GCSE Resistant Materials ‘A’ Grade

Task: 7: Alessi Museum Feature Clock

Contents…1. Task and Design Brief2. Analysis of Context3. Initial Specification 4. Research into Existing Products5. Product Analysis of PRIMARY

Research6. Materials, Components and

Adhesives7. Designer research8. Ergonomics and Anthropometrics9. User Profile10.Analysis of Research11.Design Specification12.Initial Design Proposals13.Development14.Card Model/ Modelling and testing

15.Final Design16.Cutting List17.Flow Chart of Production18.CAD/CAM Evidence19.Manufacturing Diary20.Evaluation21.User Profile Testing22.Life Cycle of Clock

D es i gn B r ie f …

A w a l l c lo ck fo r i n t e r i o r des i gn w i t h an ad ded , mood l i gh t fo r e f f ec t and a lso amb ian ce .

I w i l l r esear ch d es i gn , in c lu d i ng , a r t , mus i c , i n th e s ty le o f con t empor ar y an d a l so mod er n a r ch i t ec t u r e l i g h t in g and f u r n i t u r e . I w i l l cover des ig ns f o r hou seho ld s and i nc l ud e a mod er n s t y l e o f d es i gn . I w i l l use a l a r ge amou nt o f C AD / CA M fo r access i b l e mass p r o du ct io n .

I w i l l r esear ch cur r en t p r od uct s so l d i n museums and mass p r od uct i on s t o r es , such as I KE A and t he t op i cs t hey co ver. Th is w i l l a l so ad dr ess t he i n t e r es t o f cu s to mer s and i n tu r n th e pop u l a r i t y o f sa l es sho u l d be h i gh . I w i l l make a R R P o f £20 . I w i l l a l so l ook a t 60 ’s des ig n and mod er n des ig n . Th is co u l d in c lu de A l ess i o r maybe Memph is . A lso i n t e r i o r des ig ner s such as D iego R oss i o r R on Ar i d may be co ns i der ed .

I t a l so has t o app r oach en v i r onmen t a l i ssues - I w i l l u se th e eco b i ns i n co l l ege an d maybe co n t ac t s t o r e fo r sc r ap p r od uct .

C ont ex t : 7A ma jo r d es i gn museum w ish es to expan d i t s r an ge o f p r odu ct s on sa l e in t he mu seum sho p . I t w ishes t o se l l po pu l a r p r od uct s i n f lu enced by ma j or des ig n e r as o f t h e l as t 100 year s . D es i gn an d make a lo w - vo l t ag e l i gh t , r ad io , ph one ch ar g i ng s t an d o r iP od d ock i ng s t a t i on i n th e s ty le o f any d es i gn e r a o f th e l as t 100 year s . You can use bo ugh t - i n , o r r ecyc l ed co mpon ent s f o r t h e e lec t r o n i cs e .g . TE P r ad i o k i t s .

Controlled Assessment Task and Design Brief…

I can make the product out of materials which are durable and sturdy. The materials used to house the bulb will need to be negative conductors, but also materials available to me in college. The material will have to be strong and lightweight however to be able to support and be held up by , a hook or bracket. Plastics will consist of acrylic for the lightweight and durability. Also, the plastic will need to be partly translutant in order to be able to emit light from the bulb or light source. Woods that are available are pine, walnut, plywood, oak and miranti. Plastics available are HIPS, PVC and Acrylic.

The product should basically be able to hang from a wall or structure and enable the time to be told clearly and precisely, although not contain the numbers 1 to 12 but another form of symbol, letter, digit or shape. Furthermore ,the product will need to reflect the designer that it is based upon. The product must also be environmentally friendly, therefore, scrap wood and plastic will be used.

It should be qwerty or quirky to implicate a designer such as Alessi. Also it needs to be clever and unusual, hence the numbers refrained from being 1 – 12.

It is designed for a home or room to create a lively and effective mood and therefore light gathering acrylic should be used. The design should be clear and precise but at the same time making the reader think of the design capability and then how the design works.

The materials will be assembled through comb joints and some adhesives. Thin rods will be used as a design feature and also as support.

It is aimed to be sold in either the Alessi Museum or a designer range of shops. Museums of art such as the Tate in London or the Tate Liverpool may also be of interest. However the Alessi museum is foreign so that may cause some problems. Retail shops such as IKEA or Argos and B & Q could also be considered.

To make the product successful it will have to suit its purpose, function and ergonomics, as well as being design and aesthetically sound. To be designed successfully it must have an obvious trend to the designer.

Analysis of Context…

Research into Existing products…

The aesthetics of this star clock are basic yet effective. The colour scheme is attractive and would match several environments. The smooth texture of the surface metals would also give a smooth and aesthetically pleasing look. The product is contemporary and therefore must be a aimed at adults, probably around the age range of 30 – 50. It has a mixture of serious and fun appearances making it ideal for many environments. The product is mainly made of metals. The clock face could be made of metal and glass. The product is smooth to avoid any unnecessary bumps or grazes that could be caused by rough surface. However the edges need rounding as the points may be to sharp for my product. The product looks, in appearance, rather large. It looks to large to be made here in college therefore I need to make my product significantly smaller to that it can fit into the common walls inside a house. The cost of this product seems to be expensive.

The second product is a mood clock. The design looks effective because of its colour is ideal to create the ideal mood and the right atmospheric ambiance in a room. This is ideal for my design because of the colour scheme however the shape is not extravagant enough to be designed for an art museum, this would have to change. The digital display would also be too complicated to make and would therefore too time consuming. For this reason I will stay on the original idea of an analogue clock.

