PRODUCT DESIGN MATERAIL

PRODUCT DESIGN MATERIALS thousands of materials are available for use in product design. Most materials fall into one of four classes that are based on the properties of a particular material. Metals Polymers Ceramics Composites Within each of these classifications, materials are often further organized into groups based on their chemical composition or certain physical or mechanical properties. Composite materials are often grouped by the types of materials combined or the way the materials are arranged together.

METALS a solid material that is typically hard, opaque, shiny, and features good electrical and thermal conductivity. generally malleable (can be hammered or pressed permanently out of shape), fusible (able to be fused or melted) and ductile (able to be drawn out into a thin wire). metals are corrosion resistant except iron and steel which rust quickly. stainless steel is very rust resistant. when choosing a metal for a particular job the properties must be considered. examples of metals: steel, steel alloys, copper, aluminium, silver, zinc, nickel, lead, tin, titanium, platinum, uranium, manganese

POLYMERS made from long chain molecules which may have cross linking bonds affecting flexibility/stiffness. Some examples of polymers are plastics, PVC, nylon, polycarbonate, acrylic, epoxy resin, formaldehyde, neoprene, natural rubber, elastic bands, melamine (resin in construction material)

CERAMIC used to describe a broad range of materials that include glass, enamel, concrete, cement, pottery, brick, porcelain, and chinaware. Glass-Ceramics - an accidental overheating of a glass furnace led to the discovery of materials known as glass-ceramics. When the glass was overheated, small crystals formed in the amorphous material that prevented cracks from propagating through the glass

COMPOSITES made by combining two or more materials – often ones that have very different properties. materials work together to give the composite unique properties. one is the binding chemical and the other is the reinforcer. concrete is a composite (the cement is the binding and the gravel and steel rods are the reinforcer) as are bricks made from clay reinforced with straw. natural composites include wood, shell and bone. the first modern composite material was fibreglass. It is still widely used today for boat hulls, sports equipment, building panels and many car bodies.

MATERIAL SELECTION Material selection is a step in the process of designing. the main goal of material selection is to minimize cost while meeting product criteria and constraints. Selection begins with properties and costs of materials important to meet the performance characteristics and eco-compatibility of products….i.e., keeping a small environmental footprint. The objective is to introduce environmental considerations in the selection of the materials used in components, meeting functional and performance requirements while minimizing the environmental impact.

CLASS EXAMPLES COMMON PROPERTIES Metals Polymers Ceramics Composites Ferrous metals and alloys (irons, carbon steels, alloy steels, stainless steels, tool and die steels) Nonferrous metals and alloys (aluminum, copper, magnesium, nickel, titanium, precious metals, refractory metals, superalloys) hard, ductile and conduct heat and electricity Polymers polystyrene (cups) polyethylene (plastic bags) artificial joints…prosthetics nylon silicone PVC pipes clothing plastic water bottles widely variable, often soft and flexible Ceramics glass-ceramic cooktop armoured fighting vehicles ceramic brake disks ballistic armored vests airplane cockpit protection hard, brittle, resistant to corrosion, electrically non-conductive extremely durable, a very low coefficient of expansion. it was also transparent to radar, which made it ideal for use for anti-aircraft missiles Composites cement, concrete, brick composite wood (particle board, melamine) epoxy resin aerospace components fishing rods boat hulls light as well as strong new material can be made that exactly meets the requirements of a particular application. Provide design flexibility