1. Year 10

2. Exam – Real Exam 80 points and 90 minutes 10 reading – 1min per point G level standard question at the beginning and it gets harder as you go. Start off with simple questions, tool recognition and then an a simple product

3. Combining and detailing Then a Design question – 12 Product analysis question -13 Comparison of two similar products -13 A product analysis with environment kicker -14

4. Areas to revise Material – Oak, Mild Steel, Acrylic, PP, MDF, plywood, Alloys Finishes – for wood, Dip Coating, Electroplating Scale of production Manufacturing Techniques – Vacuum forming, blow moulding, cutting a thread in metal, Rivets. Other – EPOS, Internet, Kyoto Protocol Agreement

5. More other Elasticity, CNC, Smart Materials. Joints – not that types silly – methods of joining, wasting processes.

6. Lets get started Oak – Hardwood Properties – hard, tough, durable, high density Uses – High-quality furniture, garden benches, boat buildings, veneers Advantages – Finishes well Disadvantages – contains an acid which corrodes steel

7. More starting Ash – Hardwood Properties – tough, flexible, good elasticity Uses – sports equipment, ladders, laminated furniture, tool handles Advantages – flexible Disadvantages – can become a bit splintered

8. Board – you ain’t seen nothin yet Manufactured boards Plywood, Chipboard, MDF, Hardboard Available in large flat sheets, stable, decorated by veneers, ply and MDF can be easy to bend.

9. Board – you ain’t seen nothin yet Advantages of MDF MDF is available in large sections which means not having to join smaller planks together More dimensionally stable which means it is less likely to warp / twist /cup Cheaper than solid oak which means the table will cost less It results in more economical use of natural timbers which means that what natural timber we do have will last longer

10. Board – you ain’t seen nothin yet Plywood Aesthetics – Made of layers normally 1.5mm thick – grain of each later is at right angles to each other. Properties – Very strong in all directions, resistant to splitting because layers are in alternate directions.

11. Ply me to the moon Uses – boat building, drawer bottoms and wardrobe bottoms, tea chests, cheaper grades used in construction. Advantages – available in large sheets, thicker sheets will not warp or twist Disadvantages – thin sheets very flexible and will warp if not correctly stacked or supported.

12. Mild Steel – better for you Properties – tough, malleable, magnetic Uses – structural steel girders, car body panels Advantages - Easily worked and joined, even in a school workshop, relatively cheap, widely available in numerous forms and sections, can be recycled. Disadvantages – will oxidise (rust) if left unprotected, can only be case-hardened

13. Mild Steel – better for you Types of finishes that can be used include: plating powder coating (powder is applied electrostatically and allowed to cure in heat to form a hard skin - unlike paint doesn’t need a solvent to bind it) hammerite/paint; plastic dip coating (covers metals in a coating of polymer such as PVC to protect it) galvanising (protective zinc coating to prevent corrosion)

14. Advantages of MS over aluminium? Much cheaper than aluminium so the unit cost will be less making more profit mild steel has higher compressive strength than aluminium so can take greater forces mild steel is harder and tougher so will dent and not break as easily mild steel is easier to join/weld so therefore the process will cost less.

15. Quick test 1. Name me three different types of finishes that can be applied to mild steel 2. What are two properties of mild steel? 3. Draw or describe what a piece of plywood looks like 4. Name one advantage of mild steel over aluminium. 5. Give one use of the timber Ash. 6. Name an advantage and disadvantage of using oak.

16. Answers 1. Plastic dip coating, plating, galvanising, powder coating, hammerite/paint. 2. Tough, malleable & magnetic. 3. Made of layers normally 1.5mm thick – grain of each later is at right angles to each other. 4. Less expensive, tougher and harder, easier to join using welding. 5. Sports equipment, ladders, laminated furniture, tool handles. 6. Advantage – Finishes well, attractive, tough, durable Disadvantages – contains an acid which corrodes steel

17. Advantages of recycling MS less material is sent to landfill sites means that sites will last longer/not fill up as quickly Less mining will be required to find iron ore in order to make new steel / protects the landscape/environment Less energy is required than to produce new material Less resources required so natural resources last longer Less pollution from digging/mining materials

18. Alloy Mix of two metals Brass is 65% copper and 35% zinc Mild Steel is 99.8& iron and 0.2% carbon Properties Ductility - Definition – the ability to be drawn or stretched into thinner, smaller sections Toughness – Definition – the ability to withstand sudden and shock loading without fracture Elasticity – the ability to return to original shape once the deforming force is removed.

19. Heat treatment processes tempering - removes brittleness of the metal to make it tougher and harder - clean steel up and then heat it until the desired colour achieved (by comparing to colour chart). The piece of metal is then quenched in water immediately. Only used on high carbon steels. Normalising steel - makes the material tougher than it would by annealing. Does this by heating it to a critical temperature, soaking it and then allowing it to cool in air.

