product design Flashcards
(85 cards)
1
Q
What are the key physical characteristics that must be understood for material selection?
A
- malleability
- toughness
- hardness
- resistance to corrosion and degradation
- thermal conductivity
- electrical conductivity
- product function
- aesthetics
- cost
- manufacture and disposal.
2
Q
What are the classifications of metals?
A
- ferrous
- non-ferrous
- alloys
3
Q
Name the different types of woods.
A
- hardwoods
- softwoods
- manufactured boards
4
Q
What are the types of polymers?
A
- thermoplastics
- thermoset polymers
- elastomers
5
Q
List the performance characteristics of materials.
A
- tensile strength
- toughness
- hardness
- malleability
- corrosion resistance
- conductivity
6
Q
What are the performance characteristics of papers and boards?
A
- ability to be scored
- cutting
- folding
- surface qualities for printing
- impact resistance
- recyclability and/or biodegradability
7
Q
Fill in the blank: The ability of a material to return to its original shape after being stretched is known as _______.
A
[elasticity]
8
Q
Which materials are considered smart materials?
A
- shape memory alloys (SMA)
- thermochromatic pigment
- phosphorescent pigment
- photochromic pigment
- electroluminescent wire
- piezo electric material
9
Q
What characteristics make biodegradable polymers suitable for applications?
A
- ability to be moulded into 3D products or film
- ability to degrade with the action of UV rays, water, or enzymes
10
Q
What are the different stock forms of metals?
A
- sheet
- plate
- bar (flat, round, square, hexagonal)
- tube (round, square, rectangular, hexagonal)
- structural (H beam, I beam, tee, channel, angle)
11
Q
True or False: Composites are created by combining materials to enhance their properties.
A
True
12
Q
What methods are used to enhance the properties of polymers?
A
- UV stabilisers
- bio-batch materials
13
Q
List the performance characteristics of woods.
A
- grain pattern
- grain direction
- surface defects
- warpage
- shrinkage
- splitting
- joining
- forming
- steam bending
- laminating
- machining qualities
- resistance to decay
- moisture resistance
- toxicity
14
Q
Which types of polymers are thermoplastics?
A
- low density polyethylene (LDPE)
- high density polyethylene (HDPE)
- polypropylene (PP)
- high impact polystyrene (HIPS)
- acrylonitrile butadiene styrene (ABS)
- polymethylmethacrylate (PMMA)
- nylon
- rigid and flexible polyvinyl chloride (PVC)
- Polyethylene terephthalate (PET)
15
Q
What are the different forming processes for paper and board?
A
- die cutting
- laser cutting
- creasing
- bending
16
Q
What are some methods for forming polymers into 3D products?
A
- vacuum forming
- thermoforming
- calendaring
- line bending
- laminating (layup)
- injection moulding
- blow moulding
- rotational moulding
- extrusion
- compression moulding
17
Q
Name some common elastomers.
A
- natural rubber
- polybutadiene
- neoprene
- silicone
- Thermoplastic Elastomer (TPE)
18
Q
What is the significance of additives in polymer products?
A
Additives enhance properties like UV stability and biodegradability.
19
Q
Fill in the blank: The combining of natural timber with resins and lamination enhances properties such as _______.
A
[strength and stability]
20
Q
What are the performance characteristics of metals?
A
- hardness
- toughness
- malleability
- elasticity
- tensile strength
- density
- resistance to corrosion
- thermal conductivity
- electrical conductivity
- melting points
- ability to be alloyed
- ability to be joined with heat processes
- ability to take applied coatings and finishes
21
Q
What are some examples of biodegradable polymers?
A
- corn starch polymers
- potatopak
- biopol (bio-batch additive)
- polyactide (PLA)
- polyhydroxyalkanoate (PHA)
- water soluble: lactide, glycolide (Lactel and ecofilm)
22
Q
True or False: Modern materials include Kevlar and precious metal clay.
A
True
23
Q
What is vacuum forming?
A
A process where a sheet of plastic is heated and then formed over a mold using a vacuum.
Commonly used for creating packaging and trays.
24
Q
What is thermoforming?
A
A process similar to vacuum forming, where plastic sheets are heated and shaped over molds.
Often used for larger items compared to vacuum forming.
25
What does calendaring refer to?
A manufacturing process that involves passing plastic or rubber through a series of rollers to produce sheets or films.
## Footnote
Used in the production of flexible materials.
26
What is line bending?
A process used to bend plastic sheets along a predetermined line by heating them.
## Footnote
Commonly used for creating display items.
27
What does laminating (layup) involve?
A process of layering materials together to create a composite structure.
## Footnote
Often used in aerospace and automotive applications.
28
What is injection moulding?
A manufacturing process where molten material is injected into a mold to create parts.
## Footnote
Commonly used for producing high volumes of plastic parts.
29
What does blow moulding produce?
A process that creates hollow plastic parts by inflating heated plastic inside a mold.
