1. GCSE Revision (Section A) - Materials

2. W e A re L earning T o – You will have an understanding about material classification and how different materials can be used to manufacture products. Today you will: - Learn about different manufacturing processes.

3. Product Design Materials You have an excellent understanding of how extrusion works and how it can be used within industry. You are able to name all the different types of material classifications. You have a very good understanding of how extrusion works and how it can be used within industry. You are able to name most of the different types of material classifications. You have a good understanding of how extrusion works and how it can be used within industry. You are able to name some of the different types of material classifications. Level A B C

4. GCSE Revision Material Classification What are they? Woods Natural Pine Mahogany Oak Manmade Plywood Chipboard MDF FERROUS METALS - Metals that contain iron.

5. Packaging Material White Cardboard - is thicker than paper as it is made up of a number of layers, glue or laminated together. The diagram opposite shows a net / development of a package. It can be folded to produce a carton. Corrugated Card– Protective packaging for fragile goods. Corrugated card is a low cost protection method. The material can also be recycled. Boards and Paper Polystyrene Cup– Polystyrene packaging provides a unique combination of performance, economic and environmental benefits. Polystyrene is extremely strong yet lightweight. Provides excellent insulation, is less expensive than many other food service packaging options and has less environmental impact during its manufacture than paperboard. High Density Polyethylene (HDPE). HDPE is used to make bottles for fruit juice, milk, water, kitchen cleansing products and even furniture. It is an ideal material for the injection moulding process making it suitable for batch and continuous production. Waxed Card - They often have a waxy coating inside to keep the paper from becoming wet and collapsing from the absorption of liquid. Cold paper cups also come in several sizes and designs.

6. GCSE Revision (Section B) Materials Metals Steel, Stainless steel, Aluminium, Copper, Tin What products can be made from these materials? Where do these materials come from? Plastics Acrylic, Polythene, polystyrene What products can be made from these materials? Where do these materials come from? Woods Oak, MDF, Pine, Plywood What products can be made from these materials? Where do these materials come from? Animals Fur, Meat, Leather, Wool What products can be made from these materials?

7. GCSE Revision Modern Materials What are they? Carbon Fibre Carbon fibre consists of extremely thin fibres of carbon, twisted together to form yarn, which is then woven to create a fabric cloth. Carbon fibre cloth can be combined with a plastic resin, which bonds the fibres together, to create a very strong composite material for use in applications where a high strength, low weight material is required. Fibre Optics Fibre optics is the science of using glass fibre or plastic fibre to transmit light. Fibre optic cables enable data to be transmitted over large distances more efficiently than other forms of communication. One glass fibre can replace hundreds of copper cables.

8. GCSE Revision Combined Materials WHAT ARE COMPOSITE MATERIALS? Composite materials, also called Composites. Composed of two or more materials, that have different properties. The materials are bonded together and their properties are combined. Composite materials combine the physical properties of the individual materials they are made up of, forming a superior material. KEVLAR CONCRETE PLYWOOD GLASS REINFORCED FIBRECARBON FIBRE Concrete Concrete is a versatile and cheap material, with a vast range of applications. Concrete is regarded as a composite material because it is composed of a number of materials that combine to form this versatile building material. Most concrete is made up of Portland Cement, aggregates (gravel, crushed stones) and sand. Carbon fibre Carbon fibre is woven into a textile material. Epoxy resin is added and allowed to cure. The resulting material is very strong and light. An improvement on glass fibre reinforced plastic, although much more expensive. Uses; Aerospace, expensive sports cars, competition bicycles and motorbikes.

9. GCSE Revision Smart Materials What is smart material? Smart materials have properties that react to changes in their environment. This means that one of their properties can be changed by an external condition, such as temperature, light, pressure or electricity. This change is reversible and can be repeated many times.

10. Materials How is this product manufactured? What is it made from? Aluminium

11. Extrusion Materials What is Extrusion? Materials such as metals and plastics can be used in a process called extrusion. This means when they are heated and then pressured in a mould they can be formed into different shapes and sections The plastic and metals melt into a liquid which is forced through a die, forming a long 'tube like' shape. The extrusion is then cooled and forms a solid shape. The shape of the die determines the shape of the tube.

