1. AS Materials & Processes Design Section - Camera

2. Possible Materials Stainless Steel Aluminium Magnesium Alloy ABS HDPE Polycarbonate Compound Glass lenses LCD screens

3. Stainless steel Does not corrode or rust Fairly inexpensive for a metal

4. Aluminium Malleable Low density: – A little soft for a metal – Light for a metal (lightweight) Fairly inexpensive for a metal Durable Ductile

5. Magnesium Alloy Magnesium alloys are mixtures of magnesium with other metals (called an alloy), often aluminium, zinc, manganese, silicon, copper, rare earths and zirconium. Magnesium is the lightest structural metal.

6. Reasons to choose plastic Does not dent (unless you use low quality plastic) Absorbs impact shock, rather than transmitting it. (thank you polymer chains!) Scratch it and you don't lose the paint. Not as cold to handle in the winter Still very tough and difficult to break.

7. ABS Resistance to wear Impact resistance Toughness Variety of colours Good between temuratures of -20 to 80 degrees C.

8. HDPE Commonly recycled High strength Excellent chemical resistance Good with heat to 80 degrees C

9. Polycarbonate Compound Contains 10-20% glass fiber. This material is very durable, lightweight, and shock-resistant as well as tolerant to humidity and temperature changes. Easily worked and moulded.

10. Possible Processes Injection moulding Vacuum forming Compression moulding Die casting Milling

11. Injection Moulding Expensive to set up Excellent for large batches or more ABS HDPE Polycarbonate Compound

12. Vacuum Forming Sheet forming No negative tapers Hollow objects

13. Compression Moulding More basic shapes / parts

14. Die Casting 1 Injection moulding for metal! Stainless steel Aluminium

15. Die Casting 2

16. Milling Can be automated using CAD/CAM Aluminium Stainless steel