2. Materials and Components Candidates should have a knowledge and understanding of the processes and techniques which aid manufacture and of the commercial and industrial applications of a range of materials involved in manufacturing their products in quantity. It is expected that designing and making will address complete product issues and therefore deal with materials which would aid manufacture, such as moulds, cutting dies, printing blocks, jigs etc. as well as dealing with issues such as labelling, packaging etc. It will be important therefore that candidates can utilise a variety of suitable materials and components. Whilst undertaking product analysis activities, it is expected that candidates will make detailed references to the materials used as well as the associated manufacturing issues.

3. Classification and working properties of materials The following materials and components are considered to be suitable for candidates following this course of study. Candidates are not required to study all materials, but centres must provide opportunities for candidates to learn about a range of materials and to use them in practical contexts, during both the development and manufacture of products and during product analysis. As a minimum, candidates should study Paper/Card and one other material area. Those studying the electronic and control components are strongly advised to also study one other material area in addition to paper/Card. Candidates may employ/use any necessary materials in the modelling, prototyping or manufacture of their products. Candidates will be required to demonstrate their application of knowledge, understanding and skills in both assessment units. Health and Safety factors should be a major consideration when working with any of the materials OPTIONS Paper/Card Timber Based Materials Ferrous and non ferrous metals Plastics Ceramics Textiles Food Electronic and Control components

4. Paper/card When working with paper/card materials candidates should: be able to identify common papers such as layout, cartridge, tracing, grid, card, corrugated card, duplex board, solid white board, foam core board; understand the different properties and uses of such materials both as a media for communication and as a material for manufacturing products such as packaging; understand the availability of common components e.g. to fasten, seal, hang, pour, join, bind, index; understand that many paper based boards are laminated to other materials and that the composition can be adjusted to create different properties for specific purposes e.g. foil-backed for food packaging; understand the stock forms for paper/card materials i.e. size, thickness, weight and colour; have a basic understanding of the source of pulp and the primary processes involved

6. WHAT IS A BARCODE? A barcode is a number of vertical black strips, usually forming a rectangular shape (see example below). The strips are a graphical method of representing numbers. Computer system can read barcodes more efficiently than optically reading numbers and letters. Modern optical readers and their computer systems can read barcodes from almost every angle. CONFORMITE EUROPEAN SYMBOL Stamped on products tested to the minimum standard set by the EEC. Applies to products in the European Community Manufacturers must ensure that their products at least meet these minimum standards or risk having their products removed from the shelves of retailers throughout Europe What is on our packaging? The Logo Imagery if required showing product in use Relevant instructions or guides. Ingredients if needed. BRITISH STANDARDS INSTITUTE KITE MARK Can be stamped on products tested to high British standards. Regarded as a Quality and Safety mark.

7. CARTRIDGE PAPER - is used for general drawing. It is often good quality and generally 100 to 135g in thickness. This paper is used for design and technology projects and will take colour from pencils and felt pens without too much leaking to the opposite side of the paper. CARDBOARD - is thicker than paper as it is made up of a number of layers, glue or laminated together. The diagram opposite shows a net / development of a package. It can be folded to produce a carton. DUPLEX BOARD - This is used for containers and can contain liquids as it may have a water-proof liner on the inside. It can have a wax feel. This type of card is used by the food industry and consequently recycled card is not used in its manufacture. SOLID WHITE BOARD - This is normally top quality cardboard made from quality bleached wood pulp. It is the best card for printing on to and consequently it is used for hard backed books and more expensive items.

8. CORRUGATED BOARD - This type of board is often used for packaging large electrical items. These large boxes (often brown in colour) protect the contents from damage. Corrugated board is strong because it is composed of a top and bottom layer and in between there is a triangulated section. A triangular section is very strong compared to its weight. FOIL LINED BOARD - is good quality cardboard with a aluminium foil lining. This type of container is ideal for ready made meals or take away meals. The foil retains the heat and helps keep the food warm. TRACING PAPER -Is used pupils, students and designers. It allows the designer to copy an existing drawing / shape. Tracing paper can be useful when there is a need to produce several drawings that are based on the same outline. Also, tracing paper makes it possible to place one design on top of another to produce a second layer. The original design can be seen under the second drawing

9. Why do we have packaging? ProtectDisplayInformTransport

10. Paper/Card Last lesson we looked at different types of paper. Some of which are used for packaging, some for communication. Further information you need to know. There are two factors concerning paper size, its weight and its dimensions. Heavier paper is regarded as better quality, but heavy paper is regarded as card. Of course paper is available in variety of different colours.