The round clock to the right is created by a basic design of the usual everyday clock. However, the numbers are not just 1 -12. it is how I would like my clock to be, although not so basic in shape. The context of the clock is very interesting and I will use this idea of differential numbers and lettering in my design. Obviously I will not copy the same design exactly but will create another style of labels to enable the time to be told.

The designs shown to the left are Ron Arids bookcase, Alessi company “Citrus basket”, Diego Rossi’s “Agave” light, and “Merdilino.” All these designs are modern and funky in the way of unusual design but include every day functions.

The Basket holds fruit and is designed for a kitchen or work area. The outer poles on my first clock design were taken from this basket. I have incorporated this to give an Alessi feel and also a contemporary style. However the poles will not be made out of metal as it is hard to manufacture and mass produce. I will make the poles from light gathering or frosted acrylic to create mood and ambience.

The “Agave” light is a good design to use as a clock also. The shape is used to give the spiky feel to the second design. Alongside the light I have used the structure of the twisted poles off the side of the clock to add a design feature. Unfortunately, I could not find a picture of the vase other than in a text book and therefore no picture is shown.The bookcase is used in the third design. I liked the way Arid used the curly shape to create atmosphere and even he himself said that it was unusual and that he liked it. The bookcase would look good on any wall and is suited to any colour. Therefore I will use dark or black, light or white plastics, to make it so that it is easily twisted. I will only use scrap acrylic for the numbers so I can address environmental issues.

The toothbrush “Merdilino,” is used to base the forth design. The base and supporting stand on the head of the clock is designed as a red semi - sphere. I used this design because it is basic yet effective. It will stand solo and will be made for a desk or working space .Therefore it will need to be compact. The size of Merdilino is ideal.

Research into Existing products…

Research into Primary Photographs…

The final products below and to the right were taken by myself from home.

The first product was a free standing brass clock. The hands would be ideal to create or replicate for my design. The numbers in my design however will not be roman numerals as I feel they are to sincere for the type of young stylish person it is aimed at. I will not be making my design from brass as it will not approach the environmental issues. The mechanism however is very similar to the one I shall be using in my design.

The second clock , a wall clock , is also in roman numerals and again too sincere. The scales are too accurate for my type of design. It is too “straight and formal.” It does not reflect Alessi in a significant enough way for me to use. However I could base a design on the clock and form a twisted shape or deform the design to reflect Alessi more. The size of the product is ideal for my design.

Acrylic can be coloured, moulded, cut, drilled and formed, making it ideal for many applications including windshields, skylights, taillights, and outdoor signs. Acrylic is a useful, clear plastic that resembles glass but has properties that make it superior to glass in many ways. This makes it ideal for my design as it means there is less work to do and there is in return, no glass work involved and this also make the product less likely to crack on shatter if dropped/fallen.

Another great advantage of acrylic is that it is only half as heavy as glass. This makes working with acrylic much easier. It can also be sawed, whereas glass must be scored.I will use this in my design for the poles, I will use the light gathering acrylic.

It will be used in my product as the majority making the overall product. It is light and can create effect , especially with some sort of light source behind it.

Materials, Components and Adhesives…

MDF or medium density fibre board is relatively cheap to buy and is strong and durable. MDF can withstand drops and bumps. Even those from a height, this is ideal as it can also be cut via a router into the correct shape, which means accuracy should be high.

Another advantages effect of MDF is that it can be covered with a variety of finishes. Although this is a good factor, there are several finishes which, in my eyes, are not compatible because MDF does not have a grain or pattern on the wood, therefore it is best to be covered.

Spay paint will be the finish for my design as it is super smooth if done properly and are is long lasting. I will ensure to buy car spray paint as the finish is shinier and more attractive. However this also releases gases which are in voluntary so therefore in industry I would use a water based paint.

PVC is a light plastic which comes in a variety of colours, therefore I will use it for my hands so that if I make large hands there is a higher chance that the mechanism will move them.

Research into designers…

ALESSI products are still considered as being handicraft items made with the aid of machines: by this I mean that, even though we rely on contemporary, industrial technology and processing equipment, at depth our practice - the one I believe we ought to stick to, our inherent attitude is still rooted in a handicraft culture. Their product are mostly quirky and out of the ordinary. Therefore I must ensure that my product is the same.

ROSSI creates items based on nature. I will use the ides of Rossi will be used in my designs to reflect either stars or flowers. These are shown on the development will be added feature to give the overall clock added effect. The light shown is the effect I would like to achieve through my products light.

As in his Rover Chair, I can see RON ARAD’s early use of borrowed materials evident here through his use of borrowed concrete blocks. Additionally, this is the type of method I will use. I will use as many recycled materials as I can to implement arads ides and style. Because his ideas are enjoyable, and unique individually. I will be using his ideas in particular, his bookcase, to create some of my designs.

Anthropometrics literally meaning "measurement of humans", in physical anthropology, refers to the measurement of the human individual for the purposes of understanding human physical variation. Anthropometrics don’t really apply to my product that much however the product itself my need to include certain gaps and holes to support or hold the lights etc.

Ergonomics is the study of designing equipment and devices that fit the human body, its movements, and its cognitive abilities.Ergononimics in my design will only apply to the products size and not to humans. The functioning clock will need to be able to fit to the face of the product as will the light and speaker. The hollow inside of the product will need to fit and support three sets of wiring, circuit boards and batteries. Images of myself taking apart this clock mechanism are shown.

