Preparing for the written paper

Brian Russell & R Bramhill

2

Tip 1 – Be equipped

You will need:

• Blue or black pen (take a spare)

• Pencil (take a sharpener)

• Coloured pencils (a range)

• 300mm Ruler

• Eraser

3

Tip 2 – Pace yourself

Don’t rush

• Read the questions carefully

• Spend approximately a minute per mark

Don’t waste time

• Don’t use colour until you have completed the written questions

• Improve drawings if time allows

4

Multiple choice

• If the question asks for four responses from eight, have a go at the lot!

• Examiners mark them all and award up to the maximum mark so it is always worth having a go at more than the minimum

X

5

Tip 3 – Materials/components

• Where do materials come from?• Are they renewable/non-renewable?• How are materials classified (grouped)?• What properties do different materials have?• What are components and why are they used? • Stock forms available?• Why materials are combined?• Surface finishes?

6

Paper and card compulsory

What you need to know:

• Where it comes from

• How it is made

• Properties of different papers/cards

• How products are cut from paper/card

• How is it printed

7

Cutting Paper/card

Die-cutting(creasing done with rounded blade)

I Cut – Die Cut

PlywoodFoam layer

Card to be cut

Blade

8

Offset lithography

• Flat aluminium plates (specially treated) • Photographically exposed then wrapped around roller• Exposed parts attract water• Non exposed parts allow ink to stick• Print onto plain roller to reverse image• Transfers to card or other materials

9

Flexographic printing

• uses a printing plate made of rubber, plastic, or some other flexible material.

• Ink is applied to a raised image on the plate, which transfers the image to the printing

Ink Trough

Impression cylinder

PaperFountain roller

Anilox roller

Printing cylinder

10

Tip 4 – Design methods

Research methodsMarket researchProduct AnalysisQuestionnairesConsumer trialsModelling and testingMock-ups/prototypesSpecifications (design, product, manufacturing)

Evaluation

Sony

900

920

910

On/Off

11

New Products

Where do ideas come from?

Nature, geometry, other products…..

Can you name a designer?

Can you explain why their products

are successful?

12

Design Icons

Classic design

• Innovative

• Often copied

13

Retro design

• Modern products based on styling from the past

14

Technology push/Market pull

• How new markets are created

• How products are developed to meet specific markets

• Can you identify the market by analysing the product?

15

Product Analysis

Can you comment on:• Materials used – their properties• Function – strengths and weaknesses• Human factors – ease of use• Style – aesthetics• Manufacturing - processes used

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Tip 5 - Human factors

• Anthropometrics• Ergonomics• Improving comfort• Working triangles• Special groups• Adjustment for different sizes• Specific markets• Access

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Tip 6 – Product evolution

Why do products change over time?

• New materials

• New manufacturing methods

• New technologies

• Social changes

• Fashions/trends

• Legislation

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Continuous improvement

Manufacturers need to keep improving their products to stay competitive or to meet changing regulation/legislation.• Production staff• Consumer/retailer feedback• Maintenance engineers• Pressure groups (environment)• Financial savings…….

19

Tip 7 – Packaging

The purpose of packaging is to:

Protect

Inform

Contain

Transport

Preserve

Display

I PICT PD

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Card nets

• Flat shapes which fold into 3D forms• Often food related in exam• Glue tabs• Locking tabs• Position of images• Position of text

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Other packaging methods

• Plastics – blow moulding, blister packs, bags• Metals – aluminium, steel, cans, foil• Glass – jars, bottles

• Recycling issues

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Packaging issues

• Hygiene• Security• Composite materials• Spillage• Access• Insulation• Legal requirements

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Graphics• Clear text• Simple bold images• Impact• Position of logo/information

Can you explain:• How the artwork would be done using a

computer?• How it would be commercially printed?

