1. 1 Mobile Phone Holder Design for Manufacture

2. 2 Mobile Phone Holder Project

3. 3 Introduction Variety of Processes and Manufacturing Techniques Production of Artifacts Enhance Problem Soving and Design Capabilities

4. 4 Introduction Press Forming using ‘Foamex’ Solutions to Real Life Design Situations Development of Individualised Products

5. 5 Introduction Thematic Approach Encourage Integration of Topics Adapt Projects to meet individual Circumstances

6. 6 Objectives A Range of Manufacturing Skills: - Heat forming - The use of jigs and formers - Marking out, cutting, drilling, finishing and assembly of materials. An Understanding of The Characteristics of Thermoplastics Materials Students will Develop:

7. 7 Objectives Graphics/Design skills and techniques Product Analysis Techniques and Design Specifications Ability to Design according to User Requirements Research Skills using ICT

8. 8 Presentation Theme: Mobile phones are a worldwide phenomenon that have revolutionised the way we communicate with one another. They are both desirable and essential to our everyday lives. The ways in which we carry, protect and secure our mobile phones can be based on fashion, practicality and function. Design Brief: Design and make a functional mobile phone holder suitable for personal or desktop use

9. 9 Constraints Work within student skills range Manufacturing Processes: - Press forming - Vacuum Forming Functionality and Ease of Use High Standard of Finish – Use of Graphics Individualised Product

10. 10 Research/Investigation Designers need stimulation Provision of stimulation Personal Research – How did it influence the thought process See accompanying presentation on Research – Add to it

11. 11 Resources Materials 3mm expanded foam sheet (Foamex) 1.5mm Vacuum forming plastic 18mm MDF or suitable material for production of moulds and formers Grip range press fit nylon click fasteners Tie wraps Acrylic cement or solvent Equipment Oven Vacuum former A range of hole saws or forstner bits Scroll saw Wet and dry paper

12. 12 Making the Formers Male and Female Formers – 18mm MDF Simple Shapes Female – Larger by thickness of casing material Male – Fixed to Base (Allignment) Taper – Not necessary, Radius top edge

13. 13 Heating and Forming Material is placed in pre- heated oven (See Temperature chart ) Heated material is draped over male former Locate female former over male former Force together and hold until material cools

14. 14 Cutting Material can be trimmed to leave a 10mm lip File and finish to shape with wet and dry paper

15. 15 Cut casing material in half using a scroll saw and file to finish Support bracket can be marked from casing but its profile is cut 5mm smaller all round and filed to finish Support Bracket

16. 16 Casing is affixed to support bracket using tensol solvent/cement or a glue gun Assembly may need to be supported with masking tape during the gluing process Assembly

17. 17 Bending Support Bracket can be bent using a Strip Heater

18. 18 Finished Project

19. 19 Design Variations A number of design variations are possible using this process

20. 20 Extension Concepts Survival Kit Swimming Holidays Jewellery Power Pod CD Storage Camping Pamper Pod Baby Gear Handsets/Remote Control Pencil Case Personal Alarm Mouse House IT accessories Desk Tidy Radio Housing Instrument Case Toolbox Robot Shell Money Box Paintbox Store

21. 21 MaterialOven Temp. °C Time (Seconds) Notes 3mm Foamex14030If plastic becomes mishapen, it can be returned to the oven and reheated. 3mm Plastazote 14060 6mm Plastazote 14090 Times & Temperatures

22. 22 Links TEP International Manufacturing Centre University of Warwick Coventry CV4 7AL www.tep.org.ukwww.tep.org.uk www.crclarke.com Middlesex University Teaching Resources Unit 10, IO Centre Waltham Cross Herts EN9 1AS www.mutr.co.ukwww.mutr.co.uk Click Here to view instructional video