The pictures show the components of the clock. I have also shown how the clock will hold the “hands” in place, (via nuts and bolts.) My only concern here was that the hands on the TEP kit were very small, too small by far to be used on my clock. The hands will need to be made from plastic formed on the laser cutter. However the concern would then be that the mechanism would not be powerful enough to move the bulkier hands. Its size is 70mm X 70mm. I will ensure that the clock somehow covers this so it is not exposed to the user in the product at all.

Ergonomics and Anthropometrics…

User Profile…

Name: Michael KellyAge: 20General Interests: Landscape design, Modern art. Musical art and comprehensive design.Occupation: Student Hometown: LiverpoolCost limitations: Between £10 and £20Desired Product out come: “I would like the product to be stylish… Like myself. Also Fitting to the modern outlook on art and design. Preferably a would also like it to be related to Architectural Designs but this would not be 100% necessary.”

Name: David and Amy McDermottAge:21 and 22General Interests: Art and design, lively colours Occupation: graphic designer and artistHometown: ManchesterCost limitations: £20 - £40Desired Product out come: “We would like the product to be bright but fit into the environment around it so not to colourful therefore. A good mixture of colours which match and do not overpower. Also it needs to create a set mood.””

Name: Holly BessexAge: 18General Interests: Media and Music , Modern Occupation: StudentHometown: WarringtonCost Limitations: £15 - £20Desired outcome: “I would like the product to be generally modern and colourful to match my home environment which is also modern.”

The research into designers was a key element to my overall research for the making and designing of products. I decided from the start to make a product which relates to Allessi and other modern designers. To do this I would have to know about 3 or 4 designers and the type of work they produced. The research was good and greatly influenced my designs. The designers are all contemporary and this seems to be the theme throughout. Therefore I will ensure that my product carries the same theme.

The research into existing products had to take into account the previous slides of designers. All six were used to base my designs upon. A few on the third slide are primary research. I will use the measurements of the clock to the left to design my own. The pictures also demonstrated how professionals make their mechanisms and how they store them.

The research into materials helped me to decide a final material for each component of the products. The materials I will use have to be environmentally friendly. Some exceptions such as Acrylic will obviously be outside the category. The research was good and detailed enough to influence my decision on the materials necessary to create and develop my product.

I had to research the definition of ergonomics and Anthropremetrics. I then used the definitions to explain how they are going to be used In my product. I then took several pictures to explain why they are necessary. This will help me to decide on how I will store the mechanisms and also the size of the vacuum formed box on the rear which will store them.

Analysis of Research…

• The Final design will be based on Alessi therefore the size and shape will also be similar, the theme will be conveyed through colour and style as well as size.

• The centre piece of the design will be APPROXIMATELY 130mm in diameter plus created of light “gathering” or multicoloured tinted acrylic, this will create luminous and glowing effects from behind the face of the clock using lights. This will turn out to be “aesthetically Pleasing.”

• There is also the issue of the clock mechanism. This will be hidden from view directly behind a small circle of solid acrylic; minimum size of 70mm x 70mm

• It will be manufactured out of materials from the “eco “ bins in college but also as less materials as possible to ensure that the environment is protected and resulting in my product being sustainable. This will also mean that LESS VIRGIN MATERIALS are being used.

• I will make it easy to mass and batch produce. I will ensure this by using machines available at batch production. For example the CAD/CAM machines such as the Boxford Router, laser cutter and vinyl plotter will be greatly used in my design.

• The design of the wall clock will be a “criss cross” pattern created by laser cut frosted acrylic. This will be the border of the overall product creating a contemporary mood for the overall clock.

• Even though spray paint is high in VOC’s, I believe it will give a more professional finish. Therefore I will use spray paint on all MDF pieces. I will make up for this by using other materials from the eco-bins.

• It will include a bulb and need some sort of holding device to store / hold it safely, thus take into account the dimensions and sizes of these.

• I will also complete any finishing processes by hand. I will manually add the finishes to my design instead of using machines to reduce the CARBON FOOTPRINT of the product.

• It should cost no more than £30 to manufacture as it needs to be sold in the Museum shop and should therefore be affordable for customers. I will try and limit the cost to this by selecting cheaper materials.

• All edges will be rounded for safety to ensure people don’t injured themselves on the product.

Design Specification…

The function of the first design is a clock or mood lamp. It will be made and designed for either a art museum or large store such as IKEA. I based the design on alessi’ Citrus basket. It will be made from two main materials, Oak for effect and general strength and also acrylic for effect. The acrylic will be light gathering also to make the design even more of a mod lamp. The centre piece will be also made from blue acrylic. I found that in the market research that for mood lamps, blue or turquoise is the favourite and it will therefore appeal to young and old, 3rd and top classes. The wood will be finished with either varnish or bees wax. I will also address environmental issue with using scrap poles of acrylic. This will help achieve the randomness I hope to achieve in pole length.

The second design is based on the primary research. It is a wall clock and it has also the alessi vase curves. It will be made from different styles of wood. Including mahogany, Oak and Miranti. The poles sticking off the sides will be made from again, acrylic rods . It will be finished off with several coats of varnish or coloured emulsion. The poles may also be made from wood, cut on the router and forced into place using a finger joint. The style is good and the size is perfect, however I do think that a lot of fresh wood would more than likely to be needed. Not in fact improving environmental capability. Also the edges will be too sharp, however they could be flattened too avoid any injury.