11. Trees cut & shredded Water added Boiled up to make wood pulp Chemicals and dyes added Pulp poured over fine mesh and squeezed between rollers https://www.youtube.com/watch?v=7IP0Ch1Va44

12. Printing Press One of the most basic ways of printing with ink or paint is through the use of a 'letterpress'. If the shape to be printed is very simple it is possible to make the letterpress quite easily in a school workshop Using a letterpress is sometimes called relief printing. In simple terms the letter or shape to be printed stands above the surface. Ink or paint is then rolled across the shape/letter and paper is then pressed down onto it. When the paper is lifted up the ink/paint has been transferred to the paper. This process can be repeated any number of times Screen printing is in common use today as it is relatively cheap and a variety of colours can be used. Good examples are seen on T-shirts and posters. In industry this technique is used to produce thousands of screen printed items, even on packaging. The equipment required for this technique are shown below. 1. The material to be printed on is placed on top of the base. In the example, paper is being used. 2. A template made from card, with the required shape cut out of it, is placed on top of the paper. 3. A screen is placed on top of the template. The screen is made of stretched nylon fabric and has a wood frame to hold it in place. 4. Ink is then squeezed through the nylon fabric. 5. A blade is used to spread the ink out and push it through the fabric, through the template, and onto the paper. 6. The paper is taken out of the screen printing equipment and the printed pattern can clearly be seen.

13. Lithography is mainly used by commercial printers, printing companies that will print thousands of copies of the same item, in one production run. Lithography machines can print on both sides of paper/card and they rely on four basic colours; yellow, cyan (type of blue), magenta (type of red) and black. This is also known as the CYMK process. 1. The printing plate has the image to be printed, in relief, on its surface (the image stands out slightly from the printing plate surface). 2. The printing plate is kept dampened. Ink is applied to the plate but it is repelled from the dampened surfaces which are the non-image areas. 3. As the printing cylinder rotates the ink is transferred to the rubber blanket cylinder. 4. The ink, now on the rubber blanket cylinder, is pressed onto the paper or card as it is pulled through the machine. (The paper is trapped between the blanket cylinder and the impression cylinder - these pull the paper through the machine) With some modern lithography printing machines the image is put onto the printing plate by shining ultra violet light through a negative (similar to a photograph negative). The plate is coated with a chemical which allows the ink (made from oil) to attach to the image area. If different colours are needed for the final print - the same card/paper will be sent through the machine and each time different negatives and colours will be applied. This is done until the print, which may be a poster, is completed.

14. Dye-sublimation printers allow you to print photos at home with quality of photo lab. As the cost of the printers reduces, more digital-camera users choose to get benefit of dye sublimation technology. Unlike in inkjet printers, that produce an individual dots which look separated at a fairly close distance, dye sub printers continuous tone images that look much more realistic. Embedded in this film are solid dyes are equivalent to the four basic colours used in printing, CMYK. If you ever looked inside of dye-sublimation printer, you would see a extensive roll of see-through film layer roll of see-through film layer that resembles sheets of red, blue, yellow, and gray coloured cellophane connected together. The thermal head becomes hot while it passes along the film, causing the dyes to vaporize and fill the gloss paper before they get back cold again Laminating This also produces a high gloss finish on card and provides good protection against damage as it is normally water proof. The printed card is placed inside a plastic film/sleeve. It is then placed in the ‘in tray’ of a laminating machine which pulls the card and film through its heater and rollers. The heater warms up the film almost to melting point and the rollers press the film sleeve until it is sealed. When the card reappears in the ‘out tray’, the finished item looks glossy and professional. However, laminating is much more expensive than varnishing but gives more protection to the card. Laminated card is used for items such as menus in a restaurant. A menu will be constantly handled by customers and staff and it is important that it is protected.

15. Embossing involves raising areas of a card surface above the level of the rest. The diagram below shows a coat of arms that has been embossed on green card. The images stands out from the card as it has been produced by a stamp which presses the card to the correct shape. This process adds cost to the printing process but gives the card a 3D effect. Block Printing A simple yet effective form of printing. A Pattern is carefully cut away from a cork block, leaving a stamp. This is then covered with ink and is stamped repeatedly on a material surface

17. The first stage of vacuum forming is to manufacture a precise mould. This is a skilled job as any imperfections to the mould will show up every time it is used to shape plastic such as high density polystyrene. Bubble wrap is no exception. The mould can be used hundreds and even thousands of times to produce the same plastic part. Each part will be exactly the same. The mould is placed in the vacuum former. It is placed centrally. A sheet of high density polystyrene is paced above the mould and clamped in position. Various thicknesses are available. Usually material 1mm thick is the most suitable for this type of vacuum forming The heater is turned on. When the machine is being used from ‘cold’ it takes approximately five to ten minutes to warm up to the temperature needed to heat the polystyrene sufficiently. Once warm, polystyrene of this type takes only four or five minutes to heat up before vacuum forming can begin. The plastic (polystyrene becomes pliable and flexible after a short time. It must be very flexible before it can be formed properly. When the polystyrene is ready the shelf is then lifted up towards the polystyrene sheet. The air underneath the former is pumped out and the polystyrene takes the form of the mould

18. fasten, seal, hang, pour, join, bind, index; Fasten Seal Euro Slot - Hang Pour? Join Bind Index

19. Timber based materials When working with timber based materials candidates should: be able to identify common timbers such as pine, mahogany, teak, ash, beech used in the manufacture of products be able to identify common manufactured boards i.e. MDF, plywood, chipboard, blockboard, hardboard; understand the different properties and uses of such materials within commercial products; understand that many timber-based materials are manufactured therefore the composition can be adjusted to create different properties for specific purposes; understand the stock forms for timber based materials i.e. rough sawn, PSE, sheet sizes and mouldings; have a basic understanding of the source of timber and the primary processes involved in conversion to workable materials.

