Preparing for the written paper
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
X
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
Cutting Paper/card
Die-cutting(creasing done with rounded blade)
I Cut – Die Cut
PlywoodFoam layer
Card to be cut
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
Ink Trough
Impression cylinder
PaperFountain roller
Anilox roller
Printing cylinder
10
Tip 4 – Design methods
Research methodsMarket researchProduct AnalysisQuestionnairesConsumer trialsModelling and testingMock-ups/prototypesSpecifications (design, product, manufacturing)
Evaluation
Sony
900
920
910
On/Off
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
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
Specific Material Information
Disposal of Waste Equipment
Green dot
26
Design Protection
CCopyright
Registered Design(often used with trade marks)
Trade Mark
Patents
T M
R
P
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