This again a basic wall clock. It will be made from scrap metals. This could cause a problem in the terms of joining. The initial idea was too weld the pieces together, however after realising that such a function is not available at college, I had too change the idea. The main body, a I have said, will be made of metal. The numbers and clock face will be made from acrylic. To add a certain effect to the design. I may even add vinyl stickers too the design to create patterns and sequence. There will be know applied finishes, only sanding. I will use hand cutting saws and also the laser cutter for this design. This design is based on Ron Raids book case. It is good and effective, however could be too large and heavy to be held on a wall bracket, which, is a key part of the design.

Initial Design Ideas Proposals…

Initial Design Ideas Proposals…

The function of this design is also a wall clock. No finishes are necessary because it is made from solely plastics. This is good to catch the light in the background. The aim of the light however was to not only create mood but also to make the numbers easier to read. The use of vinyl blackout stickers on my design help to achieve this. I am however conscious about the design because of the use of plastic. I feel it does not up hold the rule of environmental issues.

The second design on this page designed from the basic British flag. Again the clocks is too basic in shape and too box like. I will make the design out of wood alone, either MDF or Oak, It will be hand cut. Some machines like the band saw may be used however the majority will still be cut with a coping saw. I will finish the product with either emulation paint or beeswax. To gain the colours shown on the picture, Vinyl stickers may have to be used. The product is very environmentally friendly as it uses wood as the most common material. I will need to sand the product to create a smooth finish and this will be done on the machine and by hand.

The third design on this page is designed around the curves and shape of Fernando Campanas “Boa Sofa.” It is made from metal and plastic. A light will be stored in the back so that the plastic numbers, which are represented by shapes. Will glow and shimmer in the dark when the power is turned on. The main body of the clock is made from metal, this could cause a problem with the environment and so I am not sure if I will have enough time to create and perfect this design to the best of my ability. It will be mostly hand cut. But and acrylic will be cut on the laser cutter. This is a good product as It creates mood. However it is bad in the sense of the environment and also the time needed. There are no applied finishes, but the metal will be sanded to create the ultimate shiny effect.

Initial Design Ideas Proposals…

The tallest of the pictures is based on alessi, “medallion.” It is a free standing clock for a desk of work surface. The clock will be made from plastic acrylic, and also oak and metal. Io can afford to use non – environmentally friendly materials on this design because it will only be small and compact. It will be finished with sanding and also varnish. It will be made on the strip heater, Laser cutter and by hand.

The star looking clock is based on Diego Rossi's Agave light shade. It will be made from plastics alone. It will also be made from acrylic on the laser cutter for accessible mass production. The vinyl stickers will also be used to make the text clear. The effect of an added light on the clock will allow mood changes and create the ideal atmosphere in a room. I have used bright colours to reflect this. The product is very effective, however it is a problem to the environment.

The next design shown below is based around a clock I saw within my primary research. The numbers however on this clock are more colourful to reflect alessi more than the original design. I would make the product from light gathering acrylic and also a mixture of oak and meranti. This will gain brittle strength as well as contemporary effect. The centre of the clock will be the mood lamp. Separate sections of coloured acrylic are used to make telling the time easier.

The final product on this page is based around Walter wayles, “Wanderhur.” It is a clock for the wall or freestanding. I will make this out of Meranti to create classy and cool composition or art and design. I will construct the piece by hand, band saw and also router. I will finish the clock with a cover of different coloured emulation and/ or gloss.

The design to the left is generally a good design, however there are a few negative points to be made. It is the most basic design so therefore would not be difficult to produce. But this could be a bad point as there are loads of designs that would be similar to this and therefore it is not unique as it should be.

This second design, again, would be easy to produce and, mass produce. It is certainly bright enough to be associated with alessi. I'm just certain the circles are to basic.

This design is also funky in its shape. Definitely good enough to be used and sold in the art museums. I designed this out of metal and this would be to hard to make and would be too time consuming to create. It could be made from a wood or plastic but it would take again to long to cut out with saws and it is not environmentally friendly to use totally plastic.

This next deign is ideal for the brief. It meets all criteria and there is a lot I could do with this in the terms of materials and indeed finishes. This is considered as the only design capable of making so far.

This design, shown to the right, is clearly designed around alessi. However I think it is to similar to his designs and therefore is not an option as it may be considered as too similar and copied.

The design based on Ron arid book case is another ideal design however I originally planned for this to be made from metal and therefore the material choices will have to be reconsidered.

This deign is far too basic however would be ideal to link to up coming events as its colour scheme is the same as the Olympic rings! The product will be made out of MDF and acrylic.

This is the second option for my product as it will inspire thought as it is supposed to and would look exceptional amongst the art work and sculptures in a museum.

This product, I have decided, is my final product. I have designed this around the alessi fruit basket and it would therefore fits in comfortably to my chosen theme. The product could easily be changed and expanded so that there can be changes throughout the process. There is one problem is that it will be needing a lot of acrylics so therefore is not totally environmentally friendly.

Initial Design Ideas Proposals(Google Sketch - Up)…

Design strategy…

Materials:

Materials will consist of mainly MDF for strength and design as it is easy to spray paint and finish, and acrylic to add colour and ambiance for the lighting, the MDF will create a comprehensive effect. I choose these as my main to material as they can both be mass produced.

Finishes

Car spray paint will be added to apply an overall better and smoother finish, this will needed to be sanded with wet and dry but will look better than emulation r other paints.

Joints and components

The main body of the product will be glued together and a 3mm piece of Acrylic dowel will be added through all the pieces in order to add extra support as well and design, this will be light gathering red.

Ergonomics

I will ensure that the design is ergonomically suitable for the walls and to ensure that all components will match to their own holes. The piece of white circular acrylic will need to be added to cover the clock mechanism and will need to be the correct size.