20. As we produce this box, we will make notes and keep details of all the relevant information that will be useful for the examination and future coursework. Box Project – Lesson 1, slide 3. MANUFACTURED BOARD Mahogany Teak Ash Beech Pines Spruce MDF Hardboard Chipboard Plywood Blockboard

21. Box Project – Lesson 1, slide 4. Pine Tree Does not lose its leaves in winter Non Deciduous. Chopped Down Stripped and loaded Stacked and dried – Air or Kiln Trim http://www.technologystudent.com/joints/forest3a.html

22. Box Project – Lesson 2, slide 2. Pines Spruce Forest Stewardship Council Wood Yard or Timber Merchant

23. Rough Sawn Timber: This is directly from the drying process. No further work has been done to the timber. It is rough to touch and you can see the saw marks in the material. It is cheaper to buy, but expensive equipment is required to make it usable. Planed Timber: It is often advisable to buy planed timber, this I when the materials has been processed using machines to make the surface smoother and square. Wood is generally machined to specific sizes. Stock Sizes: Wood is traditionally cut to specific sizes for use. This is generally referred to in inches, although mm are becoming more frequent. Wood is cut and planed to a variety of sizes for uses to buy from the shelf. This wood is generally more expensive, but it is ready for use and the sizes are consistent. Box Project – Lesson 2, slide 3.

24. Other stock forms of wood include skirting board and parts for stair cases. Such products are often made of pine because it is a cheap material and easy to use. Forest Stewardship Council (1993) In order to ensure stocks of pine are not depleted, the FSC was established in 1993. Buying material with this logo assures the customer that the tree that has been removed has been replaced with at least another tree. Box Project – Lesson 2, slide 4.

25. OAK ASH WALNUTBEECH TEAK YEW MAHOGANY

26. KNOTS SPLITS

27. Box Project – Lesson 3, slide 2.

28. Box Project – Lesson 3, slide 3.

29. Box Project – Lesson 3, slide 4.

30. Box Project – Lesson 3, slide 5.

31. Box Project – Lesson 3, slide 6.

32. Re-Manufacture it Box Project – Lesson 3, slide 7.

33. 20% of the worlds Oxygen is produced by the amazon rail forest!! Up to 28,000 species are expected to become extinct by the next quarter of the century due to deforestation. Soil erosionSoil erosion, floods, wildlife extinction, increase in global warming, and climate imbalance are few of the effects of deforestation. increase in global warming Trees are important constituents of the ecosystem by absorbing carbon. Almost half of world’s timber and up to 70% of paper is consumed by Europe, United States and Japan alone. Half of the world’s tropical forests has already been cleared. The rate of deforestation equals to loss of 20 football fields every minute. Tropical rainforests which cover 6-7% of the earth’s surface, contain over half of all the plant and animal species in the world! Box Project – Lesson 3, slide 8.

34. Re-Manufacture it

35. Manufactured Board WHERE? They are manmade materials based on wood. They come in many different forms, depending on the composition of the source material: BLOCKBOARD - This is built up with a core of softwood strips bonded together with adhesive and covered with a sheet of plywood on either side. Used as a building material and for furniture manufacture including fitted kitchens / bedrooms. CHIPBOARD - This is made up of small chips of wood bonded together with resin and formed into sheets by compression. It is not as strong as plywood and block board but it is not expensive. Chipboard is often covered with a plastic laminate or wood veneer and used in furniture HARDBOARD - This is made from wood fibres that have been pulped. The pulp is put under pressure until the fibres bond to produce a tough board that is smooth on one side and rough on the other. It is not as strong as the other boards MEDIUM DENSITY FIBRE BOARD (MDF) - A quality board, relatively cheap. This board is composed of fine wood dust and resin pressed into a board. This material can be worked, shaped and machined easily. Paint can be applied to it without the need for an undercoat or primer. Used in the building and furniture trades. PLYWOOD - This is made from veneers (plies) of timber with each grain layer being at right angles to each other and bonded together by resin and pressure. A number of grades are available, designed to suit a variety of situations. 1. Marine plywood that is moisture resistant. 2. Weather and boil proof plywood. 3. Boil resistant plywood. 4. Interior plywood.

36. Manufactured Board WHERE? Large boards Can be easy to work with Comes in stock size Easily available Made from waste material Length, Width & Thickness Cheap HOWEVER Can be ugly Strong Generally internal use only, unless, specifically made for outside

37. Manufactured Board WHERE? Internal use only Although you can buy external boards at an additional cost Manufactured boards are used extensively internally: Furniture and doors and some construction uses manmade materials. Often they are covered with a veneer of laminate to look more appealing La minate Is a piece of plastic (ABS) that is used to decorate and cover the surface of a piece of material. The laminate may come in man forms, from basic colours, patterns and even substitute wood. Laminates are hard wearing and long lasting. School tables, kitchen worktops, bedroom furniture. Veneer A veneer is a decorative piece of wood that has been cut extremely thin. This is applied to a surface, often in pattern form to make the work look more attractive. Veneers have been used for many centuries. It allows the manufacture to use expensive looking materials, whilst keeping costs down.