## Footnote
Frequently used for bottles and containers.
30
What is rotational moulding?
A process where powdered material is placed in a mold and rotated to create hollow parts.
## Footnote
Suitable for large, hollow items like tanks and playground equipment.
31
What does extrusion refer to?
A process that pushes material through a die to create long shapes or profiles.
## Footnote
Commonly used for pipes and sheets.
32
What is compression moulding?
A process where material is placed into a heated mold and compressed to form a part.
## Footnote
Often used for rubber and thermosetting plastics.
33
What is press forming?
A metal forming process that uses a press to shape metals into desired forms.
## Footnote
Used for producing parts like car body panels.
34
What does spinning involve in metal processes?
A method of shaping metal by rotating it against a tool to create symmetrical shapes.
## Footnote
Commonly used for creating bowls and cups.
35
What is deep drawing?
A metal forming process that involves pulling a sheet of metal into a die to create a deep, hollow shape.
## Footnote
Frequently used in making cans and automotive parts.
36
What is forging?
A process of shaping metal using compressive forces, often involving hammering.
## Footnote
Used for producing strong, durable components.
37
What does welding refer to?
A joining process that involves melting and fusing materials together.
## Footnote
Includes methods like MIG, TIG, and spot welding.
38
What is soldering?
A process of joining metals by melting a filler metal into the joint.
## Footnote
Used in electronics and plumbing.
39
What is brazing?
A joining process that uses a filler metal with a higher melting point than soldering.
## Footnote
Often used for joining dissimilar metals.
40
What does milling refer to in wasting processes?
A machining process that removes material from a workpiece using rotary cutters.
## Footnote
Used for producing flat surfaces and complex shapes.
41
What is turning in machining?
A process that involves rotating a workpiece against a cutting tool to shape it.
## Footnote
Commonly used for cylindrical parts.
42
What is laser cutting?
A process that uses a laser to cut materials with high precision.
## Footnote
Suitable for intricate designs and thin materials.
43
What is a dovetail joint?
A traditional wood joint characterized by interlocking 'tails' and 'pins'.
## Footnote
Known for its strength and resistance to pulling apart.
44
What is a mortise and tenon joint?
A woodworking joint where a tenon fits into a mortise hole.
## Footnote
Commonly used in furniture making.
45
What is PVA?
Polyvinyl acetate, a type of adhesive commonly used in woodworking.
## Footnote
Known for its strong bond and ease of use.
46
What is UV hardening adhesive?
An adhesive that cures when exposed to ultraviolet light.
## Footnote
Often used in glass and plastic applications.
47
What is screen printing?
A printing process that uses a mesh to transfer ink onto a substrate.
## Footnote
Commonly used for textiles and posters.
48
What is powder coating?
A finishing process that involves applying a dry powder and curing it to form a protective layer.
## Footnote
Provides a durable and attractive finish.
49
What is galvanising?
A process of applying a protective zinc coating to steel or iron to prevent rusting.
## Footnote
Commonly used in outdoor structures.
50
What is wood finishing?
Enhancing the appearance or preventing decay of wood products.
## Footnote
Includes various applied finishes.
51
List some specific finishes for wood.
* Polyurethane varnish
* Acrylic varnish
* Water-based paints
* Stains
* Colour wash
* Wax finishes
* Danish oil
* Teak oil
* Pressure treating with chemical preservatives.
## Footnote
These finishes can protect and beautify wood.
52
What are the different scales of production?
* One-off, bespoke
* Batch production
* Mass/line production
* Unit production systems (UPS)
* Quick response manufacturing (QRM)
* Vertical in-house production.
## Footnote
Understanding production scales is crucial for manufacturing processes.
53
What is Just In Time (JIT) manufacture?
A manufacturing strategy that reduces waste by receiving goods only as they are needed in the production process.
## Footnote
JIT helps in minimizing inventory costs.
54
What is the relationship between material cost and manufacturing processes?
Material cost influences the form and processes used in production and affects the overall scale of production.
## Footnote
Efficiency in material usage can lead to cost savings.
55
What are some computer systems used in manufacturing?
* Modular/cell production
* Just in Time (JIT)
* Quick response manufacturing (QRM)
* Flexible manufacturing systems.
## Footnote
These systems enhance efficiency and adaptability in production.
56
What is computer aided design (CAD)?
Technology that allows designers to create and modify designs digitally.
## Footnote
CAD includes 2D and 3D design capabilities.
57
What are some specific processes included in computer aided manufacture (CAM)?
* Laser cutting
* Routing
* Milling
* Turning
* Plotter cutting.
## Footnote
CAM processes automate manufacturing tasks.
58
What is virtual modelling in product design?
Using digital simulations to test and refine product designs before physical production.
## Footnote
Includes techniques like computational fluid dynamics (CFD) and finite element analysis (FEA).
59
What does rapid prototyping involve?
Creating physical models of products quickly using additive manufacturing techniques like 3D printing.
## Footnote
Benefits include faster design iteration and testing.
