. The egg holder would be able


2. The product would be capable of draining water out of it when removed from the saucepan.

3. The eggs would be firmly held within the slots.

Cons:4. It would not be easy to remove

the eggs from their slots.5. I don’t believe the product is as

aesthetically pleasing as it could be, as it has a very ‘cubic’ shape.

6. The shaft on the product is possibly slightly too long, which could make it hard for the user to manoeuvre the product.

Conclusion

Next, I will start to look at researching the materials, finishes and testing that I will use during the manufacture of my final product.


Research – Materials and Finishes


IntroductionOn this slide I have researched different materials, finishes and testing methods that may be appropriate for my product. It is imperative that the correct materials and finishes are chosen for the manufacture of my product if I am to ensure that it is manufactured to the highest possible quality.

MaterialsThe material that I will be using to manufacture my product will be modelling plaster, primarily due to it being durable and very easy to manufacture out of. However, if I chose to mass produce my product, I would manufacture it out of stainless steel or aluminium, as they are hard, durable and more dense than water.

To produce my final product I will use modeling plaster. I have used it before during modeling, and I believe that it is the most suitable material for me to use. Modeling plaster is also very useful as CNC millers can easily machine through it. This means that the manufacture of my product will be very precise, as CNC millers are very accurate and are capable of cutting very complicated and thin pieces, which would otherwise be very difficult to manufacture.

FinishesThe finishes that I will use on my product are vital towards ensuring that my product is an aesthetically sound product. When applying the finishes on any product, unless it is an industrial process, then a hands on approach is requiredFigure

1Figure 2

Figure 3 Figure 4

Figure 3 shows the can of spray paint which I will use to give my product a slick finish.

Once the material is cut, I will use 320 grade sandpaper to get rid of any imperfections, then I will move on to using 1200 grade sandpaper which will provide me with a very smooth product, ready to be coated with finishes.

Existing productsI will also focus on existing products that were manufactured using the same materials and finishes to provide myself with a good instinct regarding what my end product will look like.

Figure 5

Figure 4 shows a product that was manufactured from modelling plaster and finished with coats of spray paint.Figure 5 shows the colander that I analysed earlier in my project. This would be mass produced from stainless steel, which is what I would like my product to be manufactured from if it were to be mass produced.

Specifications• My product will be manufactured from modelling plaster at school and

finished with two coats of spray paint.• If it were to be mass produced it would be made from stainless steel by die

casting.

ConclusionI will manufacture my product out of modelling plaster in the workshop and then finish it with two coats spray paint. Next I will move on to researching construction techniques. 39

Research – Construction Techniques and Testing


IntroductionOn this slide I have researched the construction techniques that are most suitable for the production of my product. I have looked into how it would be constructed as a model, as well as if it were to be mass produced.CNC MillingI will use a CNC miller to manufacture my product, as it is fast and accurate. By exporting CAD work as a stereo lithography file, the CNC miller can import the file and cut the desired shape very precisely.Figure 1

Figure 2

There are some disadvantages however of using the CNC Miller in order to manufacture my product. For example, the 6mm cutter can cut only 50mm into the material, but fortunately, this should not pose any issues towards the manufacture of my product. Also, the CNC Miller cannot cut perfectly smooth curved faces, which is likely to cause some slight issues when it comes to sanding down imperfections on my product.Once I have manufactured all of my parts, I will bond them together using superglue. I will then fill in any dents, gaps or holes with Isopon P38 filler.

Figure 3

Figure 3 shows a model which I produced earlier on in my project. I manufactured it out of modelling plaster using a CNC Miller, which is exactly the same as how I am going to product my final design. By producing this model I have provided myself with some experience using certain machines, which should help prevent me from making any mistakes during manufacture.

Die CastingDie casting is the manufacturing process that I would use in order to make my product, should I ever decide to mass produce my product. I would use this manufacturing process as it would allow for my product to be produced using stainless steel.

Figure 4 – Base

Figure 5 – Handle halves nested

I will manufacture the handle as two separate parts, and I will also manufacture one spare half, as they will be very delicate and easily damaged.