38. Manufactured Board WHERE? MDF

39. Manufactured Board WHERE?

40. WHERE?

41. WHERE? They are manmade materials based on wood. They come in many different forms, depending on the composition of the source material: BLOCKBOARD - This is built up with a core of softwood strips bonded together with adhesive and covered with a sheet of plywood on either side. Used as a building material and for furniture manufacture including fitted kitchens / bedrooms. CHIPBOARD - This is made up of small chips of wood bonded together with resin and formed into sheets by compression. It is not as strong as plywood and block board but it is not expensive. Chipboard is often covered with a plastic laminate or wood veneer and used in furniture HARDBOARD - This is made from wood fibres that have been pulped. The pulp is put under pressure until the fibres bond to produce a tough board that is smooth on one side and rough on the other. It is not as strong as the other boards MEDIUM DENSITY FIBRE BOARD (MDF) - A quality board, relatively cheap. This board is composed of fine wood dust and resin pressed into a board. This material can be worked, shaped and machined easily. Paint can be applied to it without the need for an undercoat or primer. Used in the building and furniture trades. PLYWOOD - This is made from veneers (plies) of timber with each grain layer being at right angles to each other and bonded together by resin and pressure. A number of grades are available, designed to suit a variety of situations. 1. Marine plywood that is moisture resistant. 2. Weather and boil proof plywood. 3. Boil resistant plywood. 4. Interior plywood.

42. Decorative, nice grain, reddish brown, furniture……. Technically Yes, but largely No? A veneer is a very thin piece of the wood. This thin wood is then glued to MDF or chip board. It looks like the real wood, because it is, but so much less of the wood is actually used.

43. MODERNALTERNATE

44. Laminate flooring is a modern solution to wooden style flooring. As with many modern day products the boards are manufactured to a specific shape in order to be interlocking. Many modern day products are manufactured in this way to optimise ease of use.

45. 1.I’m making a garden bench? 2.I’m making a cheap kitchen table? 3.I’m making an expensive sideboard? 4.I’m need a hard wearing handle for my hammer? 5.I want to make a solid wood work bench? 6.Where would I not use MDF or manufactured boards? 7.How can I make decorative patterns in my work? Hardwood, probably Teak, its oily which is good for outside MDF/wooden frame – Melamine MDF/wooden frame – wood veneer maybe mahogany I would make this from ASH – Hardwood, good linear strength I would use Beech, it is very hard and a relatively cheap hardwood I would not use this material outside. By arranging wooden veneers in patterns

47. Manipulating and Combining Materials Candidates should learn: how materials can be combined and processed in order to create more useful, or desirable, properties; how these properties are utilised in industrial contexts; how a range of materials are prepared for manufacture, allowing for waste and fine finishing; about a variety of self-finishing and applied-finishing processes, and appreciate their importance for aesthetic and functional reasons; that to achieve the optimum use of materials and components, account needs to be taken of the complex inter-relationships between materials, form and manufacturing processes; how pre-manufactured standard components are used to improve the effectiveness of the manufacturing process and be able to identify a small range appropriate to the material areas studied. New materials Candidates should: have a knowledge and understanding that the development of new and smart materials are allowing designers to meet a variety of user needs in new and exciting ways e.g. –– Precious Metal Clays (PMC) used in jewellery manufacture, –– corn starch polymers used in packaging, –– thermochromic pigments used for thermal warning patches –– shape memory alloys –– Quantum Tunnelling Composite (QTC) used to incorporate electronics into textiles, have an awareness of the importance of the development of nanomaterials and integrated electronics in the area of Design and Technology.

48. Design and Market Influences Candidates should develop an understanding of the broad perspectives of the designed world. This will include the appreciation of line, shape, form, proportion, colour, movement and texture within a critical awareness of aesthetics and ergonomics. Evolution of Product Design Candidates should: identify ways in which products evolve over time because of developments in ideas, materials, manufacturing processes and technologies as well as because of social, political, cultural and environmental changes; have a basic knowledge and understanding of major design movements since 1900 e.g. Arts & Crafts Movement, Art Nouveau, Art Deco, Bauhaus, Modernism, De Stijl, Memphis, Post Modernism; recognise that design movements and cultural influences are still influencing new product development; have a knowledge and understanding that manufacturing industries are involved in continuous improvement (CI) and this is a major influence in product evolution; have a knowledge and understanding that sometimes new products are developed because of marketing pull and sometimes because of technological push

49. identify ways in which products evolve over time because of developments in ideas, materials, manufacturing processes and technologies as well as because of social, political, cultural and environmental changes; Social & Political

50. Family Slideshow

51. have a basic knowledge and understanding of major design movements since 1900 e.g. Arts & Crafts Movement, Art Nouveau, Art Deco, Bauhaus, Modernism, De Stijl, Memphis, Post Modernism;

52. recognise that design movements and cultural influences are still influencing new product development;

53. have a knowledge and understanding that manufacturing industries are involved in continuous improvement (CI) and this is a major influence in product evolution; have a knowledge and understanding that sometimes new products are developed because of marketing pull and sometimes because of technological push

