Manufacturing Foundations of Technology Manufacturing © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology Teacher Resource – Unit 3 Lesson 2

The BIG Idea Big Idea: Manufacturing is the process of producing goods and materials and ensuring that the properties of materials meet the desired function of the product. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Materials and Manufacturing Materials have different properties, limitations, and durability. Selecting the appropriate material for a product is an essential task. Materials can be generally classified as natural, synthetic, or mixed. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Materials and Manufacturing Selecting the appropriate material is based on three qualifications: The material type and the function The manufacturing process, quantity, and cost Sustainability © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Types Materials are generally categorized into the following groups: Metals Ceramics Polymers Composites © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Types Metals are elements, compounds, or alloys that account for roughly two-thirds of all materials and have properties that include: Strength, ductility, high melting point, thermal and electric conductivity, and toughness Metals can be easily bonded—they have free electrons that can easily move from one atom to the next. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Types Ceramics are an inorganic and nonmetallic material formed from powdered materials through the application of heat and have properties that include: Strength, hardness, resistance to high temperatures but often brittle, and depending on how the product is formed, dense or lightweight, conductive or not, magnetic or not © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Types Polymers are commonly referred to as plastics or rubber. Plastics are group of synthetic materials that are formed or molded into shape. Rubber can be easily deformed and return to its near original shape. Polymers often resist corrosion, resist conduction, and are less dense than metal or ceramics. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Types Polymers are divided into two categories: Thermoplastics – materials that can be melted and then molded or extruded into a product (polyethylene, polypropylene) Thermoset plastics – materials that cannot be melted or remelted (resins, epoxies) © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Types Composites are any combination of two or more distinct materials that maintain their original properties. Common composites include: Reinforced plastics Metal or ceramic – matrix composites Concrete and fiberglass © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Functions The properties of materials can be generally categorized into the following groups: Mechanical Electrical Magnetic Thermal © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Tensile Strength – measures the material’s resistance to being pulled apart © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology Material Force

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Compression Strength – measures the material’s resistance to being squeezed © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology Material Force

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Fatigue Strength – measures the material’s resistance to various types of rapidly changing stresses © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology Material Force 3 Force 2 Force 1

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Hardness – the material’s resistance to permanent indentation © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Elasticity – the material’s ability to return to its near original shape after a stress has been applied and removed © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Brittleness –how easily a material breaks or shatters when a tensile stress is applied © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology Force

Material Functions Mechanical properties of materials involve a reaction to a load or application of a force. Ductility and Malleability – the material’s ability to stretch, bend, or twist without breaking © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Functions Electrical conductivity is the measure of how well the material accommodates the movement of an electrical charge. Electrical resistivity is the measure of how well the material resists the movement of an electrical charge. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Material Functions Magnetic permeability is the ability of the material to become magnetized. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology Material

Material Functions Thermal conductivity is the property of a material to transfer heat. Thermal expansion is how much a material expands as heat is increased. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Types Primary processes turn raw materials into standard stock (example – timber cut into boards) Secondary processes turn standard stock into finished products (example – boards turned into furniture) © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Types Secondary processes are further broken down into one of three types: Custom Batch Continuous © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Types Custom Manufacturing: A product that is one of a kind and manufactured by a specialist. Product examples: Yacht, homes, very specific parts or products, custom furniture © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Types Batch Manufacturing: Products made in groups, where the components of a product are traditionally completed at one station before moving to the next station. Product Examples: bakery items, paints, shoes © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Types Continuous Manufacturing: Products made with no interruption in the production line Product examples: cars, food products, bricks © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Types Determining how a product will be manufactured has a large impact on the material(s) selected. Different methods of forming, casting, machining, joining, and rapid manufacturing will impact tool cost, the volume that can be produced, and the rate of production. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Processes Parts or products are produced in several different ways, included in the list below: Forming – the process where a raw material is reshaped to form the desired part Casting – when a liquid material is poured into a mold, which represents a hollow version of the part, also known as the cast © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Processes Parts or products are produced in several different ways, included the list below: Machining – the process in which a piece or raw material is cut into the desired part; generally involves a controlled removal of the raw material Joining – the process of joining two materials using some type of fastener © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Manufacturing Processes Parts or products are produced in several different ways, included the list below: Rapid manufacturing – also known as additive manufacturing or 3D printing – is the process of making a part from a digital model by adding material in layers © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Interchangeable Parts Interchangeable parts are identical parts manufactured to a specification so that one part can easily replace another without having to build a custom part. The invention of interchangeable parts was developed by the printing industry using moveable type. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Interchangeable Parts The interchangeability of parts has greatly increased the efficiency of all manufacturing processes. Product examples: © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology

Sustainable Manufacturing Sustainable manufacturing is the creation of products and processes that do not pollute, conserve energy/natural resources, and are economically sound and safe for employees and consumers. Sustainable manufacturing also recognizes the importance of producing sustainable products and producing products that are energy-efficient. © 2013 International Technology and Engineering Educators Association STEM  Center for Teaching and Learning™ Foundations of Technology