Social, moral and cultural

I will need to ensure that the design does not offend different cultures or social classes. That it is not seen cause violence or injury and also that it is of a low price to connect with all types of buyer.

Adhesives

I will use Tensol glue to glue all Acrylic together and well as Araldite to glue acrylic to wood. I will clean all light gathering and frosted acrylic with methylated spirits.

Development of the final Idea…

The original design was to simply have several varieties of poles protruding from around the product. I have firstly developed the idea to have rings with 12 LED light bulbs built in, or one big light behind the clock face. This then turned into a much more wacky and bendy design than before. However there will only be one thick layer of the shape cut on the router. The colour scheme has been kept the same because it works well. The blues can go with most colours found in the home. Most walls in a home are light colours which will generally work well with the colour scheme I have in mind. The rings for the top picture will be made by the laser cutter then glued into place using Araldite and tacks to keep it in place.The squares on the bottom picture will be cut the same and then jointed using small metal rods , “grubs” or nuts and bolts. The shape on the left will have to be layered to gain the thickness and the acrylic will be cut on the laser cutter to gain the exact shape and will also be glued in layers with tensol and then a thin metal rod for support. They will then be glued to the product with Araldite.The final, fourth product will be made in structure as the first and constructed the same. Except this time it is made with jagged edges and not rounded edges. Instead of layering the plastic I could also rotate the same shape at different angles to create a greater effect.

Development…The poles on the outer of the product are not shown on the design CAD work as they were too awkward to develop and were not able to be created on the program available.

To create the poles on my design I will design the outer shape in 2D Design Tools and then cut it out using frosted acrylic cut on the laser cutter in a solid shape, unlike my original idea shown to the left by which I could use several rods joined with Tensol and comb joints. As I think this will be easier to make and more secure when finished.

My clock face will need a considerable amount of work and thought of how it will be attached. My original idea was to just screw it to the front, however this would leave an untidy finish so I will cover the holes and screws with another white ring of acrylic which is removable in order to gain access to the screws. I shall use either a hinge or hook to gain this feature. This is shown below.

Then there is the problem of the visible mechanism, I shall cut a small piece of acrylic which shall be attached at the centre in border to hide the mechanism. This is also shown below. I tested to see if this would be hidden on a scrap piece of card and it worked.

Development…

I was originally going to make my product from plywood bent around two pieces of solid MDF. I changed my mind when I realised how difficult this would be after testing some plywood. It will be easier to cut some MDF rings and have acrylic rings in between them to allow the light to shine through giving it a more aesthetic appeal. I will cut all MDF on the Boxford Router to make sure they are all more accurate than if I did it by hand.

You can see from left to right how each of the rings would be assembled using araldite glue for strength. This would make it string and more durable. Also MDF is more environmentally friendly than using Plywood as it is made from recycled woods.

I will finish off the product with car spray paint for a smooth and aesthetically pleasing look and also for protection. I will have to use glass paper and wet and dry paper to ensure an extremely smooth finish. I will need to use 9mm thick MDF which I will use on the centre of the product. I will be having two borders and some of the inside rings made from 6 mm acrylic which will be attached to the sides on the inside using small grooves and also small 3mm diameter screws as well as the acrylic shelf glued using Araldite.

Development…

I will cut all of my acrylic pieces on the laser cutter because it will make my pieces accurate and precise instead of cutting it by hand as this would take longer and not achieve the desired finish; even after wet and drying the edges. The hand designs are also shown below, these will be cut out of HIPS as this is light and can still rotate on the clock mechanism without weighing too much.

The pillar drill, show bottom, will drill the holes into my wood and plastics when they need to be joined together by the 3mm rod.

Tensol glue will be the glue that I use in order to hold my 6 plastic rings in pairs.

I shall also use araldite to glue the acrylic to the MDF as support to the dowel and Tensol.

The rings of Acrylic will be glued, with tensol plastic glue. Also four holes will be drilled through all of the pieces or order to add 3mm rods of wood through the whole product in order to add strength.

Modelling and testing (on card)…I designed all of my card model on 2D Design V2 using CAD. I then linked this up to the laser cutter (CAM) to complete my design and cut out the card sections. I chose this because it means all of my acrylic designs are completed as they would be on the day and I also know how I am going to assemble my product and also how accurate my work will be. I was aware that CAD/CAM would make my work more efficient to construct and would also make my work more accurate and easier to create. Thus saving on waste and company money if made in industry.

After finishing my card model I have decided to make my clock a lot shallower in order to create it easier and more effective, although not as heavy. I will remove approximately 150mm off the depth to save materials and ensure it hangs safely on the wall without falling off. Other than the depth it does feel that the other parts of the product are as they should be. When comparing it against the specification, I feel that my product has been completely successful as it works and functions as intended.

In addition to this, I have added a border which I based on the Alessi fruit basket. I think that this completes the overall design and meets the design brief comfortably solidifying the appearance of Alessi.

In making this card model, I have reduced the time spent and also materials wasted. It has also shown me how my design will appear when finished and the advantages and disadvantages of the design. I can now see that it is easy to move around and looks good in any environment, although colour choices may yet be an issue in certain circumstances and I have not been able to address this aspect as yet. I will only have a really grasp of colour once made as it is too big to waste frosted acrylic in the testing. We have no other frosted materials to test on in school.

Final Idea…

I will make the centre of the clock out of a mixture of acrylic ( Light gathering) and 9mm MDF I have chosen these materials because they look great together and compliment each other but only if the right colours are chosen. The acrylic will be cut on the laser cutter using CAD/CAM and 2D design. The MDF will be cut on the roater. This will speed up the time spent on my design and allow me to spend extra time on sanding and filing to create a smoother result.