I will manufacture the base on its own.

ConclusionI will now move on to present my list of detailed specifications.

Figure 6

40

Detailed specification

Introduction

On this page I have presented all the design specifications that my final product must satisfy. I have put them under headings from Pugh's plates to split them up, and will use this criteria to evaluate the success of my final product.

Pugh’s Plates

Function

• The product must be able to hold at least 4 eggs securely.

• It must make the removal of eggs from saucepans very swift and easy.

• The product must be strong and durable, so it does not break easily when placed into a saucepan.

• It must also drain water through it when placed in and removed from the saucepan.

Ergonomics

• The product must be easily gripped.

• It must be easy for the user to remove the eggs from the holder.

• The product must not have any sharp edges which could harm the user or the eggs placed within it.

• It must be compact, so that it can easily be stored in kitchen cupboards.

Aesthetics

• The egg holder should be a contemporary design which would be able to please the eye of a wide range of consumers.

• It must have an organic look.

Durability

• The egg holder must be strong, and in the meantime flexible, so that it does not break when lifted at an angle

• It must be durable so it resists any knocks which it may endure during use.

• It must not get damaged at high temperatures (in water).

• It must not get scratched easily, as this would rapidly decrease its aesthetic quality.

• The material used must be suitable for current day lifestyles and the modern market.

Size

• The product must be able to fit into a normal sized saucepan.

• The product must be able to be stored in kitchen cupboards with ease.

• The product must have a diameter no wider than 185mm and must be at least 160mm tall.

Anthropometrics• The finger grooves on the edges of the egg

slots must fit a finger of thumb with a normal width.

Manufacture• I will manufacture my final product using the

CNC miller. To give a smooth and rounded finish I will sand the product down using sand paper, then I will then finish the product with spray paints.

Materials• For my models I will use Styrofoam, as it is a

light, easy to shape and quick material to use when manufacturing prototypes.

• For my final product I will use modeling plaster , as it is strong, durable and quite flexible.

• For mass production I would use stainless steel, as it is a strong, durable and aesthetically pleasing material. It would also not float, which was a fundamental feature to consider when choosing the most suitable material to use.

ConclusionUsing the information I have collected I can now evaluate my product. However on the next few slides, I will present my final proposal.


Final proposal

The egg holder has been purposely designed, to make it considerably easier to place and remove eggs from a saucepan. The unique shape makes it an attractive product to look at.

Organic


OrganicFinal proposal

The holes in the egg slots allow for water to drain through the product when removed from water. The shape of the handle is similar to that of an egg, which aids the product fit in to its designated environment. The small grooves on the edges of the egg slots allow for the user to easily remove the eggs from their slots.Sam Naylor | GCSE Resistant Materials | Organic

43

OrganicFinal proposal

Waste material on the underside of the product has been removed.

The small ring in the centre of the base of the product provides a diverse aspect to the product.

Sam Naylor | GCSE Resistant Materials | Organic 44

Engineering DrawingIntroductionOn this slide I have presented my engineering drawings for my product. An engineering drawing defines the necessities for a product. This will include the dimensions of the product presented from different views. Also included in an engineering drawing is the material which is to be used, any finishes and finally the colour that is desired. Engineering drawings are used in order to allow for the product to be reproduced accurately, therefore it is an essential process which must be undertaken in industry.

This will help me during manufacture, to machine, assemble and plan the final working product and to make sure all material is cut down to the right size when it is being prepared.

Material- I will manufacture my parts out of modeling plaster, using the CNC machine to get a accurate finish. I will also use filler and sand paper to give for a smooth end product. If I were to mass produce this product it would be made of stainless steel.Finish- I will finish the product with spray paints to give a faultless, modern look. Colour- The egg holder will be a slightly off-white, in order to allow for the product to fit into a kitchen environment, but in the meantime stand out as a top quality product.

ConclusionI will now go on to show my other engineering drawings of the other parts of my final product.

Part 1 – Base of holder

Side elevation


Plan view (from above)

3-D view

3-D Representation

45

Engineering Drawing (continued)

IntroductionOn this slide I have continued to present the engineering drawings for my product. I have presented the drawings for the handle of my product, and also looked at the drawings for half of the handle, because I will be manufacturing the handle in two parts.