60
What is the role of electronic data interchange (EDI) in manufacturing?
Facilitates the exchange of business information electronically to improve efficiency in operations.
## Footnote
Includes applications like electronic point of sales (EPOS).
61
What does production planning and control (PPC) involve?
Planning and controlling all aspects of manufacturing, including material availability and scheduling.
## Footnote
PPC systems help streamline production processes.
62
What are the key requirements for product design and development?
* Fitness for purpose
* Accuracy of production
* Meeting specification criteria.
## Footnote
Critical assessment of products can lead to new design innovations.
63
What is inclusive design?
Designing products that can be used by a wide range of users, including those with disabilities.
## Footnote
Focuses on accessibility and usability for all.
64
What is the Health and Safety at Work Act (1974)?
Legislation that outlines the responsibilities of employers to ensure safe working environments.
## Footnote
Affects manufacturing practices significantly.
65
What are patents?
Legal rights granted to inventors to exclude others from making, using, or selling their inventions for a specified period.
## Footnote
Patents protect intellectual property.
66
What are the six Rs of sustainability?
* Reduce
* Reuse
* Rethink
* Recycle
* Repair
* Refuse.
## Footnote
These principles guide sustainable design and manufacturing practices.
67
What is a feasibility study?
An assessment of the practicality of a proposed project or system, including market research and testing prototypes.
## Footnote
Helps determine the viability of new designs.
68
What is the importance of marketing in product development?
Identifying customer needs, establishing brand identity, and promoting products effectively.
## Footnote
Marketing strategies impact product success significantly.
69
What is the iterative design process?
A repetitive cycle of prototyping, testing, and refining designs based on user feedback.
## Footnote
Encourages continuous improvement in design outcomes.
70
What are key design styles and movements?
Arts and Craft Movement, Art Deco, Modernism (e.g., Bauhaus), Post Modernism (e.g., Memphis)
## Footnote
These styles represent various principles of design that have influenced product design and manufacture.
71
Name an influential designer associated with the principles of different design movements.
Phillipe Starck, James Dyson, Margaret Calvert, Dieter Rams, Charles and Ray Eames, Marianne Brandt
## Footnote
Each designer has contributed significantly to the evolution of design through their work.
72
How did the Bauhaus influence furniture design post WW1?
Development of furniture for mass production
## Footnote
This movement emphasized functional design and the use of new materials.
73
What were the impacts of WW2 on product design?
Rationing led to the development of 'utility' products
## Footnote
These products were designed to be practical and economical during times of scarcity.
74
What are examples of major developments in technology impacting product design?
* Microelectronics
* New materials
* New methods of manufacture
* Advancements in CAD/CAM
## Footnote
These advancements have transformed how products are designed and produced.
75
What are the social responsibilities of designers?
* Sustainable materials
* Ethical production methods
* Culturally acceptable products
* Inclusive design
* Addressing social problems
## Footnote
Designers must consider the societal impact of their products.
76
What does the product life cycle include?
Design introduction, evolution, growth, maturity, decline and replacement
## Footnote
Understanding the life cycle helps designers refine and redevelop products.
77
What are the stages of a design process?
* Investigations and analysis
* Use of inspiration materials (e.g., mood boards)
* Ideas generation
* Illustration
* Development of a design specification
* Modelling
* Planning
* Evaluating and testing
## Footnote
These stages guide designers in creating effective products.
78
What is the iterative design process?
A cyclic nature of design and manufacture used in corporate contexts
## Footnote
This process involves continuous improvement and refinement of products.
79
What is the importance of feedback in product evaluation?
Informs future modifications and development
## Footnote
Ensures that the views of interested parties are considered for objective feedback.
80
What are good and safe working practices in design?
* Correct tools for tasks
* Safety for oneself and others
* Development from prototype to mass production
## Footnote
Ensuring safety and efficiency is crucial in both workshop and commercial settings.
81
What does accuracy in design and manufacture refer to?
* Determining quantities of materials
* Calculation of sides and angles
* Use of datum points and geometry
## Footnote
Accuracy is essential to eliminate errors and ensure quality.
82
What is the concept of a circular economy in design?
* Conservation of energy, materials, and components
* Minimum environmental impact
* Sustainable manufacturing methods
## Footnote
This approach aims to reduce waste and promote resource efficiency.
83
What is quality assurance?
Procedures and policies to reduce waste and ensure products are accurate
## Footnote
Includes systems like Total Quality Management (TQM) and Six Sigma.
84
What are specific quality control methods?
* Monitoring of materials and products
* Use of 'go-no go' gauges
* Digital measuring devices
* Non-destructive testing
## Footnote
These methods ensure that products conform to acceptable tolerances.
85
What are key national and international standards in product design?
* British Standards Institute (BSI)
* International Organisation for Standardisation (ISO)
* ROHS directive
* WEEE directives
## Footnote
These standards help ensure safety, quality, and environmental responsibility in product design.