20. Heat treatment processes Case hardening - increases the carbon content of mild steels. Introduces a carbon surface. Can either heat it up to a cherry red and then dip into carbon powder (have to do this many times) or can put in a box packed with charcoal and heated up in an oven for several hours. The steel will have a softer core but hard outside.

21. Heat treatment processes Annealing - heating up a metal such as mild steel to relieve it’s internal stresses allowing you to work with it much easier. It is heated up and then allowed to cool slowly. This allows it to become softer and ductile and have no internal stresses. By working the metal (i.e. planishing, bending etc.) the metal becomes work hardened and brittle and annealing will have to be done again.

22. Materials Acrylic Good impact strength (not shatter but in large pieces), lightweight, good electrical insulator, durable Car indicator covers/reflectors, baths and bathroom furniture, ornamental fish tanks Advantages – can be recycled, excellent environmental stability, polishes and finishes well, available in numerous colours Disadvantages – relatively soft, scratches easily, poor chemical resistance.

23. ABS High impact strength, tough, scratch-resistant, lightweight, durable, good resistance to chemicals, good electrical insulator Uses – kitchenware, camera cases, toys, car components, telephone cases Advantages – available in numerous colours Disadvantages – relatively expensive when compared with polystyrene

24. Thermosetting plastics Made up of lines of molecules which are heavily cross- linked. It creates a rigid molecular structure. They may be heated the first time and shaped but they become permanently stiff and solid. They cannot be reshaped again. Epoxy resin Melamine formaldehyde (MF) Polyester resin (PR) Urea formaldehyde (UF)

25. Smart Materials – literally can add up and stuff Photochromic Paint Shape memory alloys Reactive Glass Carbon nanotubes

26. Scale of production One off production -one product is made often a prototype. Batch production -A small quantity of the product is made two or more up to one hundred. Mass production - A large number of the product is made on a production line. Many hundreds of the product could be made. This is often called repetitive flow production. Continuous production - Many thousands of the product are made. The difference between this and mass manufacturing is that continuous production is on 24 hours a day. Just in time production - The arrival of parts at just the exact time that they are required in the factory

27. Wasting processes When materials are removed i.e. using the wood or centre lathe, milling machines, laser cutter, fret saw, disc sander and hand tools such as files, saws and planes etc. Forming processes are when the material is shaped into desired form without removing any material i.e. vacuum forming, injection moulding, bending, forge work etc.

28. Advantages of injection moulding produces identical copies so each one is made to the same standard; no overhangs / undercut shapes which means it can be easily released from the mould, several can be made in one mould making it cheaper in the long run no additional surface finishing is required which means the overall production time is faster, high tolerances can be achieved which means the pieces will be very accurate it is a self-finishing process which means no other surface treatment will be required.

29. Blow moulding For making bottles and things which are hollow Advantages – very cheap unit costs, highly automated process, hot very labour-intensive, idea for high volume, continuous production since it can run 24/7 Disadvantages – initial costs of machine and tooling very high, not suitable for small production runs, sometime a seam is left around product when mould closes, products sometimes need to have flashing removed.

30. Extrusion Materials such as polystyrene, nylon, polypropylene and polythene can be used in a process called extrusion. These are thermoplastics - this means when they are heated and then pressured in a mould they can be formed into different shapes and sections These are cut and welded to form whole units such as uPVC window frames

31. Vacuum forming Lightweight, hollow products can be made, relatively cheap mould can be made from MDF in the school workshop for a one-off item, surface texture can be moulded into products. Thermoplastic materials sometimes thins too much and may burst or pop, webs sometimes form between items, meaning that the formed product cannot be used, products need to be trimmed and cut out.

32. Adhesives PVA Epoxy resin Tensol cement Contact adhesive

33. Knockdown fittings They are usually fixed with screws to the two pieces being joined and are pulled tightly together by a locking screw. Most are used for temporary joints which hold pieces together without the use of glue. They are usually used with self assembly furniture.

34. Tap & Dies cutting tools used to create screw threads, which is called threading

35. Video conferencing advantages include less travel required so time can be saved / fuel saved / emissions reduced cheaper because no travel expenses will be incurred lots of people can be involved which means decisions can be taken by all parties involved in the project time can be saved in the overall design and manufacture because discussion can take place live and decisions made

36. Waste minimisation in furniture making reduce packaging of materials which will reduce the amount that needs to be thrown out use biodegradable packaging materials which will break down quicker / will reduce the amount of space required in landfill use recycled materials / better for the environment; make sure standard size boards and material sections are used any off cuts can be used for smaller other parts / new products waste can be burned to provide heat for the factory good lay planning to ensure effective use of material reduce section sizes / use standard sizes/ keep sections square accuracy of marking out and cutting