Part 2 – Handle of holder

3-D View

Plan view (from above)

Side elevation of handle

Side elevation of half of handle

ConclusionNext, I will move on to produce my manufacturing plan, which will demonstrate all of the steps which I will take during the manufacture of my product. 46

Manufacturing Plan and list of all tools and equipment


IntroductionOn this slide I have presented my manufacturing plan, which demonstrates the stages that I will take to complete my finished product. The manufacturing plan is an industrial process.

Also in the manufacturing plan I will draw attention to areas where techniques that ensure quality are used, to result in the best possible product. As well as this, I will underline any key tools which were fundamental in the manufacture of my product. The manufacturing plan also helps predict how much time is needed as it points out the stages where I will need to spend the most amount of time. This is vital as far as how efficiently the steps of manufacture go is concerned.

The manufacturing plan should be set up alongside my final design and engineering drawings.

Start

Prepare the material – cut out both blocks of modeling plaster. Base - 150×160×40 in size, handle - 160×160×30 in size.

Plane material down to the right thickness and measure it using with a vernier calliper.

Stick the material down onto some plywood, that is a similar size, using double sided sticky tape.

I can now use the CNC miller to machine my product.

Stick down material to bed with hot glue gun and hold down until glue has dried.

Lower the cutter to the correct depth according to the part and material being machined and move it to bottom left hand corner of the material, setting each axis to zero.

Continued on next page…

YES

YES

YES

YES

YES

YES

NO

NO

NO

NONO

NO

Check all the pieces are flat, level and that the thickness is correct.

Is there enough tape on the board?

Is the board flat?

Is the material flat on the bed?

Is the cutter at the right depth? Has it been zeroed?

Is the software on the exact settings? Is it set on the right cutter on the right material, whilst cutting the correct side?

Set the MDX 3P software to the right setting for the part (i.e. Correct material and cutter)

Press start on draft cut, and then alter to fine cut.

Once it is finished, blow or brush away any dust and start to remove the plywood and the glue away from the bed, so that it can be used again.

47

Wipe down product with cloth, then spray away dust with high pressure air.

Buy off-white gloss paint. Spray base of product with two layers of gloss paint and leave to dry until paint is dry, and the product feels solid.

Once the base is dry, spray the handle with two coats of gloss paint and leave to dry.

Manufacturing Plan and list of all tools and equipment

Sand away all unnecessary filler from product with 320 sandpaper, as well as any marks which may show up when spray painting.

Spray away any dust with high pressure air, then spray product with one coat of grey primer. Slightly sand down any imperfections with 1200 grade sandpaper.

YES

NO

On this slide I will continue my manufacturing plan.

List of tools• Band saw• Plainer thicknesser

(although only used by member of staff)

• Hot glue gun • CNC miller• 360 sandpaper• Isopon P38 filler• Grey Primer• 1200 wet and dry

paper• Off-white gloss paint• Super glue• Vernier• Compressed air

Finish

ConclusionI now have a clear and well thought structure which provides me with a good basis from which I can work from.

Next I will start my diary of manufacture

Are there any more imperfections or marks?

Place the machined parts into white spirit tank and allow to soak for ten minutes. After ten minutes, remove parts from tank and start to peel away unwanted material (sticky tape etc.)

Glue all parts together with super glue, then use Isopon P38 filler to fill in any gaps between the parts.

NO

YES

Have the majority of the imperfections on each part been sanded away?

Repeat process for flip job (if necessary), otherwise start to sand away imperfections using 320 grade sandpaper.

Can any imperfections now be seen or felt?

NOYES

Is all of the product covered with a thick coat of gloss paint?

YES

NO


Diary of Manufacture – Ensuring quality (preparing the material and CNC Milling)


IntroductionOn this slide I have presented how I made my product and the techniques used during manufacture. During manufacture one of my aims was to ensure that quality and precision was maintained throughout. This was important for my project as I was working with a complex shape for my final design. I am focusing on this slide on how I prepared the material, which was an essential stage in making the product. I will highlight areas where ensuring quality was considered.

