1. Craft and Design

2. Design Aesthetics. What things look like. Design process
If a designer wants to change the Aesthetics of this chair,
they could try some the following things
Design
process
Investigation/research
Evaluation
Analysis of brief
Design brief
Specification
Idea generation
Planning for manufacture
Manufacture
Change the colour of the chair. Bright, dull, contrasting.
Anthropometrics.
Measuring and recording the sizes of people.
Change the shape
of the chair.
Circles, triangles, curves.
Anthropometric data table.
You can use this instead of
doing all the measuring yourself.
Change the texture
of the chair.
Rough, smooth, furry.
Change the material of the chair. Wood, metal, plastic, concrete.
Ergonomics.
How things are designed to suit the sizes of the human body
If you measure the height of the whole population you will
get a few small people, a few big people, and a lot in between.
We cant design for everyone, so we forget about the
smallest 5% and tallest 5% of the people.
So we design for people between the 5th and 95th percentile.
If you want to design something for small people use the 5th percentile sizes. If you want to design something for tall people use the 95th percentile. If you want to design for the average size use the 50th percentile.
Ergonome.
When a designer is working on a product they might use an ergonome. This is a model of a person of average size (50th percentile)
Smallest
people
Tallest
people
An ergonome being used to design a desk.

3. Wood Wood joints Wood glue Types of wood.
The main glue used with wood is PVA. A joint glued with PVA need to be tightly clamped and left for 9-12 hours to get to full strength.
Types of wood.
There are two families of wood;
Softwood
These come from trees which have needles. They do not have leaves to fall.
Softwoods include; Red pine, Cedar, Douglas fir
Hardwood
These come from trees which loose their leaves in the autumn.
Hardwoods include Oak, Beech & Mahogany
Manmade boards
These are made from wood, but usually cheap or unsightly pieces that cant be used on their own.
Plywood Blockboard Chipboard MDF
Butt joint
Dovetail joint
Rebate joint
Mortice and tenon
G-Clamp
Dowel joint
Sash cramp
Cross halving
Housing joint
Hand router
Used to make a flat
bottom in a housing joint.
Mortice machine:
Used to cut the mortice (hole) in a
mortice and tenon joint. If you cut it by hand, then
you would use a mortice chisel.
Knock down fitting.
Used so that customer can build their furniture at home. Means furniture can be transported flat instead of built up
Stopped housing joint

4. Wood Cutting wood Woodscrews Finishing wood:
How to prepare for putting in a wood screw
Countersink
Clearance hole
Smoothing Plane:
Used for taking small cuts
from wood to shape it.
Jack Plane:
Used for smoothing long
edges of wood.
Pilot hole
Holes to be drilled
With screw in place
Tenon saw
Bevel edged chisel:
Multi-purpose workshop chisel.
Bradawl:
Used to make pilot hole in
wood to allow screw to start.
Coping saw
Mortice chisel:
Used to hand cut a
mortice hole.
Jig saw
Finishing wood:
Wood must have a finish put onto it to keep it looking good, and to protect it from rain.
Varnish:
This is usually clear, so it protects
the wood from rain, but you can still
see the wood underneath.
Paint:
This covers up the wood.
It protects the wood, but you would use
it on cheaper woods or man made boards.

5. Wood Shaping Wood 1 Woodworking hand tools.
Wood turning. Making cylinder shaped objects in wood.
Driving centre. Has teeth which bite into wood. This makes the wood spin round
Try square
Gouge
Headstock
Tailstock
Steel rule
Parting tool
Cross pein
(Warrington) hammer
Tool rest
Increase the speed of the lathe for the last cut to improve surface finish.
Claw hammer
Live centre. Spins on ball bearings, and supports the other end of the wood. Dead centre could have been used but this does not spin, so burns the wood.
Outside callipers:
Used to measure the
diameter of the wood
you are turning.
Getting ready
Nail punch
Mortice gauge
Spur
Stock 1. 2. 3.
Draw diagonals on each end. Saw down 3mm on each diagonal with tenon saw.
Draw circle on each end using dividers.
Use smoothing plane to take off the corners to make an octogan.
Marking gauge
Stem

