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

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

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

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

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?

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

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

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

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

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

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

Design Icons Classic design Innovative Often copied

Retro design Modern products based on styling from the past

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?

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

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

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

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…….

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

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

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

Packaging issues Hygiene Security Composite materials Spillage Access Insulation Legal requirements

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?

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

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

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

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

Product maintenance Care labels

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

Social issues Environmental: Product life cycles Throw-away products

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

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

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

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

Organising manufacturing Production lines Work spaces Sequencing tasks

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

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

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

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

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

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

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

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

Lathes Work revolves against cutter Cylindrical Conical Spherical

Laser cutters Very accurate cutting for sheet materials engraving

Embroidery Machines Detailed designs on fabric Text & graphics Repeat patterns

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

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

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

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

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

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

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