54. Products evolve for a variety of reasons, including technological push and market pull, social changes and fashion. Products also change because manufacturers continually try to better their products, so time is spent assessing current work. Continuous improvement (CI) Companies that work to recognised standards such as BS EN ISO 9001:2008 can demonstrate production control and product quality to their consumers. Many internationally recognised companies such as Toyota and Rolls Royce, involve employees at every level in the process pf continuous improvement (CI). Groups of employees, known as quality circles, ensure the product is continually improving through contact with the client and updating the product specification. A range of issues may be taken into account including: New Technology Legislation Improvements to production methods Fashion Impact upon the environment Product maintenance Product durability and obsolescence Costs Feedback from the client or consumer Consumer Issues

55. Quality Control (QC): As a product or its component parts are manufactured, a series of samples may be taken from the production line and checked to make sure that each part meets a specific, previously set standard. This is known as quality control (QC) and may take place any time during production. Depending on the product it may be tested after every ten, hundred or thousand have been produced. These tests might include factors such as accuracy of dimensions, weight, flammability, fit and use. Manufacturers should include quality control checks for their own products. Quality Assurance (QA) is an overall approach to ensure that products attain a consistently high standard. Throughout the manufacturing process, materials, equipment, production processes and training of staff need to be checked an monitored. Consumer views will also be considered in the process. THE BSI kitemark and ‘CE’ marking relate to quality assurance as well as product safety. Some manufacturing guilds have their own quality standards and award a quality symbol, such as woolmark. Tolerance: If a large quantity of a product is to be made. It is not always possible to guarantee that every product is absolutely identical. So a tolerance may be applied dictating, for example, minimum and maximum measurements. Tolerances are the acceptable range of differences from the agreed standard. These differences are usually documented as plus and minus values, and would be applied to such factors as size, weight and performance.

56. have a knowledge and understanding that sometimes new products are developed because of marketing pull and sometimes because of technological push Market Pull is basically when society has a demand for a product. A good example of this are smaller and more environmentally friendly cars. Technology push is when new advances in technology allow for innovative and creative new products. The tablets we use today are a key example of this. Bill Gates in 2002 with his first tablet PC. The ipad was created in 2010.

57. Design in Practice Product development Candidates should: respond creatively to briefs, developing their own proposals and producing specifications for products and associated services discuss and analyse the situation/problem; know how to gather and respond to research, evaluate and select information and data to support the design and manufacture of products; consider the factors involved in the design of a product which is to be produced/manufactured in quantity; consider a wide range of users and create designs which are inclusive; determine the degree of accuracy required for the product to function as planned, taking account of critical dimensions and tolerances in determining methods of manufacture; understand how graphic techniques, ICT equipment and software, particularly CAD, can be used in a variety of ways to model aspects of design proposals and assist in making decisions; have a knowledge and understanding that design ideas are protected in law through copyright, patents and registered designs.

58. 1.the exclusive legal right, given to an originator or an assignee to print, publish, perform, film, or record literary, artistic, or musical material, and to authorize others to do the same. 1.a government authority or license conferring a right or title for a set period, especially the sole right to exclude others from making, using, or selling an invention If you register a design, you will be protecting the external appearance of the article.

59. Communication and representation of ideas Candidates should use a range of graphical techniques such as annotated sketches, formal drawing conventions, CAD to communicate design details in a clear and appropriate manner; develop a range of presentation techniques and media to portray materials, texture or finish such as mood boards, presentation drawings, digital photography, CAD; use line, tone, colour rendering using a range of media; use formal page layout techniques as an aid to planning and presenting drawings and information; use a range of prototyping and modelling methods in order to explore design alternatives during the design process as well as a means of communicating proposals which can be used for evaluation purposes; use a range of ICT equipment and software to communicate, model, develop and present ideas.

60. use a range of graphical techniques such as annotated sketches, formal drawing conventions, CAD to communicate design details in a clear and appropriate manner;

61. develop a range of presentation techniques and media to portray materials, texture or finish such as mood boards, presentation drawings, digital photography, CAD; use line, tone, colour rendering using a range of media; use formal page layout techniques as an aid to planning and presenting drawings and information;

62. Design Methodology Candidates should understand that designing is not a linear exercise but is iterative. The traditional design cycle is just one of many methods for successful designing; understand that empirical problem solving, a systems approach and intuitive designing are all valid approaches to designing; experience a variety of design approaches. Be able to use the following as starting points for designing and making: –– natural form, pattern and structure –– geometry and mathematics –– the work of well known artists, designers, craftsmen and technologists –– detailed product analysis –– religious and cultural influences.

63. Traditionally Task – Pre written Analysis – Work out what to do Research – Look at……..stuff? Ideas – Draw some pictures Development – Draw more ideas, but different Production – Make it Testing – Test it Implementation – Use it Evaluation – Evaluate Redesign – Accept it was rubbish and do it again Band Project – Lesson 2, Slide 2.

64. How can I research before I know what the design is? How do I develop an idea? I have no imagination. I really can’t draw! I drew my best picture…..EVER in my ideas!! I can’t develop it further? I have never made anything like this before, I don’t know how to make it. Band Project – Lesson 2, Slide 3.

65. Designing is no longer a Linear exercise. Mix it up! Band Project – Lesson 2, Slide 4.

66. understand that empirical problem solving, a systems approach and intuitive designing are all valid approaches to designing;

67. experience a variety of design approaches. Be able to use the following as starting points for designing and making: –– natural form, pattern and structure –– geometry and mathematics –– the work of well known artists, designers, craftsmen and technologists –– detailed product analysis –– religious and cultural influences.

