1. You are not alone! Brian Russell

2. The examination room Surrounded by 160 other students Surrounded by good examples of design Surrounded by loads of materials and finishes Surrounded by standard components Surrounded by different examples of manufacturing

3. The exam pack Both the pencil case and the rule are made from PVC which is a thermoplastic The pencils are made from cedar which is a softwood The eraser is made from a synthetic rubber which is an elastomer The pencil sharpener has been die-cast from aluminium The BIC pen has a polystyrene barrel and a polypropylene top The Berol pen is made from polypropylene

4. BIC pen László and George Bíró designed the first ballpoint pen in 1931 and we continue to use the word Biro to describe all ballpoint pens. In 1950 Marcel Bich bought the patent for the pen from Bíró, which soon became the main product of his BIC company. A Design Icon! Design Icons set the standards for other products to follow

5. Safety Have a look at the pen top Most are now manufactured with a hole in them This is to prevent children choking to death if they swallow them This is a great example of risk assessment!

6. Safety The Berol pen has a similar breathing hole in the pen top Although this type of pen is a quality product, providing a good line at low cost it has built in designed obsolescence (it has a very limited lifespan). From an environmental viewpoint it is hard to justify this type of product as it cannot be repaired, refilled and is also difficult to recycle.

7. Just a polo shirt? Designed by René Lacoste in 1926 and originally known as the tennis shirt the design for the polo shirt has been copied by manufacturers throughout the world. It’s a Design Classic Another Design Icon!

8. What else do we know? Made from piqué cotton jersey knit (which means the fabric is knitted not woven) The logo is CNC embroidered in small batches A great example of batch production because only small quantities are needed.

9. Flexible manufacturing The computerised machine embroidery file can be quickly swapped to produce a different logo for another organisation This is a simple example of flexible manufacturing

10. And the sweatshirt? Also batch produced The fabric is a mixture of cotton and polyester A good example of a combined material

11. Combined materials Materials are combined to improve the properties or to create a material with enhanced properties Don’t write “to make it stronger”. Lycra is added to denim to make the material stretch. Polyester is added to cotton to make it more crease resistant. It also reduces the cost.

12. Properties of materials Breathable Washable Flexible Soft Good insulator...... If asked to describe the properties of a textile material use descriptions such as:

13. What else are you wearing? Just check out how many standard components you are wearing It is usually cheaper to manufacture these in large quantities in specialist factories rather than for each manufacturer to make their own Repairs are much easier when standard components are used Standard components generally help products to be considered as more environmentally friendly

14. What are standard components? These are pre-manufactured parts which are bought in to aid the production of the product Nuts, bots, screws, buttons, zips etc. are all standard components In the food industry, components would include stock cubes, sauces, pastry cases, pizza bases, chocolate flakes etc.

15. Benefits to manufacturers and users These might include: Lower costs due to economies of scale Consistent quality Easier to maintain Better for re-using spare parts Standardisation of sizing Ease of production Reduced need to carry stock

16. Just a school chair? The school chair is based upon another Classic Design by Robin Day “The Polypropylene Chair” Over 14 million of the original chairs have been produced Loads of copies A Design Icon because it was so innovative when first designed

17. Why so popular? Very cheap to produce in large quantities Ergonomically very good – fits almost everyone! Seat is flexible Stacks so easy to store/transport Very easy to copy once Robin day had done the hard work. Copies are made under license as the design is patented.

18. Design protection Copyright Registered Design (often used with trade marks) Trade Mark Patents Design ideas are protected by law and products usually carry one of these symbols

19. Polypropylene Don’t forget, you are propped up on a polypropylene chair! Polypropylene is a thermoplastic

20. Properties of materials If asked to describe the properties of the materials used in the design of the chair use descriptions such as: Polypropylene seat is flexible Legs are stiff and rigid

21. 5 th – 95 th percentile When considering anthropometric data ignore the extremes Top 5% and bottom 5% taken out Consider the rest as a normal range Be selective – tallest for doors, shortest for chairs? The Polypropylene Chair is an excellent example of this as it is comfortable for almost everyone.

