1. KS4 Graphic Products

2.  Describe the process of block modelling of MDF & Styrofoam and rapid prototyping using stereolithography (SLA) and 3D printing (3DP).  Name and describe the use of common workshop tools, equipment and components used in making graphic products.  Explain the reasons for using rapid prototyping in the development of graphic products.

3.  Why do we model products before making them for real?

4.  Helps the designer to determine the shape, dimensions and surface detail of making 3D models of the proposed product  Useful in determining the ergonomic factors of many products  It allows the designer to get a ‘feel’ of the product  It soon becomes apparent which products are aesthetically pleasing or ‘user friendly’ and worth developing further

5.  Used in the development of 3D product design and vacuum form moulds

6.  It is ideal because:  it can be cut and shaped easily with a range of hand tools, as it has no grain  Has an excellent surface finish when sanded smooth  Can be spray-painted, once sealed, to achieve a high-quality professional finish

7.  the main advantage of using MDF to make a vacuum form mould is:  because it doesn’t have a grain, it will not leave an imprint on the vacuum form plastic

8.  A completed mould should be:  very smooth  have slightly angled sides (usually 5 0 ) and rounded or ‘radiused’ corners and edges. This will ensure the mould is easily removed afterwards.

9.  Can be easily cut and shaped using a range of hand tools.  Can be produced reasonably quickly especially at the development stage.  Final models can be sanded extremely smooth and can be painted to give a quality finish  Several layers of plaster, sanding down in between give a more professional finish and then sprayed with acrylic or car paint.

10. These are some of the tools you can use. On your sheet explain their uses. Bandsaw Heavy-duty electric saw for cutting out most sheet material

11. Vibrosaw Bench mounted electric saw for cutting thin sheet materials

12. Hot wire cutter Cuts out foam materials

13. Coping saw Saw for cutting curves out of sheet materials include thin wood and acrylic.

14. Pillar Drill Bench mounted electric drill for holes in most materials

15. Surforms Roughly shaping soft materials, e.g. laminated MDF block models

16. Rasp Shaping soft materials

17. File Creating a smooth finish on acrylic and MDF

18. Glass paper Makes a smooth surface finish on woods and Stryofoam Wet and dry paper Makes a smooth surface finish on acrylic and MDF Sanding sealer Sealing the porous surface of MDF prior to printing

19. Spray paint Applying a professional looking finish to MDF once sealed.

20. Rapid prototyping cuts down on the time and costs of developing a product. RPT is much more efficient as a computer controlled process builds up a model from scratch instead of taking materials away from a block.

21. Advantages of using RPT include:  Fast entry to the market due a shorter lead times (the time between the initial design ideas and the actual product being sold)  Reduced development time which saves money  Produces complex, intricate shapes accurately directly from a CAD data

22.  Accurate testing of models as materials are more representative of the final product i.e. this process uses an actual polystyrene rather than MDF or styrofoam

23. Stereolithography (SLA)  3D products are used using laser technology to solify liquid polymers or resins.  Specialist software has to be used to convert the 2D CAD drawings into 3D models

24. Stereolithography (SLA)  The process involves the computer ‘slicing’ the virtual 3D object into hundreds of very thin layers.  The data from each layer is transferred to the laser.  The laser draws the first layer of the shape onto the surface of the resin causing it to solidify.

25. Stereolithography (SLA)  This layer is supported onto a platform that moves down, enabling the next layer to be drawn.  The process of drawing, solidifying and moving down quickly build the shape up, one layer on top of another until the final 3D product is made.

26. The process of Stereolithography (SLA) http://www.youtube.com/watch? v=iceiNb_1E0I http://www.youtube.com/watch? v=BUfh5wxj3qA http://www.youtube.com/watch? v=ygHVVKkJWlI

27. 3D Printing  Can produce models in minutes in an office situation.  CAD software sends the 3D image to the 3D printer and the item is ‘printed’ layer by layer in a range of materials.  Can produce concept models quickly with working parts using desktop-sized 3D printer.

28. 3D Printing  3D printers offer speed, low cost and ease of use which makes them suitable for visualising designs during the development stage of the design process.  Process similar to stereolithography by converting a 3D CAD file into thin cross- sections.

29. 3D Printing  Another variation involves an inkjet printing system.  Layers of a fine powder are bonded by ‘printing’ an adhesive from the inkjet printhead in the shape of each layer (as sliced up by the CAD file).  This system allows the printing of full colour prototypes. http://www.youtube.com/watch? v=O863HbRzGc8

30. 3D Printing  Another system feeds a liquid photopolymer through an inkjet- type printhead to form each layer of the model.  These are photopolymer phase machines and they use an ultraviolet (UV) floodlamp mounted on the printhead to solidify each layer as it is deposited.  http://www.youtube.com/watch ?v=IM8WU8JfyI8 http://www.youtube.com/watch ?v=IM8WU8JfyI8

32. 3D Printing http://www.youtube.com/watch?v= 7QP73uTJApwhttp://www.youtube.com/watch?v= 7QP73uTJApw Colour printing http://www.youtube.com/watch?v= q68yzJiiVUUhttp://www.youtube.com/watch?v= q68yzJiiVUU Denford UP  http://www.youtube.com/watch?v =1xZyF7l5_8w http://www.youtube.com/watch?v =1xZyF7l5_8w  Inside Microsoft’s Model Shop where prototypes are printed in 3D

33. Exam questions Using notes and sketches, explain the process of producing a prototype using stereolithography. (4 marks) Explain why a designer would use the services of a rapid prototyping company when developing a product. (4 marks)

34. Exam questions Explain why is there is still a need to for craftspeople such as model makers who make models primarily by hand? (2 marks)