68. Packaging Candidates should have a knowledge and understanding of a variety of materials and processes used to package products and to be able to balance the likely impact upon the environment in terms of social responsibility and sustainability; understand the different basic functions of packaging such as protect, inform, contain, transport, preserve and display; have a knowledge and understanding of the need for product labelling and the common symbols used to indicated hazards, storage and handling, maintenance, disposal and design protection.

69. Where does it all go?

70. The Great Pacific Garbage Patch

71. Packaging Candidates should have a knowledge and understanding of a variety of materials and processes used to package products and to be able to balance the likely impact upon the environment in terms of social responsibility and sustainability; understand the different basic functions of packaging such as protect, inform, contain, transport, preserve and display; have a knowledge and understanding of the need for product labelling and the common symbols used to indicated hazards, storage and handling, maintenance, disposal and design protection.

72. have a knowledge and understanding of the need for product labelling and the common symbols used to indicated hazards, storage and handling, maintenance, disposal and design protection. Put litter in bin Keep Britain Tidy POLYTHENE TEREPHTHALATE (PET) Recycleable alluminium Portions Do not dispose in bin (Batteries)

73. Product marketing Candidates should: have a knowledge and understanding of the power of branding and advertising and the effect that they have upon different consumer groups; be able to promote their own products using a variety of techniques, e.g. leaflets, flyers,

74. Band Project – Lesson 1, Slide 1.

75. Human factors Candidates should understand: that for products to be effective, designers, manufacturers and craftsmen need to take account of a wide range of human factors in an attempt to produce inclusive rather than exclusive designs i.e. access, cultural values; that anthropometrics and ergonomic considerations affect many design decisions; that design decisions for large scale manufacturing often aim to cover the needs of the 5th–95th percentile; the effect of colour used in product design to reinforce messages such as “danger” or to help to produce moods such as “warmth”; social, economic an ethnic groups of people often have specific values and needs which can be an aid to focused designing, i.e. disabled, elderly, religious groups; that efficient manufacturing systems result from the layout of materials, equipment and controls, such as working triangles in

77. Safety Candidates should understand: the relevance of safety with regard to themselves, the manufacturer and the product user; that designers and manufacturers have both a moral and legal responsibility for the products that they create; how to undertake simple tests to ensure that the products they make are safe for the specific user group they are designed for; the importance of risk assessment at all stages of designing and making.

78. Quality Candidates should: ensure that their products are of a suitable quality for their intended user; understand that many judgements regarding quality are subjective and will be dependent upon various criteria e.g. cost, availability of resources and other social factors; have a knowledge and understanding of commercial methods which are used to improve quality assurance e.g. quality circles, teamworking, BS EN ISO 9000; be able to devise and apply test procedures to check the quality of their work at critical points during development and manufacture,

79. Quality Control (QC): As a product or its component parts are manufactured, a series of samples may be taken from the production line and checked to make sure that each part meets a specific, previously set standard. This is known as quality control (QC) and may take place any time during production. Depending on the product it may be tested after every ten, hundred or thousand have been produced. These tests might include factors such as accuracy of dimensions, weight, flammability, fit and use. Manufacturers should include quality control checks for their own products. Quality Assurance (QA) is an overall approach to ensure that products attain a consistently high standard. Throughout the manufacturing process, materials, equipment, production processes and training of staff need to be checked an monitored. Consumer views will also be considered in the process. THE BSI kitemark and ‘CE’ marking relate to quality assurance as well as product safety. Some manufacturing guilds have their own quality standards and award a quality symbol, such as woolmark. Tolerance: If a large quantity of a product is to be made. It is not always possible to guarantee that every product is absolutely identical. So a tolerance may be applied dictating, for example, minimum and maximum measurements. Tolerances are the acceptable range of differences from the agreed standard. These differences are usually documented as plus and minus values, and would be applied to such factors as size, weight and performance.

80. Products evolve for a variety of reasons, including technological push and market pull, social changes and fashion. Products also change because manufacturers continually try to better their products, so time is spent assessing current work. Continuous improvement (CI) Companies that work to recognised standards such as BS EN ISO 9001:2008 can demonstrate production control and product quality to their consumers. Many internationally recognised companies such as Toyota and Rolls Royce, involve employees at every level in the process pf continuous improvement (CI). Groups of employees, known as quality circles, ensure the product is continually improving through contact with the client and updating the product specification. A range of issues may be taken into account including: New Technology Legislation Improvements to production methods Fashion Impact upon the environment Product maintenance Product durability and obsolescence Costs Feedback from the client or consumer Consumer Issues

81. Ethical, Environmental and Sustainability Issues Candidates should take into consideration the ethical, environmental and sustainability issues relating to the design and manufacture of products i.e. fair trade, product miles, carbon footprint, product disposal, and the following related principles: re-use, recycle, repair, reduce, rethink, refuse, etc. have a knowledge and understanding of the main factors governing environmentally friendly products, or “Green Designs” and be able to identify a range of these; have a knowledge and understanding of the main factors relating to recycling and/or reusing materials or products i.e. material identification, material separation, collection, processing,

82. take into consideration the ethical, environmental and sustainability issues relating to the design and manufacture of products i.e. fair trade, product miles, carbon footprint, product disposal, and the following related principles: re-use, recycle, repair, reduce, rethink, refuse, etc.