I started by taking a large block of modelling plaster and then cutting it down to size using a band saw, as shown in figures 1 and 2.

Figure 1

Figure 2

I used the band saw to cut down the material, until precision was much more vital. In this case, I asked a member of staff to plane down the material using the planer thicknesser, as shown in figure 3.

Figure 3

Figure 4

Figure 5

A vernier was used in order to measure the exact thickness of the material, and judge how much more of the material had to be removed.

Figure 6

Figure 8

Figure 7

Figure 5 shows the double-sided sticky tape that I placed on the underside of the material before I had peeled off the other side of it. In figure 6, I have peeled it off and it is now ready to be stuck on to the plywood.

Figure 7 shows the control panel of the CNC miller which is used in order to make the desired set up. The box on the left hand side within the figure shows all of the buttons that are required in order to place the material on the correct part of the bed. The box on the right side of the panel shows where the required buttons are in order to turn on or off the spindle and then higher or lower it. Figure 8 shows the CNC Miller that I used in order to manufacture all of the parts for my product. In that image, I had not yet chosen the cutter that I was going to use.

49


Diary of Manufacture – Ensuring quality (during CNC machining of base)

Figure 4

Figure 1

Introduction

On this slide I am continuing my diary of manufacture, and how I ensured that I produced a quality product, while I was manufacturing the base of my product.

Figure 1 shows the base of my product in MDX 3P format. I used this software to find out the exact dimensions of the base in order to prepare the material. Figure 2 shows the base of my product after the first process of machining was complete.

Figure 4 shows the base of my product being machined. At that point in time, it was carrying out the flip-job for the base, as the CNC miller could not cut out all of the product without it being flipped over to the other side. When flipping the base, I had to make sure that it was turned over into the exact same position, to ensure that quality was maintained.

Figure 2

From figure 3 you can see I placed it into the white spirit tank in order to ease the removal of the product from the sticky tape on the plywoodFigure 3

Figure 5

Figure 5 shows the base of my product once both sides of it had been machined. I was very happy at this stage of my manufacture, as I had managed to perfectly align the base up in the correct place so that it was cut accurately.

50


Diary of Manufacture – Ensuring quality (CNC Milling, bonding, filling and sanding the machined parts)

Figure 4Introduction

On this slide I am continuing my diary of manufacture, and how I ensured that I produced a quality product.Figure 1

Figure 5

Figure 2

Figure 1 shows the small icons that appear on the right side of the screen when using the MDX 3P software that is used for the machining of parts on a CNC miller. These are necessary in order to carry out a flip-job on the miller.

Figure 5 shows the superglue that I used in order to glue all of my parts together. Superglue is a contact adhesive and it is highly renowned for forming strong bonds in a very short space of time. One of the key properties is that it sets within about a minute or so. This was a key factor that ensured that my product glued together as precisely as possible.

Figure 6 shows my product fully assembled, along with the filler that I used to fill in any gaps or marks in on the product.

Figure 6

Figure 4 shows the three handle halves that I machined. I machined 3 so that I could then choose the 2 best quality parts from them.

Figure 3 shows a piece of 320 grade sandpaper which I used to sand down my product after it had been machined. I cut them into small pieces, so that I could get into small, intricate places, such as the insides of the egg slots – shown in figure 4.

Figure 3

51


Diary of Manufacture – Ensuring quality (Applying primer, filler and gloss coats)Introduction

On this slide I am continuing my diary of manufacture, and pointing out all of the key stages that ensured quality, in the build up towards applying the finish.Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 1 shows my product after having a coat of grey primer applied to it. After applying this coat, I was able to see many more imperfections that before, so I used filler when necessary, then started to sand once more, this time using 1200 grade sandpaper. I had to repeat this process many a time, all in order to give my product a top quality finish.

Figure 2 shows the extractor fan within the room in which I used to spray my product with the primer and the gloss paint. This was a very important machine involved during the spraying process, as it meant that I could spray my product inside, without the risk of breathing in harmful gases.

