1. Preparing for the written paper
Next Page is What is CADCAM
Brian Russell & R Bramhill

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. 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. Multiple choice
If the question asks for four responses from eight, have a go at the lot!
Examiners mark them all and award up to the maximum mark so it is always worth having a go at more than the minimum

5. Tip 3 – Materials/components
Where do materials come from?
Are they renewable/non-renewable?
How are materials classified (grouped)?
What properties do different materials have?
What are components and why are they used?
Stock forms available?
Why materials are combined?
Surface finishes?

6. Paper and card compulsory
What you need to know:
Where it comes from
How it is made
Properties of different papers/cards
How products are cut from paper/card
How is it printed

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

8. Offset lithography Flat aluminium plates (specially treated)
Photographically exposed then wrapped around roller
Exposed parts attract water
Non exposed parts allow ink to stick
Print onto plain roller to reverse image
Transfers to card or other materials

9. Flexographic printing
uses a printing plate made of rubber, plastic, or some other flexible material.
Ink is applied to a raised image on the plate, which transfers the image to the printing

10. Tip 4 – Design methods Research methods Market research
Product Analysis
Questionnaires
Consumer trials
Modelling and testing
Mock-ups/prototypes
Specifications (design, product, manufacturing)
Evaluation

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

12. Design Icons
Classic design
Innovative
Often copied

13. Retro design
Modern products based on styling from the past

14. Technology push/Market pull
How new markets are created
How products are developed to meet specific markets
Can you identify the market by analysing the product?

15. Product Analysis Can you comment on: Materials used – their properties
Function – strengths and weaknesses
Human factors – ease of use
Style – aesthetics
Manufacturing - processes used

16. Tip 5 - Human factors Anthropometrics Ergonomics Improving comfort
Working triangles
Special groups
Adjustment for different sizes
Specific markets
Access

17. Tip 6 – Product evolution
Why do products change over time?
New materials
New manufacturing methods
New technologies
Social changes
Fashions/trends
Legislation

18. 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…….

19. Tip 7 – Packaging I PICT PD The purpose of packaging is to: Protect
Inform
Contain
Transport
Preserve
Display
I PICT PD

20. Card nets Flat shapes which fold into 3D forms
Often food related in exam
Glue tabs
Locking tabs
Position of images
Position of text

21. Other packaging methods
Plastics – blow moulding, blister packs, bags
Metals – aluminium, steel, cans, foil
Glass – jars, bottles
Recycling issues

22. Packaging issues Hygiene Security Composite materials Spillage Access
Insulation
Legal requirements

23. Graphics Clear text Simple bold images Impact
Position of logo/information
Can you explain:
How the artwork would be done using a computer?
How it would be commercially printed?

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

25. Environmental Issues Recycling symbol Disposal of Waste Equipment
Green dot
Specific Material Information

26. Design Protection Copyright Registered Design Trade Mark Patents
(often used with trade marks)
Trade Mark
Patents

27. Tip 8 – Product information
Symbols found on a range of products and their packaging/labelling
Maintenance schedules
Assembly instructions
Handling instructions
Storage instructions

28. Product maintenance
Care labels

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

30. Social issues
Environmental:
Product life cycles
Throw-away products

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

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

33. Manufacturing in quantity
Name a suitable material
Process to be used:
CAD/CAM, moulding, stamping, forming, printing etc.
Order of work
Quality assurance
Health & safety
200 needed

34. Manufacturing aids Explain how you would use: Jigs, moulds, formers
Patterns/templates
Die cutters/press knives
What are the advantages of these?

35. Organising manufacturing
Production lines
Work spaces
Sequencing tasks

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

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

38. Tip 11 – Using ICT Computer Aided Design Computer Aided Manufacture
Computer Numerical Control
Advantages:
Sharing information
Accuracy
Repeatability
Flexibility (ease of making changes)
Speed……

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

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

41. 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

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

43. 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

44. Lathes
Work revolves against cutter
Cylindrical
Conical
Spherical

45. Laser cutters
Very accurate cutting for sheet materials
engraving

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

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

48. ICT in Manufactring Further than CAD/CAM
Electronic Data Interchange (EDI)
Electronic Product Definition (EPD)
Product Data Management (PDM)

49. Remote manufacturing Very common especially in the printing industry
Maximises savings by manufacturing abroad

50. Just in Time Shared information systems Reduced lead times
Less finance tied up in stock

51. Automation Numerous interlinked sub-systems centrally controlled
Use of robots for repetitive/dangerous tasks
Monitoring/measuring
Logistics

52. Flexible Manufacturing
Benefits of one-off production at mass production prices
Only possible with ICT

53. Tip 12 – Buy a Revision Guide
Written for this course
£3.50 each
Read it
Use workbook to check
your understanding