22. Ergonomics Size Comfort Stability Safety How easy to lift and stack... Ergonomics is generally concerned with how easy and efficient products are to understand and use:

23. Design features Seat is injection moulded in one piece in polypropylene – can you see the injection point? Legs are fabricated in mild steel – welded together then powder coated Screwed to seat (an example of a standard component!) Try feeling these features when you are sitting on the chair!

24. Quality assurance How could you ensure that each of the chairs are manufactured to the same quality? Injection moulding ensures all of the seats are the same. Jigs are used to hold all of the metal parts in the correct position before welding

25. Quality assurance Often involves self-checking by workers of their own quality against agreed standards Puts more emphasis on prevention of poor quality rather than checking for poor quality Establishes quality standards and targets for each stage of production

26. Quality assurance Control checks are made at various stages Samples of the correct standard are given to the customer Rigorous testing takes place The BSI Kitemark means the product has been independently tested CE means that the product has been approved for sale in the European Union and may only have been tested by the manufacturer.

27. Quality assurance – Key terms Fitness for purpose (the product should be suitable for the intended purpose) Right first time every time (mistakes should be eliminated).

28. Manufacturing tolerances Acceptable range of difference from standard Sometimes measured in plus/minus No product manufactured in quantity can be considered to be perfect in every detail

29. The exam desk Made from mild steel tubing with a MDF top Designed to fold for easy storage/transportation Furniture like this is usually batch produced Saving space is a vital as they are only used for a few weeks a year

30. Ergonomics continues Designed to complement the school chair Correct working height Regulation size work area and is a good example of a working triangle as everything is easily within reach Designed to fit the 5 th -95 th percentile

31. Materials and manufacturing The desk top is a good example of a combined material The top is MDF with a melamine laminate on top Melamine formaldehyde is a thermosetting plastic The slot has been routered Using standard materials has helped keep the cost down

32. Properties of materials If asked to describe the properties of the materials used in the design of the table use descriptions such as: Table surface is firm, smooth and hard wearing Legs are stiff and rigid Because the legs are hollow tubes they are also lightweight

33. Materials and manufacturing The frame has been formed from mild steel round tubing hinged with two machine screws and nuts It has been powder coated to give a hard durable finish The top is held in place using a screwed bracket and a folded steel clip The screws are a standard component as are the plastic feet!

34. Designed for 5 th – 95 th percentile Whilst the table is a fixed size many products adjust to make them more suitable for a wider range of people This has been a regular question in the past

35. Adjustable products Designed to be adjusted to fit a range of sizes: Belts Watch straps Bras.... You might be wearing the answer

36. Don’t take spectacles for granted They are another great example of flexible manufacturing. The frames are mass produced (but adjusted for each customer) The lenses are sometimes made as one-offs They are assembled using standard components such as screws Every pair built to match your own prescription!

37. Specs may remind you Two different smart materials are sometimes used in spectacles Think “specs can make you look SMART”

38. Photochromic materials These materials change colour in response to changes in light. Some spectacles have reactive lenses which become darker as the light increases

39. Shape memory alloys Shape memory alloys are used in some spectacle frames and these super-elastic alloys can be squashed beyond the point other frames would snap and will return to their original shape at room temperature.

40. Jewellery The jewellery you and your fellow students are wearing can also be a great resource. Metals and jewels are all non-renewable materials

41. Jewellery Jewellery is often constructed using standard components. These are known as “findings”. Using standard components make it much easier to repair or replace lost parts

42. Jewellery Think about all of the metals you might be wearing: Gold Silver Platinum Titanium Anodised aluminium These are all non-ferrous metals

43. Watches as well Many watch parts are standard components such as straps, hands etc. Leather straps are a good reminder of renewable materials (can be re-grown) Think about all of the human factors which have been taken account of

44. Keys The keys in your pocket are also a resource Standard blanks are manufactured in large quantities using mass production They are usually cut in small batches Replacement keys are cut as one-offs Most commonly made from brass or nickel alloy The blanks are usually forged or stamped out

45. Key cutting Usually done with a grinding operation This is an example of the general manufacturing group “wastage” It is easy to remember as the bits of metal that are cut off the blank are waste materials Grinding is a type of abrading process

46. Key fobs The pewter cast key fobs you made are a great example of a product you could manufacture in quantity in school. Think of simple shapes with any decorative parts as a raised layer.