6. Metal Shaping Metal 1 Ferrous metals contain iron Non ferrous don’t.
e.g. Cast Iron, Mild steel. e.g. Aluminium, Brass, Copper, Tin.
Files
Shaping
Metal 1
File card.
Used to clean teeth
of file.
Anvil
Tongs.
Used to hold hot metal
Forge work.
Where metal is heated and beaten into shape using a large ball pein hammer against the anvil.
Drilling
Guard
Chuck
Chuck key to
tighten drill bit
Table
Safety
Tie hair back
Wear goggles
No loose clothing
Hand Drill
Brazing hearth
Heat treatment.
We can change the strength of metal by heating it up and cooling it down in different ways.
Annealing.
Steel is heated up to a dull red colour and left to cool.
This makes the steel easier to bend or hammer into shape
Hardening.
Steel is heated up to deep red and cooled immediately
This makes the steel hard but brittle.
Tempering.
Steel is heated up gently and left to cool.
This makes the steel not quite as hard, but much less brittle.
Twist drill bit
Machine vice
Pillar Drill
Countersink bit
Sawing metal
Hand vice.
For holding thin sheet
metal while drilling
Folding bars.
For holding sheet metal
while it is being bent.
Junior Hacksaw
Hacksaw
Sheet metal work
Hide Mallet.
For hammering sheet
metal to shape.
Tins snips.
For cutting out shapes in thin metal

7. Metal Shaping Metal 2 Metal lathe Facing off Parallel turning Safety.
Headstock
Chuck
Guard
If cutting tool is too low you will be left with a small piece in the middle when you have made a cut.
This is called a pip. If this happens adjust the height of the cutting tool up and continue.
Tailstock
Cutting tool is passed across the end face of the work piece to produce a mirrored flat surface.
Cutting tool is passed along the length of the work piece to reduce the diameter.
Safety.
Wear goggles
Tie hair and clothing back
Make sure chuck key is removed
Make sure guard is in place
Parting off
Knurling
Bed
Tool post
Saddle
Compound slide.
Can be set to any angle. Used to cut tapers.
Thin parting tool is passed through the work piece to cut it off from the bar.
Lathe is set to slow speed. Knurling tool leaves criss cross print on metal to give it better grip.
Taper turning
Cross slide
Measuring
Micrometer:
Used to very accurately measure sizes when using the metalwork lathe.
Cutting a cone shape. COMPOUND SLIDE ONLY must be used.
Drilling
Centre drill
Use Jacobs chuck in tailstock.
Start with centre drill to make pilot hole, then use twist drills to work up to finished size.

8. Metal Joining Metal Riveting Welding Nut and bolt Gluing 1 2 3
Pop Rivet.
Quick and easy rivet to form. They can be
formed from only one side of the job.
Rivet set
Electricity is passed between 2 pieces to be joined.
This generates a lot of heat, melting the edges to be
joined making a strong permanent joint.
Riveting
Permanent joint
Welding
Permanent joint
Joining
Metal
Riveted Joint.
Snap head both sides
Types of rivet head
Nut and bolt
Can be taken apart
Die
Die stock
Gluing
Permanent joint
An epoxy resin glue can be
used to glue metal together,
Tap wrench
Using the die.
For first cut tighten
middle screw and loosen outside ones.
Second cut.
Loosen middle
one and tighten both outside ones.
Use taps in this order
1. Taper tap
2. Intermediate tap
3. Plug tap
Cutting a screw thread.
An inside thread (nut) is cut with taps.
An outside thread (bolt) is cut with a die.

9. Metal Shaping Metal 3 Marking out Metal Casting. Marking out Measuring
A hole is formed in sand using a mould. The mould is removed, and
The hole left behind is filled with molten aluminium (650 – 700 °C).
Used to make irregular shapes in metal.
Odd leg callipers
Ball pein hammer
Engineers square
Marking out
Dividers
Runner
Riser
Crucible
Steel rule
Centre punch
Scriber
Measuring
Outside callipers
Inside callipers
Micrometer

10. Plastics THERMO PLASTICS THERMOSETTING PLASTICS Marking out
can be heated up and reshaped many times. They have plastic memory; this means they remember they were made in big flat sheets, and will try to go back to this flat shape when heated.
Acrylic is a Thermo plastic.
THERMOSETTING PLASTICS
cannot be heated up and reshaped. They will stay in the shape they were made in permanently.
Melamine is a Thermosetting Plastic
Marking out
Edge finishing.
Cross file
Draw file
Draw file with wet and dry.
Polish with metal polish
Oven.
Used to heat up the whole of a piece of plastic
Pen or pencil
Vacuum forming
This is a process where you heat thin Thermoplastics up and place it over a mould. You then suck out the air (a vacuum) and the plastic takes up the exact shape of the mould. Click on the picture of the Vacuum forming machine below to see a Youtube video of it. You will not be able to watch this in school!
Strip heater.
Used to heat a thin area of the plastic to make precise line bends.
Cutting
Fluidising tank (Dip coating machine.)
Coping saw
Dip coating.
Puts a plastic coating onto metal. It makes metal tools more comfortable to use, and stops steel from rusting.
Vacuum forming mould.
Must have sloping sides to allow the mould to be removed from the plastic this is called draw. It must also have rounded corners to stop the plastic splitting as it stretches over the mould.