From figure 3, you can see an image of me holding the spray paint that I used in order to spray my product with the final gloss paint. I sprayed it an off- white colour, shown below in figure 4. I had to spray the base and the handle of the product separately, so that it could rest on a surface while drying, and the paint would not get smeared or marked.

Figure 4 shows my product resting in a cup which is in a clamp. Only the handle is making contact with any of the surfaces, which is important as it is the only part of the product that hasn’t got wet paint on it. As you can see, the paint offers a very slick, glossy look after being applied.

Figure 5 shows my final product after having two coats of gloss paint applied all over the product. Once the second coat was applied, I left the product over night, not only for the paint to dry, but also solidify its surface to make it more durable. As you can see above I decided to place some eggs into some of the slots, to make sure that there were no changes that I had to make, for example if the holes were too small or too wide. I also did this in order to check that the finger grooves on the sides of the egg slots were large enough in order to fit a finger or thumb within them.

Fortunately, everything functioned well and there was no need for me to make any major modifications to my product.

52


Diary of Manufacture – Illustrating any mistakes that were made

Introduction

On this slide I am continuing my diary of manufacture, however I will now be looking at pointing out any of the mistakes that I made. Due to myself modeling my final product out of modeling plaster, it is not an exact representation of what my product should be, because if I were to mass manufacture my product, it would be made out of stainless steel.Material – Modeling Plaster

Although I will not be able to properly test my final product, due to it having a gloss paint applied, I can still point out some of the issues regarding the products function.

If I were to place my product in boiling water in order to boil some eggs, then it is likely that the gloss paint would be removed from the products surface, so I must not do so. However, I discovered that when I placed a piece of modeling plaster on its own into water, it floats, which would affect the way in which my model would function. I am not sure how many eggs would be needed in order to weigh down the model to the bottom of a saucepan, where the water is at its hottest temperature, however six eggs were placed into the product, then I am sure that the model would not float.

So, I have now realised that modeling plaster was perhaps not the most suitable material to choose in order to manufacture my product, however fortunately, I will not be fully testing my model in boiling water anyway. I will however still check if it fits well into a saucepan, as shown below in figure 1Figure 1

Spray painting – Gloss coat

Unfortunately, on one occasion after I had applied a coat of gloss paint, I lost focus and accidently touched some wet spray paint on the base of my product, leaving a large finger print marking within the paint after it had dried.

I left it until it was dry, and then sanded away slightly where I had left my finger print on the base, using 1200 grade sandpaper. It was not a drastic mistake, however it did cost me some time, which could be a much more severe mistake if a similar thing were to happen during mass manufacture.

53


Evaluation (Satisfaction of Design Brief and Specifications)

IntroductionOn this slide I have begun to evaluate my product. Evaluation is an organised judgment of the worth and significance of something using criteria against a set of standards. Evaluation is often used when subjects of interest are charactarised and assessed.

MethodTo evaluate my product the most important thing to see was how successful it is. In order to do this I went through a number of tasks. Firstly I tested the product against my design brief and specifications that I had created after research, during the project.I also carried out a user test and gave questionnaires to a range of people of different ages to get down on paper any possible improvements that I could make to my product.I will also examine any weaknesses in the egg holder and explain what improvements I could make.

Design BriefThe product must be easily removed from saucepans,

hold at least 4 eggs, fit a range of saucepans and keep the

consumersafe from burning themselves.It must also be aesthetically pleasing, as

otherwise, theconsumers would be less drawn in to buying the product.

I feel I have successfully completed my design brief. I believe that my egg holder is aesthetically pleasing and would keep the consumer safe from burning themselves if used correctly. It can hold 6 eggs and fit into a range of different sized saucepans.

Does my product meet with the design specifications?

Function

• It must hold at least 4 eggs.

• It must significantly eggs the placement and removal of eggs from a saucepan with boiling water within.

• It must allow for water to drain easily throughout the product.

I feel that the case satisfies the specifications created for function. The product can hold more than 4 eggs, it certainly eases the placement and removal of eggs into a saucepan containing boiling water and it has a simple and effective drainage system that could easily drain out any water.

