1. 1 Preparing for the written paper (or 12 tips to success) 1 st July 2003 Brian Russell Chief Examiner Principal Moderator GCSE Product Design

2. 2 Tip 1 – Be equipped You will need: Blue or black pen (take a spare) Pencil (take a sharpener) Coloured pencils (a range) 300mm Ruler Eraser

3. 3 Tip 2 – Pace yourself Don’t rush Read the questions carefully Spend approximately a minute per mark Don’t waste time Don’t use colour until you have completed the written questions Improve drawings if time allows

4. 4 Tip 3 – Materials/components Where do materials come from? How are materials classified (grouped)? What are components and why are they used? Know about paper/card: Where it comes from How it is made How products are cut from paper/card

5. 5 Making Paper Trees cut & shredded Water added Boiled up to make wood pulp Chemicals and dyes added Pulp poured over fine mesh and squeezed between rollers

6. 6 Cutting Paper/card Die-cutting (creasing done with rounded blade) I Cut – Die Cut

7. 7 Tip 4 - New Products Where do ideas come from? Nature, geometry, other products….. Can you name a designer? Can you explain why their products are successful?

8. 8 Tip 5 – Product evolution Why do products change over time? New materials New manufacturing methods New technologies Social changes Fashions/trends Legislation

9. 9 Continuous improvement Manufacturers need to keep improving their products to stay competitive or to meet changing regulation/legislation. Production staff Consumer/retailer feedback Maintenance engineers Pressure groups (environment) Financial savings…….

10. 10 Tip 6 – Packaging The purpose of packaging is to: Protect Inform Contain Transport Preserve Display I PICT PD

11. 11 Food packaging Materials (food grade) Composite materials Spillage Security Hygiene Insulation Legal requirements How are they made?

12. 12 Graphics Clear text Simple bold images Impact Can you explain how the artwork would be done using a computer?

13. 13 Labelling Key information found on labelling Includes: Product name Description Safety information Contents Storage/maintenance information Environmental information

14. 14 Tip 7 – Human factors Anthropometrics Ergonomics Improving comfort Working triangles Special groups Adjustment for different sizes

15. 15 Tip 8 – Product maintenance Symbols found on a range of products and their packaging/labelling Maintenance schedules

16. 16 Product maintenance Care labels

17. 17 Tip 9 - Consumer Protection BSI Kite Marks European Standards (Conformité Europeenne) Trade association standards

18. 18 Tip 10 - Manufacturing Preparation of materials Industrial manufacturing processes Use of labour Quality Assurance/Quality Control Implications of ICT Scales of production

19. 19 Your own manufacturing Ensure that you can explain: How you would make models and prototypes The tools you would use Use of quality control Manufacturing aids (e.g. jigs) Making in quantity

20. 20 Commercial manufacturing Materials are processed using: Moulding/casting Forming Wastage/separation Conditioning Assembling Finishing

21. 21 Health & safety Consider: Your own safety when making The user’s safety Manufacturing processes Manufacturing waste Risk Assessment

22. 22 Tip 11 – CAD/CAM Computer Aided Design Computer Aided Manufacture Advantages: Sharing information Accuracy Repeatability Flexibility (ease of making changes) Speed……

23. 23 Computer Aided Manufacture Printers Vinyl cutters Milling/engraving machines Routers Lathes Laser-cutters Embroidery machines Rapid prototyping

24. 24 Inkjet & laser printers Used for one-offs/prototypes Small print runs Large areas Direct onto fabrics/carpets Transfer printing Sublimation printing

25. 25 Vinyl cutters Signs (especially vehicles) Graphics on prototypes Iron-on vinyl (T shirts) Labels for prototypes Card nets for prototypes Masks for stencilling/sandblasting Decoration on ceramics

26. 26 Milling/engraving machines Cutting flat (2D) shapes in rigid materials Engraving copper board for electronics Signage name plaques etc. Raised forms (3D)

27. 27 Routers Used mainly on timber (MDF) and rigid foams 3 axis – partial 3D 4 axis – turns material to get full 3D 5 axis – full 3D, much better detail

28. 28 Lathes Work revolves against cutter Cylindrical Conical Spherical

29. 29 Laser cutters Very accurate cutting for sheet materials engraving

30. 30 Embroidery Machines Detailed designs on fabric Text & graphics Repeat patterns

31. 31 Rapid Prototyping Prototype built up layer by layer – Stereo lithography 3D printing 3D layering

32. 32 Tip 12 – Buy a Revision Guide Written for this course Read it Use workbook to check your understanding