The rings for the out side of the product will also be made from acrylic and cut on the laser cutter to save time. Acrylic does also not need any sort of finish which also allows even more excess time for any necessary finishes I may need. Also after I have finished this I will also create another secondary border also out of acrylic so that my product can have some extra design features.

The text and the numbers which will be added at the end of the task will be cut out on the laser or vinyl cutter. They will be used to give the piece some more relevance to art and design which is my overall theme. The text will be design on alessi.

The hands which will be added at the end of the task will be cut out on the laser cutter. They will be used to give the piece some more relevance to art and design which is my overall theme. The text will be design on alessi. They will be I have changed to this design from my original idea of simple numbers and have decided not to have the titles of meal time around the outside as on my original drawing. I changed these to meet the theme of alessi and his weird and wonderful ways. It does look better like this and therefore I will keep it like this.

460 mm

440 mm

150 mm deep

Cutting list…Part Materials Thickne

ssSize (mm)

Colour Quantity Finishes to be applied

Border - Exterior

Frosted acrylic 3mm Green 1 N/A

Border - Exterior

Frosted acrylic 3mm Blue 1 N/A

Border - Interior

LG Acrylic 3mm Blue 4 N/A

Centre LG Acrylic 3mm Orange/Yellow

6 N/A

Centre MDF 12mm N/A 6 Emulsion

Mechanism

Hands

Face/Numbers

N/A

Acrylic

Acrylic

N/A

3mm

3mm

N/A N/A

White

Frosted green, solid White

1

2

24

N/A

N/A

N/A

Flow chart of production… (x2 slides)

Design wooden parts on the 3D Design program and set up the Boxford router. 1hr

Open up the software and copy the design from the 2D design onto the screen set the scale to 90mm by 90mm. 1hr

Quality check: Are all the rings exact ?

10 min

Sand the product well using first the sander and then different roughness's of sandpaper degrading each time so that I can create a smooth finish, initially for the exterior of the product. Use Wet and dry to create the super smooth finish for your spray paint. 1hr

Quality Check: ensure the product has no bumps or scratches.

Spray the product with the filler spray for the undercoat of the polar grey spray paint. This will need to be applied several times and could take up to 15 minutes to dry for each coat. In total the undercoat should take around one and a half to two hours to be completed. 3 hrs

Afterward complete the exterior coloured paint in the same way, applying as many coats as necessary. See the can instructions to check up on this when the paint and filler is purchased. Again several coats may need to be added so I will allow two hours in total. 2hr

Design the rings for in-between the MDF circles. These will need to be designed on 2D design to the same measurements as the MDF rings. They will be cut on light gathering acrylic and will create the mood atmosphere30 min

Make sure all pieces fit together and line up and then drill through the plastic pieces will a 6mm bit so that the rod can run directly through all of the segments. Do not cut and make the back yet as this will be made later. 30 mins

Quality Check: check all pieces line up

smoothly.

I will need to create them out of the correct plastics and colours. However, there is no need to design them again as I can use the same design sheet as the one for my card model. 1 hr

I decided to use the border inspired by Allessi fruit basket. I will cut them on the laser cutter from two sheets of frosted acrylic - one blue and one green - so that the contrast of hot colours from the rings in the centre and cold colours from the borders can interact with each other.2hr

Glue the border acrylics to the product with Araldite glue. Glue two light gathering acrylic circles, one yellow, one orange together for effect. 30 mins

Quality Check: Does the acrylic line up with the MDF

Start

Ensure the 6mm blade is in place using the tools. If it is already in place then start the mill, continue for the 6 rings but ensure that two have engravings for plastic.

10 min

Flow chart of production… (x2 slides)

Cut sand and spray the back of the product. Then drill a small hole to screw the light to. The light will also need a larger hole for wires and maybe some small holes for ventilation. This will be attached immediately and then tac into

place on the back of the product.1hr

Construct the hands on 2D Design and cut from acrylic , the hands with the mechanism are too small and basic. Be aware of weight. 30 mins

The figures will be cut out of an orange or black piece of acrylic and stuck onto a white ring which shall be hinged. This allows access to the clock mechanism. I will also place a small circle to the front made of white to hide this mechanism.1hr

Quality Check: they all evenly screwed and are the gaps equal and the same?

Assemble everything together as one product and when everything is working, attach the chosen hook to the back and ensure it has the capability to hold the product in place. There will be instructions on the packaging to follow to cover this. When everything is in order turn on and see if the product is fully correct and functional.1hr

Quality Check: There must be a small hole in the centre for the mechanism to fit through. the hands.

END

Evidence of CAD/CAM…

I used 2D Design to draw out the MDF rings for the middle of the clock / lamp. These were cut out using the Boxford Router which took about 2 hours in total to put in the machine and change all the tools. I found when I came to use the router that the wrong drill bit was in place. I also had to swap this to a 6mm drill bit so I could use it on my MDF as shown opposite.

If mass producing the clock, I could keep on pressing “make another“ so that it was easier and quicker for me to create exact replicas of the product. I have designed my product previously for my card model on 2D design V2. I copied it into the router software and started the mill.

I used 2D design software to design all my acrylic pieces and then used the laser cutter to cut them out. My 2D Design screen shots are shown opposite. I used the process so that I can manufacture my product quickly and efficiently whilst receiving a proper and accurate result and the correct finish. The pieces were cut out of acrylic for effect and also simplicity when constructing. The two sets of borders and also the clock face and hands were cut on the laser cutter.