83. Fairtrade is a global movement which promotes fair pricing and work rates globally. Fairtrade is largely associated with farming, banana’s, chocolate, sugar, coffee and tea. Although not directly linked to what we do in school, knowing fairtrade exists, what it does and recognize the logo is a requirement for the exam. Product Miles What are product miles? Product miles are the total distance produce is transported from its place of growth or production to the place of consumption. The concept of product miles is widely used in food production where there is a push by consumers for locally produced products.

84. http://www.carbonfootprint.com/calculator.aspx A carbon footprint is defined as: The total amount of greenhouse gases produced to directly and indirectly support human activities, usually expressed in equivalent tons of carbon dioxide (CO2). In other words: When you drive a car, the engine burns fuel which creates a certain amount of CO2, depending on its fuel consumption and the driving distance. (CO2 is the chemical symbol for carbon dioxide). When you heat your house with oil, gas or coal, then you also generate CO2. Even if you heat your house with electricity, the generation of the electrical power may also have emitted a certain amount of CO2. When you buy food and goods, the production of the food and goods also emitted some quantities of CO2. Your carbon footprint is the sum of all emissions of CO2 (carbon dioxide), which were induced by your activities in a given time frame. Usually a carbon footprint is calculated for the time period of a year

85. Six words beginning with the letter R. Each describes an action that can be taken to reduce the environmental impact of products. Recycle Reduce Reuse Rethink Refuse Repair It’s important that designers do their part in taking these things in to account when designing new products. When a product comes to the end of its useful life, it has to be disposed of. No matter how we dispose of a product it will add tour carbon footprint, however, we can reduce the impact by using the 6 r’s

86. Products are converted back to their basic materials and remade into new products. Examples include: Glass crushed, melted and made into new bottles. Aluminium cans melted down to make new products Plastic bottles recycled into drainage pipes and clothing. (It takes 25 two-litre plastic bottles to make one fleece.) Designers and manufacturers of products need to design products for recycling. Car manufacturers are obliged to label all plastic parts in new cars to aid recycling of all those parts. Electrical and electronic products now have to include recycling instructions for the consumer. Many local councils now collect materials that can be recycled separately from normal domestic waste.

87. Consumers need to look to reduce the number of products they buy, or consider buying products that use less energy. Manufacturers are looking to design products that: have less materials in the product take less energy to manufacture need less packaging during transport. Retailers can reduce carbon emissions by transporting products straight to the consumer from the place of manufacture, instead of via warehouses and shops

88. Lots of items can be reused in the same form. Glass milk bottles are a classic product that is reused. A more recent product that can be reused is a printer cartridge, which can be refilled. Some products have filters that can be washed rather than using disposable, single-use filters. Consumers could sell or donate products they no longer use themselves, so that someone else can use them.

89. Consumers can ask the question, “Do I really need this product?” (Do you really need to replace your mobile phone every year?) Designers and manufacturers can make products that do the same job more efficiently. They can design the packaging so that it is easier to recycle (for example, by making the packaging from a single material).

90. The consumer has the choice as to whether they buy /use a product or not. They can ask the following questions: Should they refuse the product because it is too inefficient (in use, or in its use of materials)? Should they refuse the product because its packaging creates too much waste? (Disposable cups from the coffee shop, plastic carrier bags from the supermarket, plastic water bottles.) The designer and manufacturer have an increasing need to think about how the consumer will react to their products; will they refuse them? Disposable Refillable

91. Instead of throwing things away consumers need to think more about having things repaired. Designers have a responsibility to design products that can be repaired more easily. It takes fewer resources to replace a part of a product, than to replace the whole item. Could an item be upgraded instead of replace with a new one?

92. Around 65 million carrier bags are thrown away in the county every year, with many ending up in landfill sites where they take many years to degrade. What are supermarket’s doing to help reduce the number of carrier bays their customers use? Tesco’s are asking their customers to refuse the standard carrier bag and instead rethink about how they carry their shopping. Instead they offer bags for life. The customer can buy a thick carrier bag which can be reused. If the bag breaks they can exchange for a new one, the old one will then be recycled. They also offer a strong fabric bag - The Natural Green bag. This bag can also be reused but it can also be repaired should it need to be. Customers are also encouraged to recycle any unwanted carrier bags.

93. have a knowledge and understanding of the main factors governing environmentally friendly products, or “Green Designs” and be able to identify a range of these;

94. have a knowledge and understanding of the main factors relating to recycling and/or reusing materials or products i.e. material identification, material separation, collection, processing,

95. Consumer issues have a knowledge and understanding of the work of consumer groups and pressure groups and the way products are evaluated – e.g. Which? reports; have a knowledge and understanding of the work of standards agencies (BSI, ISO etc) and how these standards affect product design and manufacture and subsequent testing; have a knowledge and understanding that a wide range of legislation exists to protect consumers and that designers and manufacturers need to conform to it.