ErgonomicsThe product must: • Not have many, if any corners or sharp edges.• Be easy to clean after use. • Be easy to hold (with one hand if necessary).

To a large extent I would say that my product satisfies these specifications. However, although my product is very curved and rounded, it does have some edges which are quite poignant, on the other hand I would not say that they pose any real threat towards cracking an egg. It is easy to clean after use, however some areas of the product could be quite difficult to reach with a washing up brush. The specification that I believe it satisfies best though, is that it is exceptionally easy to handle.

Aesthetics

• The egg holder must be aesthetically pleasing in shape, colour and texture.

• The product must be well finished and have a smooth, rounded shape.

• The product must have a modern look.

I would say that all of these specifications have been met with my product. I believe it is aesthetically pleasing due to it having such a slick, modern and rounded look.

Figure 1 – Final product in context.

Figure 2 - Testing the egg holder

Figure 3 – Checking the product fits well into a saucepan.

Figure 3 – Handle As I was aiming for, the handle has a smooth egg-like shape, which was something that I specified for during the aesthetic development stage of my project

54


Evaluation (Satisfaction of Design Brief and Specifications)

IntroductionOn this slide I have continued to test my product against my design brief and specifications.

Durability

• The egg holder must be strong, and in the meantime flexible, so that it does not break when lifted at an angle

• It must be durable so it resists any knocks which it may endure during use.

• It must not get damaged at high temperatures (in water).

• It must not get scratched easily, as this would rapidly decrease its aesthetic quality.

• The material used must be suitable for current day lifestyles and the modern market.

Obviously, it is a challenging task to test my model against these specifications, as I do not want to damage my product. However, if my model were made out of stainless steel, then I would try to test it against these specifications, and I believe that the design would be capable of satisfying them.

Size

• The product must be able to fit into a normal sized saucepan

• The product must be able to be stored in kitchen cupboards with ease.

• The product must have a diameter no wider than 185mm and must be at least 160mm tall.

My product satisfies these specifications to a good standard. I know that the product would be able to fit into a normal sized saucepan, and that it is not wider than 185mm. It also has a height of 180.5mm, so it would provide ample space for the user to hold the product into a saucepan without being in danger of burning themselves. The product would be able to be stored into a kitchen cupboard with ease as it can balanced without needing to rest on anything. However, the product is not that compact, so it would take up quite a large area when not in use, due to its large diameter.Figure 1 – Height of product in context

Anthropometrics• The finger grooves on the edges of the

egg slots must fit a finger of thumb with a normal width.

As you can see below in figure 2 my product satisfies this specification.

Figure 2 – Testing finger grooves

Manufacture• I will manufacture my final product

using the CNC miller. To give a smooth and rounded finish I will sand the product down using sand paper, then I will then finish the product with spray paints.

These manufacture specifications have been satisfied, as these were just some of the stages that I went through in order to manufacture my product.

55

Evaluation (User trials and testing)

IntroductionOn this slide I am presenting the results of my questionnaire that I gave out to people. For my questionnaire, 8 people were questioned. This process provides me with excellent first hand feed back on the product. I will represent the results using graphs.

Evaluation of ‘Organic’

Questionnaire

May you please fill out this questionnaire after testing the product so that I may then evaluate the success of my product.

Please circle your rating below according to your opinion. ( 1 being the lowest and 5 being the highest)

Q1) Would you say that the product would fit into its surroundings? YES/NO

Q2) How much easier does the product make the placement and removal of eggs from a saucepan in comparison to a regular spoon? 1 2 3 4 5

Q3) How attractive is the design and shape of the egg holder? 1 2 3 4 5

Q4) Do you feel that the product provides enough height away from boiling water in order to prevent the user from burning themselves? YES/ NO

Q5) How is the finish and manufacturing quality of the product? 1 2 3 4 5

Q6) Would you prefer for the product to be made out of (1) stainless steel or (2) rubber? (1) / (2)

Please could you jot down any sketches or comments that you believe would benefit my product, thank you.


Yes No

Question 1 – Would you say that the product would fit into its surroundings?