The settings for each process on the laser cutter are below:

AcrylicCut – Speed 1.7%, Power 100%Engrave – Speed 90%, Power 10% HIPS (High Impact Polystyrene)Cut – Speed 2.2%, Power 100%Engrave – Speed 2.0% Power 100%

Without the use of CAD/CAM my product would not have the same quality finish and I would not have made it in time to finish the project.

Manufacturing Diary with QC…

o The router was used to cut the MDF rings for the centre of my product. These were first of all made on 2D design.

o The router was a good advantage to my work as it enables easy production ideal to the design industry. And is not as time consuming as cutting it by hand it is also more accurate.

o There was no real problems with this method however plenty of advantages. There was therefore no corrections or changes either.

o I had to ensure that I was stood near the safety button and that I reset the mill to the start position before opening the protective lid.

o I then sanded the MDF using Sandpaper. I used a cork block in order to give a better finish. This had to be smooth so I could spray-paint it.

o I have also used the block to give it a flatter result.

o The advantage of this is that my product will have a better finish.

o I before I could spry – paint my product I must first of all have given it several coats of filler primer.

o I used a spray booth to do this and then had to sand the outcome with wet and dry in order to give it a smoother finish when applying the colour.

o The advantage of this is that my product will have a much better finish than if I had used another type of spray, emulsion for example, this also give a better surface for my spray paints.

o I then designed and cut out my plastic pieces on the laser cutter which were designed in 2D Design first. These rings and other shapes and borders were then cleaned with chemicals.

o As this was all completed by machine there were no problems at all concerning the plastics.

o Because I had made the plastic rings too small for the wooden sections a these had to be altered in this process by a few mm. also I had to ensure that I had a safety mask when using the methates as the fumes can cause discomfort.

o When the filler primer for my MDF was dry I used the coloured polar grey spray several times- around 4– 5 around the edge of my product however I did not cover the front and back because they will not be seen when I glued the front to the back.

o the only problem is that some oft the glue does run so partly smothers the smooth finish, when sanding this again I added a rounded edge inadvertently. This then had to be filled slightly,

o I glued the two pieces of MDF into pairs. This was created with PVA.

o I used the glue itself and also a small plastic piece called a spatula.

o the only problem with this is that it would not be strong enough to hold as one piece when the whole product is together, so , as you can see, I Have drilled four holes through all the pieces so that I can put dowel through it all for more support.

o these were then clamped to the desk in order to apply pressure and a strength to the finish.

Manufacturing diary…

o I then cut out my clock face and numbers, when I did this I first designed them in 2D Design then cut out of acrylics on the laser cutter.

o This did in fact go superbly. There were no errors at all. As I would expect considering it was all done by machine. I had to auto set the machine to ensure it was in the correct place. For smaller tasks I used scrap acrylic so also needed to ensure that they were in the correct place when the machine carried out the task.

o When I drilled the holes into my product I drilled some of the holes in the wrong position. To resurrect this I ensured that they were not visible to the eye when the product was put together. To aceive this some of the holes are filled with small pieces of dowel so that when the product was painted it would not be seen.

o Next time I use the pillar drill to make my deign, I will make a jig to ensure that the holes are drilled in the correct place. The holes are all 3mm. The jig will, next time, be cut on the laser cutter out of card not plastic. This also therefore addresses environmental issues.

o I then had to cut the screw size down as I stuck out of the clock to much at the rear. I then screwed the light to the back of the product, ensuring the at the wires carried through the hole and through the hole in the MDF.

o Then my product had to be araldite together. This was done as extra support of the light gathering dowel. There is also a white disc to partly hide and drilling errors and add extra design. The numbers were glued using araldite to the border and the dowels put in place. The three top rings were glued together with tensol so that the face can be glued to the front of it for easy access.

o This is to make sure that the product does not fall apart when in use. It also ensures that it is neat and tidy.

o I then designed and cut out the hands on the laser cutter. These were cut on orange PVC so that they could be moved smoothly by the mechanism. These were made of orange in order to meet the colour scheme.

o Then I screwed the back and the acrylic front onto the clock to not only complete the design but also and design effect.

o This went very smoothly and next time there is nothing I would change.

Evaluation against spec…After consideration of my product against the spec the only area I did not take into account was that of the cost. This was mainly because I was not aware of the full price of acrylic and the amount used at the end was not the amount I was going to use at the start. However I felt it was necessary to use this amount to create the effect I wanted. I also added further components such as the lamp which cost a further £6, the clock mechanism at a further £3, other purchased components such as the screws with mirrored affect caps and wall mounted brackets. So overall it was very expensive, yet if eel these extra’s are what make it a commercially viable product.

Evaluation…oThe product meets the criteria on the specification in several ways. In the specification it states that the product must be based on Alessi. My product has a clear link to Alessi and its designs. The borders are not only brightly coloured, for example, but they are also clearly based around the citrus basket designed by Alessi. Although the final product does not have made compartments for any protruding wires it does hide mechanisms on different ways and install certain functions well. It does also turn out to be aesthetically pleasing, the colour schemes match superbly and it would match most environments.

oThe product is easy to use because there is easy access to the centre through small screws at the front which are also a good design feature, this is also good because it allows the change in battery easy to achieve. The light at the back is easy to turn on because of the long wire protruding from the back hole.

oThe product also functions in the way it should. The light turns on giving an overall pleasing effect. Plus the mechanism is strong enough to turn the hands with enough power so therefore the clock works also.