96. Product Manufacture Candidates should learn: how a range of materials are cut, shaped and formed to designated tolerances; the difference between quality control and quality assurance techniques; to produce detailed working schedules, e.g. flow charts, production plans, identifying critical points, i.e. QA and QC, in the making process and providing solutions to possible problems; to evaluate the quality of their personal project work and to devise modifications that will improve their products.

97. Quality Control (QC): As a product or its component parts are manufactured, a series of samples may be taken from the production line and checked to make sure that each part meets a specific, previously set standard. This is known as quality control (QC) and may take place any time during production. Depending on the product it may be tested after every ten, hundred or thousand have been produced. These tests might include factors such as accuracy of dimensions, weight, flammability, fit and use. Manufacturers should include quality control checks for their own products. Quality Assurance (QA) is an overall approach to ensure that products attain a consistently high standard. Throughout the manufacturing process, materials, equipment, production processes and training of staff need to be checked an monitored. Consumer views will also be considered in the process. THE BSI kitemark and ‘CE’ marking relate to quality assurance as well as product safety. Some manufacturing guilds have their own quality standards and award a quality symbol, such as woolmark. Tolerance: If a large quantity of a product is to be made. It is not always possible to guarantee that every product is absolutely identical. So a tolerance may be applied dictating, for example, minimum and maximum measurements. Tolerances are the acceptable range of differences from the agreed standard. These differences are usually documented as plus and minus values, and would be applied to such factors as size, weight and performance.

98. Products evolve for a variety of reasons, including technological push and market pull, social changes and fashion. Products also change because manufacturers continually try to better their products, so time is spent assessing current work. Continuous improvement (CI) Companies that work to recognised standards such as BS EN ISO 9001:2008 can demonstrate production control and product quality to their consumers. Many internationally recognised companies such as Toyota and Rolls Royce, involve employees at every level in the process pf continuous improvement (CI). Groups of employees, known as quality circles, ensure the product is continually improving through contact with the client and updating the product specification. A range of issues may be taken into account including: New Technology Legislation Improvements to production methods Fashion Impact upon the environment Product maintenance Product durability and obsolescence Costs Feedback from the client or consumer Consumer Issues

99. Methods of production Candidates should: understand that products are manufactured to different scales of production i.e. one-offs, batch, mass, continuous, just in time (JIT); design and make for one-off, batch and mass production; work as part of a team on the batch production of products and/or components; work as part of a team and experience different functions within simple batch production systems; use a range of procedures including CAD/CAM, where appropriate, to ensure consistency in the production of their products; use both hand and machine methods of cutting and shaping materials appropriate to the scale of production.

100. Single Item/One off PROTOTYPES SPECIALIST MODELS HANDMADE ITEMS SPECIALIST ENGINEERING ONE OFFS

101. Batch Production FURNITURE ELECTRICAL GOODS CLOTHING NEWSPAPERS BOOKS SAMPLE PRODUCTS

102. Production Line Continuous Production CARS PETROL / OIL PRODUCTS BRICKS MANY FOOD PRODUCTS WASHING POWDER WASHING-UP LIQUID CHEMICALS

103. CONTINUOUS PRODUCTION BASIC CARS WATER FOOD ITEMS PENCILS MEDICINE TOYS

104. Parts/components take up lots of room The idea of JIT is that we only get the parts when we need them at that stage of manufacture. Engine block – Made in Scotland, needed on day one of production. Piston, cranks, cams and gaskets – Made in London, needed on day two of production Rocker cover, exhaust manifold and belts – Made in Wales, needed on day three of production By using the JIT strategy, less money is wasted in storage and time in finding products. However production can be hampered with late deliveries

105. Methods of production Candidates should: understand that products are manufactured to different scales of production i.e. one-offs, batch, mass, continuous, just in time (JIT); design and make for one-off, batch and mass production; work as part of a team on the batch production of products and/or components; work as part of a team and experience different functions within simple batch production systems; use a range of procedures including CAD/CAM, where appropriate, to ensure consistency in the production of their products; use both hand and machine methods of cutting and shaping materials appropriate to the scale of production.

106. Manufacturing systems understand that commercial manufacturingis a system, or group of sub- systems which requires: –– special buildings or places of work; –– the organisation of people; –– the organisation of tools and equipment; –– risk assessment and compliance with health and safety regulations; –– the organisation of materials; –– information systems to help people communicate with each other reliably; –– ways of changing the shape and form of materials to increase their usefulness; –– ways of using tools and equipment to transform the materials into products; –– the design and production of many products in a systematic way; –– quality assurance procedures and quality checks to be made; –– efficient working methods; –– ways of safely taking care of the unwanted; –– outputs of manufacturing i.e. disposing or recycling of waste materials, and ways

107. Use of ICT (Information and Communication Technology) Candidates should understand how ICT facilitates a wide range of manufacturing functions, e.g. just in time (JIT), video conferencing, software sharing, stock control, data transfer and remote manufacturing; have an understanding of the application of CNC (Computer Numeric Control) in modern manufacturing as appropriate to a specific material area; understand how computer-aided manufacture (CAM) is used both in manufacturing in quantity and in the production of single items and small batches; understand how CAD/CAM allows for higher levels of accuracy, repeatability and efficiency.