Analysis of results - According to my results, 7 out of 8 people would say that the product would fit into a kitchen environment.

Question 2 – How much easier does the product make the placement and removal of eggs from a saucepan in comparison to a regular spoon?

Analysis of results -According to my results, 1 out of the 8 people gave a 3 out of 5 rating for how much easier it was to place and remove eggs into a saucepan than a standard spoon. 4 out of the 8 people gave it a 4 out of 5 rating and 3 out of the 8 gave in a 5 out of 5 rating. This suggests that my product is very effective at carrying out its function.

Rating 1Rating 2Rating 3Rating 4Rating 5

56


IntroductionOn this slide I will continue to present the results of my questionnaire, while analysing them in the meantime.


Question 3 – How attractive is the design and shape of the egg holder?

Analysis of results - According to my results, 7 out of 8 people would say that the egg holder is an extremely attractive product, in terms of its design and shape, while only one person rated it a 4 out of 5.

Rating 1 Rating 2 Rating 3

Rating 4 Rating 5

Question 4 – Do you feel that the product provides enough height away from boiling water in order to prevent the user from burning themselves?

Analysis of results - According to my results, all of the people who participated in the questionnaire believed that the product provided a perfect amount of height above the boiling water for the user to comfortably use the product.

Yes No0%

10%20%30%40%50%60%70%80%90%

100%

Question 5 – How is the finish and manufacturing quality of the product?

Analysis of results - According to my results, all of the people who participated in the questionnaire believed that the product provided a perfect amount of height above the boiling water for the user to comfortably use the product.

Rating 1 Rating 2 Rating 3 Rating 4 Rating 50

0.51

1.52

2.53

3.54

4.5

57


IntroductionOn this slide I have presented the final slide of the results of my questionnaire.


Question 6 – Would you prefer for the product to be made out of (1) stainless steel or (2) rubber?

Analysis of results - The results of question 6 show that all of the questionnaire participants believe that if the product were to be mass produced, they believe it should be made out of stainless steel. One of the participants, noted down in the comments section at the end of the questionnaire that they thoroughly believe the product should be made out of stainless steel, as ‘Stainless steel is the material that best fits the kitchen environment’.

(1) Stainless Steel(2) Rubber

Conclusion of user Trial

I have now finished the user trial and testing section of my evaluation and I will now go on to showing what improvements could be made to made to my product.

I was extremely glad with the results that I recorded and got a lot of positive feed back, it has also helped to reinforce as well as discover any areas that I need to develop.

However, one thing that I must take into consideration is that my results could be slightly biased as the majority of the people that participated were friends and family that I have known for a considerable amount of time. So, perhaps the feed back that they gave me concerning my product was slightly more positive than they really intended to give.

58

Evaluation (Social, Moral and Environmental Benefits)

Introduction

On this slide I will be looking at how socially, morally and environmentally friendly my product is. It is important to point out these issues as they are becoming of more and more interest to the public.

I will try to make clear all of the different ways that I tried to improve the social, moral and environmental benefits of my product.


Reducing material waste

When I manufactured my product, I aimed to use as little material as possible, however there were a few occasions at which I used more material than necessary.When designing my product however, there were several parts of the product at which I reduced a considerable amount of waste material. For example, on the base of the product, I cut down a lot of unnecessary material on the underside of my product, as shown in figure 1. I also made the wall thickness as thin as possible, while guaranteeing that the function of the product was not effected, nor the durability (shown in figure 2). I also made the drainage holes as large as possible (figure 1).Figure 1 Figure 2

Figure 3

Maintenance

The product is also very environmentally friendly as it can be maintained. None of the parts would have to be replaced after a certain amount of time, which would contribute towards reducing the waste material.

Disassembly and Recycling

Due to the product being made solely out of stainless steel, it would not need to be disassembled before being melted down and recycled when it is no longer required.

Ways of minimising environmental impact further

There are not any particular areas where I clearly could reduce the environmental impact of my product further. However, I could shell the handle and shaft of my product, which would reduce the amount of material used to manufacture my product further.

