1. Higher Design and Manufacture
Revision Session 1

2. Topics Materials and Manufacturing Processes Types of materials
Processes Used for those materials
Economic and Environmental impacts of materials and the processes they use

3. Materials
Plastics
Metals
Woods
Composites

4. Plastics Thermo and Thermosetting Plastics Thermo Thermosetting ABS
HIPS
Acrylic
Polypropylene
Polyethane
Polystyrene
Thermosetting
Urea Formaldehyde
Melamine Formaldehyde
Bakelite

5. Plastics Elastomers and Polymers Elastomers (Rubber) Polymer
Silicon Rubber
Ethylene Vinyl Acetate (EVA)
Polymer
Polypropelene etc

6. Metals Ferrous, Non Ferrous and Alloys Ferrous Non Ferrous Alloys
Cast Iron
Tin
High Carbon Steel
Mild Steel
Non Ferrous
Aluminium
Copper
Gold
Silver
Alloys
Brass (zinc and copper)
Solder (lead and tin)
Bronze (tin, aluminium, +)
Stainless Steel (chromium and nikel)

7. Woods Hardwoods, Softwoods, Manufactured Boards Hardwoods Softwoods
Meranti
Mahogany
Oak
Balsa
Ash
Beech
Softwoods
Red Pine
Parana Pine
Redwood
Spruce
Manufactured Boards
MDF
Hardboard
Plywood
Chipboard

8. Composites Carbon Fibre Reinforced Plastic Chipboard
Medium-density fibreboard
Glass fibre-reinforced plastics

9. Plastic Processes Using an oven Strip Heater/Line Bending
Injection Moulding
Vacuum Forming
Rotational Moulding
Blow Moulding
Rapid Prototyping
Extrusion
Compression Moulding

10. Wood Processes CNC Router Traditional Joinery Wood turning Lathe
Knock down fittings
CAM manufacture

11. Metal Processes Piercing and Blanking Forging Drop Forging CNC Milling
Sand Casting
Die Casting
Welding
Brazing

12. Questions
State a product that could be made for each process. Justify your answer:
Sand Casting
CNC Router
Vacuum Forming
Blow Moulding

13. Questions
State an appropriate material that could used with each of the following processes. Justify your answer:
Die Casting
Injection Moulding
Compression Moulding
CNC Milling