1. Edexcel – Product Design: Graphics
Other Materials
Edexcel – Product Design: Graphics

2. Other Materials Composites Modern materials and products
materials made from two or more constituent materials with significantly different physical or chemical properties
Modern materials and products
Smart Materials
have properties that react to changes in their environment

3. Composites Carbon fibre Glass reinforced plastics (GRP)
Medium density fibreboard (MDF)

4. Composites Carbon fiber Sports equipment
Excellent strength to weight ratio
Very expensive, only available in black, hard to recycle
high stiffness,
high tensile strength,
low weight,
high chemical resistance,
high temperature tolerance,
low thermal expansion,

5. Carbon Fiber Production
The carbon atoms are bonded together in crystals
Atoms are aligned parallel to the long axis of the fiber
This gives the fiber high strength-to-volume ratio (making it strong for its size).
Several thousand carbon fibers are bundled together to form a tow
Can be used by itself or woven into a fabric.

6. Carbon Fiber Advantages Excellent strength to weight ratio
Better tensile strength than steel alloys
Can be formed into complex and aerodynamic one piece structures
Disadvantages
Very expensive
Only available in black
Highly specialised manufacturing required
Cannot be easily repaired as structure loses integrity
Cannot be easily recycled

7. Composites Glass reinforced plastics (GRP) Vehicle bodies
Excellent strength to weight ratio
Expensive, high quality mould needed
GRP, sometimes called glass fibre. is stranded glass that is set in a polyester resin . The glass fibres are approximately 50 mm long and are bonded together in a flexible mat. The polyester resin is in liquid form. A catalyst, or hardener, is added to the res in to start a c hemica l reaction and make the resin set. A colour pigmen t is also normally added. The glass fibres proVide strength , while the resin
bonds the fibres and prov ides, in the gel-coat, a smooth surface finish.

8. GRP How it’s made: Highly polished mould
Mould covered with release agent
First layer is gel coat (coloured polyester or epoxy resin)
Polyester resin and catalyst/hardener is mixed to ensure resin ‘sets’
Chop strand mat/glass fibres or woven wordings used
Layers of polyester resin and chopped woven & layered on mould
air rolled out of polyester resin, CSM layers
Can be hand rolled or use resin/CSM spray gun
Edges need to be trimmed after lay up
Mould is removed leaving shell structure

9. GRP Moulds

10. GRP

11. GRP Advantages Excellent strength to weight ratio
Resistance to corrosion
Water resistant
Ideal for external shell structures
Wide range of colours (pigments added to resin)
Can be repaired easily
Disadvantages
Expensive material
Specialised manufacturing process required
High quality mould needed

12. Composites Medium density fibreboard (MDF) Flat pack furniture
Consistent in all directions
Heavier, dulls blades quicker

13. MDF Advantages Less expensive than natural timbers
Available in large sheet sizes and range of thicknesses
No grain (so no tendancy to split)
Consistent strength in all directions
Disadvantages
Heavier (resins are heavy)
Requires appropriate finishes to seal surface fibres
Swells and breaks when waterlogged
Warps or expands if not sealed
Duls blades quickly
Contains urea-formaldehyde which causes eye and lung irritation when cutting and sanding

14. Modern materials and products
Liquid crystal displays (LCDs)
Phosphorescent pigments
Electroluminescent (E.L.) lighting

15. Modern materials and products
Liquid crystal displays (LCDs)
Digital watches and TV’s
Goes dark when a voltage applied
In TV’s has RGB layers

16. LCD Displays Benefits Slim/lightweight/suitable for portable devices
Quick response to data input
Range of colours on display
Can be used to display photos/ moving images/web/
Low power so very little battery use
Clear to see/high resolution

17. Modern materials and products
Phosphorescent pigments
“Glow in the dark”
Absorb energy from light and stores it during the day
Releases slowly at night

18. Modern materials and products
Electroluminescent (E.L.) lighting
Used for LCD backlighting and advertisements
Converts electrical energy into light
Waterproof and highly visible

19. E.L. Lighting How it works: Coverts electrical energy into light
Power is applied across electrodes
Organic phosphor sandwiched between the electrode conductors
When electrical charge is applied phosphor crystals are charged
Phosphor crystals emit radiation which is seen as light
(different organic compounds emit different colour light/green/yellow)
Features
Extremely low current/very high voltage
Low energy consumption
Can be ‘packaged’ in variety of panels/wires/strips for different applications

20. Smart Materials Thermochromic liquid crystals/film
Piezoelectric crystals
Smart ink
Radio frequency identification (RFID)

21. Smart Materials Thermochromic liquid crystals/film
Reacts to temperature
E.g. Forehead thermometers
The conductive ink is screen printed onto film (or other material) – on the back
On top is a layer of normal ink (if needed)
There is then a thermochomic layer, which is black when cool

22. Smart Materials Piezoelectric crystals
Converts movement into electricity and back
Used in inkjet printers to push out ink
Convert kinetic energy (movement energy) into a voltage
Expands and contracts when electric current is applied

23. Smart Materials Smart ink Also known as electronic ink (or e-ink)
Kindle
Displays only use energy when the display is refreshed

24. Smart Ink (e-ink) How it works:
Top transparent electrode, bottom electrode
Clear fluid
Negatively charged black pigment/beads
Positively charged white pigment/beads
Labels for +/- charges on bottom electrode

25. Smart Materials Radio frequency identification (RFID)
A method of identification
Uses tags to store and track data
Used in libraries, factories etc
Benefits / uses:
Replaces need for regular stock management/inventory control
Reduces labour costs due to ability of self-scanning
Reduces theft/allows link to store security
Allows for easier stock/product identification
Reduces re-stocking/JIT stocking of products
Allows product tracking
Allows for sales analysis/track how many are being sold

26. RFID: Features Radio waves/wireless system to transmit/ store data.
A method of identification using tags.
Transmission is two way.
The transmitter sends a signal.
The transponder receives the signal.
The transponder transmits a response signal.
Transmitter then receives the signal.
Transmitter also known as the reader.
Transponder known as tag.
Tag is attached to the product.
Transmitter identifies position of the tag / product.

27. RFID Disadvantages of RFID Potential loss of privacy (1)
Passive (receive only) and active (transmit and receive) tags can be inbuilt into labels and products (1)
Auto price checking (1)
Stock levels can be measured automatically/Auto reordering when low (1)
Don’t have to scan products so reduces queue time when purchasing goods (1)
Anti theft properties/alarm trigger as products tags can hold unique info (1)
Marketing information can be made available/tracking product sales (1)
Simple to install in products for tracking (1)
Not easy to replicate information held (1)
Do not require direct line of sight to work (1)
Range can be greater distance (1)
Disadvantages of RFID
Potential loss of privacy (1)
Big brother is watching you scenario (1)
Interference can hinder reception/affected by certain materials (1)
Range can be short: Passive (1)
Reliability still not known as RFID is relatively new (1)
Could be used by non-emergency services/ non-official services to monitor (1)
Adds cost (1)

28. Task On the computer on the student dropbox: Fill out the sheet
Subjects and Departments / Design Technology / Graphics / Year 12
Open the topic you are given
Fill out the sheet
Write a brief description for each material
Find images of example products
Advantages and disadvantages of each material
Composites
Modern materials and products
Smart Materials