12. GCSE Revision Standard Components ADVANTAGES OF USING STANDARD COMPONENTS Standard components can be manufactured in vast quantities, keeping costs down. Standard components are supplied in standard sizes. Consequently, they are easy to order. Safety / quality testing is easier when dealing with standard components. Often a number of standard components, from a batch will be tested. Manufacturers of ‘complex’ products (computers TVs, etc....), usually assemble their products from standard components. This allows them to concentrate on the development of their specialised product, rather than having to design each individual component. This speeds up product development. Setting up a mass production line is easier if standard components are used. It is easier to train staff / the workforce, as they are dealing with the same standard components, when assembling products. Standard Component A standard component is usually an individual part or component, manufactured in thousands or millions, to the same specification (such as size, weight, material etc...). A good example is a steel bolt. Bolts are available in a vast range of standard sizes. Use pages 134 – 135 in the AQA workbook

13. GCSE Revision Standard Components Standard Component

14. Hardwoods and Softwoods Woods are classified into two main groups, softwoods and hardwoods. Trees are either coniferous (bears cones and have needle shaped leaves that stay green all year round) or deciduous (has flat leaves that fall in autumn). The timber that comes from the coniferous tree is known as softwood and the timber that comes from deciduous trees is known as hardwood. HARDWOODS Oak Mahogany Teak SOFTWOODS Pine GCSE Revision (Section B) Types of Woods

15. Hardwoods Manmade Boards CHIPBOARD - This is made up of small chips of wood bonded together with resin and formed into sheets by compression. Chipboard is often covered with a plastic laminate or wood veneer and used in furniture. HARDBOARD - This is made from wood fibres that have been pulped. The pulp is put under pressure until the fibres bond to produce a tough board that is smooth on one side and rough on the other. It is not as strong as the other boards. MEDIUM DENSITY FIBRE BOARD (MDF) - A quality board, relatively cheap. This board is composed of fine wood dust and resin pressed into a board. PLYWOOD - This is made from veneers (plies) of timber with each grain layer being at right angles to each other and bonded together by resin and pressure. GCSE Revision (Section B) Types of Woods

16. Thermoplastics and Thermosetting Plastics Thermosetting: Once 'set' these plastics cannot be reheated to soften, shape and mould. Many adhesives (glues) are thermosetting plastics. A good example is ‘Araldite ’ Thermoplastics: These plastics can be re-heated and therefore shaped in various ways. Example Acrylic, HIPS (High Impact Polystyrene) At a molecular level, a thermosetting plastic has more bonds holding it together. A thermoplastic has fewer bonds, allowing the plastic to be reshaped several times. GCSE Revision (Section B) Plastics

17. Non- renewable Materials A non-renewable material is one that can NOT be replaced. Once it is used up it can not be re- generated. Anything that can be dug from the earth that will eventually run out. Eg, Copper, Iron, Oil Non-renewable Products Foil wrappers Cans Plastic bottles Mobile phones Cars Renewable Products Cardboard chip cartons Paper burger wrappers Solid wood furniture Newspapers Renewable Materials A renewable material is one that can be replaced. Anything that can be consistently re-grown. Eg: Trees that are replanted. GCSE Revision (Section B) Renewable Materials

18. Hardwoods GALVANISING STEEL AND IRON Steel is usually coated. For example, the Golden Gate Bridge in San Francisco receives a new coat of rust resistant bronze paint every five years. This prevents rust damaging the structural integrity of the bridge. The steel bolt seen below shows the damage caused by rust. If this occurs to the bolts holding together the parts of a bridge, the bridge would be in danger of collapsing. Most materials require a suitable finish to protect for from the elements/environment or to enhance its appearance VARNISH TEAK OIL PAINT GCSE Revision (Section B) Finishes

19. GCSE Revision Task Task 4: Research where metals, plastics and woods come from? Task 5: Research three different metals. Task 6: Research three different plastics. Task 7: Research the difference between hardwoods and softwoods. Task 8: Research three different hardwoods. Task 9: Research three different Softwoods. Task 10: Research three different man made woods. Task 1: Research three different types of packaging materials. Task 2: Research and explain how packaging is printed using Lithography. Task 3: Research and explain how packaging is cut out using Die Cutter. Task 11: Research, explain and give examples of a renewable material. Task 12: Research, explain and give examples of a non- renewable material. Research Task