o There was one continuous comment which says that the screws are too dominant to the outcome and also that they need to be covered with a cap. Therefore I used this feedback and bought some chrome capped screws to hide them.

oThe intended user would indeed purchase my product as through several views from the picture I have found that most of the people I asked were in my age range and liked the colours and they enjoyed the size and scale of the product.

oSome consumers did think that the colours would not match all of the wall colours. For example, the orange and yellow would not match a pink or green wall. However if it was put with the correct wall colours, i.e.. White, grey or black. It would match superbly. This was my main problem. If this product was to be made again, in this case, I would ensure that there were neutral colours. Another problem was some persons did not like the screws on the front of the product. This next time would be made with a hinge or another form of joint.

oThe product was mostly made out of plastic so therefore is not green total. The products plastic is key to its design so this cannot really be significantly reduced. Alternatively I could have found more reusable plastics from recycle bins or use recycled plastics that are bought in from eco friendly stockists. This would have needed further planning that I had not thought of. Spray-paint also releases gases which are involuntary so therefore in industry I would use a water based paint.

oI would not make any modifications to the products appearance. But the manufacturing could be made accurate in some ways through my lack of knowledge when working with certain machines.

oThe main problem I had when making and constructing this product was that I drilled some holes in the wrong place on the pillar drill. This I attempted to resurrect with small dowel pieces within the MDF. This is now not visible. However for the next time I make this product I will ensure that I first create a solid acrylic or card jig to make sure that all MDF pieces are drilled correctly. Also, at first the spray-paint would not stick to the MDF. This was time consuming and overall quite disappointing. I will next time ensure I use a better quality paint such as Plasticote and not Halfords own car spray-paint. Although it was cheaper it is much better to gain a better result and spend the extra money on a quality spray.

Evaluation…

• My original idea was to have the light gathering orange on the exterior however when it came to be glued the tensol would show through. Therefore I ensured that the solid white was on the exterior.

• Also I added two layers or coloured acrylic as large numbers as part of my results said that some people could not read the time smoothly.

• I feel that the product in its final form is as expected, even though there were a few errors that could be resurrected easily when made again in mass or batch production. In my opinion, it followed the design proposals and specifications religiously apart from the costing's which would be improved next time.

• To find out what other people thought of the final product, I designed a questionnaire which is concluded on the following pages.

Intended User Questionnaire…

results…

Name Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9

Danny Smith 15 - 20 Male Yes Yes No Yes – Its Colourful and

Jazzy.

Possibly Self - coloured Yes

Emma Quinn 31 - 40 Female Yes Yes Perfect size – Good fashion

statement

Yes defininetely, contemporary and stylish

yes Dual coloured

Yes

Mike Kelly 15 - 20 Male Yes Yes, its a good size

possibly Yes – Used Modern colours

effectively

Possibly Yes Yes

Johanna Phillips

21 - 30 Female Yes Perfect Yes Yes – its retro and colourful

No N/A Yes

Sheena Brownbill

50 + Female Yes No, Its too large

Yes Yes its very bright

Yes Yes Yes

Intended User Questionnaire…

Following my questionnaire I found that most people agreed with the colour schemes. I do need to practise my machinery skills. I added the large white and orange numbers at the end of the product so that the part of the evaluation which touches upon the visibility of the time is improved.

results…Nam

eQ10 Q11 Q12 Q13 Q14

Danny Smith

Unique • screws are too dominant•There is small amounts of glue showing•Good hand designs•Nice weird Shapes

Possibly No N/A

Emma Quinn

Unique •Excellent creativity•Good style•Some further enhancements made to enhance the colour.

Yes Yes There are some errors and you could improve these by having

better planning and more confidence with machinery.

Mike Kelly Thought provoking

•Easy to read•Unique design• Letters are not evenly spread out.

Yes No N/A

Johanna Philips

Amusing • Colourful• Easy to see the time.• Led light could be used but the main light could also be duller in order so they can be seen.

Yes Yes There are some small errors visible, other than that any errors are

hidden well

Sheena Brownbill

Contemporary • Good creativity•Excellent colour scheme• No mistakes would be good.

Yes Yes N/A

Intended User Questionnaire…

Life Cycle of Clock (MDF)…

The dust and shards of the trees cut down are then collected and piled up ready to be compressed and injected with Epoxy resin.

All the small shreds and dust are compressed into one solid piece of wood – MDF – this is then left to dry.

The wood is then transported to schools or factories around the country to be used on projects and products. Any scrap is the recycled and put back into the system.

My MDF body originally started out life as a simple tree which was then cut down and collected and then eventually “skinned”.

Paint and other finishes can be striped and removed before recycle.

Final product is sold.

Life cycle of the clock (Acrylic)…

Acrylic plastic polymers are formed by reacting a monomer, with a catalyst. A typical catalyst would be an organic peroxide. The catalyst starts the reaction and enters into it to keep it going, but does not become part of the resulting polymer.

Molding powders are made by a process known as suspension polymerization in which the reaction takes place between tiny droplets of the monomer suspended in a solution of water and catalyst. This results in grains of polymer with tightly controlled molecular weight suitable for molding.

Acrylic plastic sheets are formed by a process known as bulk polymerization. In this process, the monomer and catalyst are poured into a mold where the reaction takes place. Two methods of bulk polymerization may be used: batch cell or continuous.

Final product is sold.

The acrylic is then transported to a school or production line. Then altered and manufactured into the correct shape via band saw, hand or, most likely, laser cutter.

There is not an easy way of recycling acrylics but there are companies which can separate and melt down certain component so that it can be used partly again.