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Labelling

Key information found on labelling

Includes:• Product name• Description• Safety information• Contents• Storage/maintenance information• Environmental information

25

Environmental Issues

Recycling symbol

Specific Material Information

Disposal of Waste Equipment

Green dot

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Design Protection

CCopyright

Registered Design(often used with trade marks)

Trade Mark

Patents

T M

R

P

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Tip 8 – Product information

• Symbols found on a range of products and their packaging/labelling

• Maintenance schedules

• Assembly instructions

• Handling instructions

• Storage instructions

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Product maintenance

Care labels

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Tip 9 - Consumer Issues

• BSI Kite Marks• European Standards• (Conformité Europeenne)• Trade association standards

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Social issues

Environmental:

• Product life cycles

• Throw-away products

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Tip 10 - Manufacturing

• Preparation of materials

• Industrial manufacturing processes

• Use of labour

• Quality Assurance/Quality Control

• Implications of ICT

• Scales of production

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Your own manufacturing

Ensure that you can explain:

• How you would make models and prototypes

• The tools you would use

• Use of quality assurance

• Manufacturing aids (e.g. jigs)

• Making in quantity

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Manufacturing in quantity

Name a suitable material

Process to be used:• CAD/CAM, moulding, stamping,

forming, printing etc.• Order of work• Quality assurance• Health & safety

200 needed

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Manufacturing aids

Explain how you would use:

Jigs, moulds, formers

Patterns/templates

Die cutters/press knives

What are the advantages of these?

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Organising manufacturing

• Production lines

• Work spaces

• Sequencing tasks

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Commercial manufacturing

Materials are processed using:

• Moulding/casting

• Forming

• Wastage/separation

• Conditioning

• Assembling

• Finishing

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Health & safety

Consider:

• Your own safety when making

• The user’s safety

• Manufacturing processes

• Manufacturing waste

• Risk Assessment

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Tip 11 – Using ICT

• Computer Aided Design• Computer Aided Manufacture• Computer Numerical Control

Advantages:• Sharing information• Accuracy• Repeatability• Flexibility (ease of making changes)• Speed……

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Computer Aided Manufacture

• Printers• Vinyl cutters• Milling/engraving machines• Routers• Lathes• Laser-cutters• Embroidery machines• Rapid prototyping

40

Inkjet & laser printers

• Used for one-offs/prototypes

• Small print runs

• Large areas

• Direct onto fabrics/carpets

• Transfer printing

• Sublimation printing

41

Vinyl cutters

• Signs (especially vehicles)

• Graphics on prototypes

• Iron-on vinyl (T shirts)

• Labels for prototypes

• Card nets for prototypes

• Masks for stencilling/sandblasting

• Decoration on ceramics

42

Milling/engraving machines

• Cutting flat (2D) shapes in rigid materials

• Engraving copper board for electronics

• Signage name plaques etc.

• Raised forms (3D)

43

Routers

• Used mainly on timber (MDF) and rigid foams

• 3 axis – partial 3D

• 4 axis – turns material

to get full 3D

• 5 axis – full 3D,

much better detail

44

Lathes

• Work revolves against cutter

• Cylindrical

• Conical

• Spherical

45

Laser cutters

• Very accurate cutting for sheet materials• engraving

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Embroidery Machines

Detailed designs on fabric

• Text & graphics

• Repeat patterns

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Rapid Prototyping

Prototype built up layer by layer –

Stereo lithography

• 3D printing

• 3D layering

48

ICT in Manufactring

Further than CAD/CAM

• Electronic Data Interchange (EDI)

• Electronic Product Definition (EPD)

• Product Data Management (PDM)

49

Remote manufacturing

• Very common especially in the printing industry

• Maximises savings by manufacturing abroad

50

Just in Time

• Shared information systems

• Reduced lead times

• Less finance tied up in stock

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Automation

• Numerous interlinked sub-systems centrally controlled

• Use of robots for repetitive/dangerous tasks• Monitoring/measuring• Logistics

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Flexible Manufacturing

• Benefits of one-off production at mass production prices

• Only possible with ICT

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Tip 12 – Buy a Revision Guide

• Written for this course

• £3.50 each

• Read it

• Use workbook to check

• your understanding