I could also reduce some of the material on the underside of the base of my product, between the egg slots, as shown below in figure 3..

59

Evaluation (Recommended future improvements)

Introduction

On this slide I will present any suggested improvements for my product through sketch work that was produced by questionnaire participants. I have also come up with some possible ideas that could improve my product further, which have also been illustrated on this slide.


Figure 1 Figure 2

Figure 3

Method

By looking at the results of my questionnaire, comments left at the end of them and the specifications that had not been entirely satisfied, I was able to identify any areas for improvement on my product. I then sketched some ideas, and have presented them on the right, explaining each one.

Figure 1 shows a timer that would be inbuilt into the handle. This would allow for the user to know how long their eggs have been in the saucepan for, and provide them with a way of making sure they take their eggs out at exactly the right time according to their desires.

Figure 2 shows a possibility of having small LED’s and a buzzer that would indicate to the user when the timer has gone off. This would provide the user with a clear signal concerning when they need to take the eggs out of the saucepan, There would be a detachable glass top that would protect the LED’s and the buzzer from getting wet. Figure 3 shows an idea that I came up with that involves the product being made out of a smart material, that would change colour as the temperature of it increased. This would provide the user with an idea of what temperature the water is at and how well the eggs are cooking.

Conclusion

Next I will move on to evaluate what went well during the project as a whole and finally suggest how I could mass produce the product should I so wish.

60

Evaluation (What went well and mass manufacture)

IntroductionOn this slide I will finish the evaluation of my project by looking at what was carried out successfully during my project and then at how my product could be mass manufactured.


MethodFirstly I will evaluate how efficiently my time was managed, the quality of my folder work and then my final outcome.

ConclusionI have been very pleased with the development of my project and how it has progressed. The evaluation has helped me show that the finished product has successfully solved the problem. Skills and research that I have used in this project will aid me in my exam at the end of the course.

Time PlanningI will evaluate how successfully I managed my time during the project against my Gantt chart which I produced at the very start of my project. I feel that my Gantt chart actually provided me with a good approximation of how long each part of my project work would take. However there were of course a few incidents that altered how fast or slowly I was managing to get through my project, in that some of my work I produced faster than others and vice versa. For example, I vastly underestimated the amount of time that it took for me to complete my initial ideas section. I said in my Gantt chart that it would take my only take me about a week to complete this section, whereas when it came to it this section took me about 3 weeks or so. On the other hand I also thought that it would take me about 12 weeks to manufacture and finish my product, whereas this only took me about 8 weeks in total. I feel that I could have made better use of my time during the project, although I managed to finish it on time. If I were to carry out the project again, I would aim to meet the exact requirements and deadlines much faster.

Final Outcome and Manufacture I am very happy with my final outcome, although there are some areas for improvement, which I have addressed during my evaluation. Some of the results of my questionnaire were especially pleasing to see, for example that 7 out of the 8 participants thought that the aesthetics of the final product were of an excellent standard, while the only participant who believed otherwise still believed that it was a product that is very pleasing on the eye.The manufacture went fairly well, mainly due to the fact that I did not have to use any time constraining techniques in order to manufacture my parts. However, sanding was for me personally a very time consuming process, as I have many rounded faces on my product that are very difficult to sand down accurately in a short space of time. I also had quite a few small, intricate places to sand which took up a lot of my time during manufacture.Folder workI am content with my folder work that I have produced during the course of my project, as well as the in depth research of the problem area and other relevant research that I carried out.Mass ManufactureI will now look into how I would mass manufacture my product.As I have pointed out earlier in my project, I would like to produce my product using the die casting process. The material used would be stainless steel.

Figure 1

How Die Casting WorksDie casting is a very common industrial process, that is relatively easy to comprehend:• Firstly, the desired metal that is to be

used is heated until molten.• It is poured into a crucible, and then

pressure up into a die with the desired shape.

• Molten metal solidifies within the die.• Unnecessary molten metal pours back

into crucible.• Dies open up and the solidified metal is

ejected in the desired shape.• The process is complete, and can now be

repeated.

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Sam Naylor

Documents

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design processplanning

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