47. Chocolate moulding The same basic design could be used for chocolate moulding Keep it simple!

48. Water bottle Take a water bottle into the exam Blow moulded from PET (think of it with a furry tail!) The top has been injection moulded from HIPS Every year over 50 billion plastic water bottles are sent to landfill in this country A great example of a product which should be recycled, or even better, reused!

49. The exam paper itself! The exam paper booklet has been printed using offset lithography The colours are produced from 4 process colours – yellow, cyan, magenta and black It is made from A3 paper which has been creased and stapled Staples are a standard component!

50. Offset lithography This is the best process to specify for printing your packed lunch container if you are using solid white board

51. Flexographic printing This is the best process to use if you are printing onto Kraft board

52. Die-cutting Die-cutting is the method card shapes are cut out. A rounded blade creases where the container will be folded. The exam paper is one of the few paper products that is not die-cut as a guillotine is used because all of the sides are straight

53. Die-cut lunch containers Remember that the first question will require you to design a packed lunch container which will be die cut. You will need to be able draw it 3D This question is likely to take more than the allocated time!

54. Solid white board Solid white board is best if printing in full colour

55. Kraft board Kraft board is made from recycled fibres, this is an unbleached board which is a pale brown colour. It is the best material for the environment

56. Which type of card? Sustainability Biodegradable = Kraft board Compostable Full colour printing = Solid white board The answer may well be written in the design question itself. Read it carefully

57. Envelope bottom net This type of container uses an envelope bottom

58. Crash bottom net This type of container uses a crash bottom

59. Adding dimensions Make sure that you know how to accurately show three main dimensions. Use projection lines then neat arrows which touch the projection lines. Measurements should be in millimetres.

60. Dimensioning the handle Do not put dimensions over the top of the drawing

61. Adding a window Rounded corners are much stronger Use cornstarch for the window

62. The exam room The doors are made from blockboard as they need to be very strong The door furniture (handles etc.) are all standard components The doors and frame are finished in gloss paint Walls eggshell paint on concrete block Climbing bars varnished What other finishes can you identify? How many other components?

63. Blockboard This is a manufactured board made up of a core of softwood strips. These strips may be up to about 25mm wide. The strips are placed edge to edge and sandwiched between veneers of hardwood. The sandwich is then glued under high pressure.

64. Paints and varnishes Gloss-finish paints are generally more resistant to damage than emulsion paint, more resistant to staining, and easier to clean. Eggshell paint is also very durable but does not shine as much so good for rougher surfaces Emulsion paint is a mix of oil and water and is not very durable Varnish is simply a transparent finish. Think of it as a clear paint which can be gloss or eggshell Paints and varnishes are used to protect the materials and to improve the visual appearance

65. Concrete blocks Concrete is a great example of a combined material Made of sand, gravel and Portland cement it is very strong at withstanding compression forces The materials which make up concrete are non- renewable as they come out of the ground

66. There is always a clock Made from standard components Clock mechanisms are now standard components! Clock face screen printed Powered by battery Batteries cause big environmental problems!

67. Environmental issues - batteries Means that the product cannot be placed in a normal bin and needs specialist recycling facilities. Usually found on electrical products and batteries This has been a very common question in recent years

68. Instruction board Usually a flip chart to record start and finish time Aluminium frame The whiteboard surface is melamine formaldehyde covered chipboard or MDF and is another good example of a combined material Lots of human factors to consider – size weight etc.

69. Aluminium A lightweight non-ferrous metal Usually a dull grey colour although it can be polished to a very high gloss Frames are made by extruding the aluminium (which means pushing it through a shaped die) This is a good example of forming materials

70. Feel better? No other exam has so many resources to assist you But don’t turn around to look around! You are being watched!