Year 11 Resistant MaterialsSeminar

7th June 2013

The exam• The exam is 1 hour and 15mins long• Section A consists of three questions

based on the technical aspects of working with materials, tools and equipment

• Section B consists of two questions on the design of products reflecting the wider aspects of sustainability and human use (ergonomics). At least one question will require you to design

You will need to bring with you: sharp pencil, pen, rubber and ruler

The language used in the exam• State, name OR giveThis requires a specific name of a tool, process, construction technique or material.

A one or two word answer is fine.Example: Name a suitable material for the wooden chairTHE ANSWER CANNOT BE HARDWOOD OR SOFT WOOD IT MUST BE

SPECIFIC i.e. Oak or Beech

• DescribeThis requires you to give an idea of how something works. Example: Describe how the Ø60mm hole could be cut in the wooden back.

• ExplainWhen this is used they require a detailed answer and will always carry at least two

marks.

• DiscussWhen you are asked to discuss something you need to give

well reasoned points adding examples to show the examiner what you are thinking. There are usually six marks for this part of the question and these are split as follows:

3 marks for three relevant points2 marks for the quality of your explanation1 mark for a specific example to support your answerEXAMPLE: Discuss the impact that self assembly has had on the design

of many household products. (6)

The language used in the exam

Industrial Production

Pupils should understand:

• Basic commercial production methods

• The impact of new technologies including:– The application of CAD/CAM– Rapid prototyping and rapid manufacturing

• Globalisation

Commercial Production Methods

One-off- The production of a single product (prototype)Batch- The production of a series of identical products

(usually between 2 and 1000)Mass Production or Repetitive Flow- The production of large quantities of productsContinuous Flow- Constant production of products (24/7)

Which Production Method?

One-off

Batch

Mass Production(repetitive flow)

Continuous Flow

Rapid Prototyping

From sketch to prototype in seconds

3D PrintersThe Spider Web Theory

3D printing video10:13

How has rapid prototyping changed the manufacturing industry?

Globalisation

- The modern way of producing, distributing, and consuming products

- Britain grows its own apples, yet we import 60% of apples consumed in the UK come from overseas. Why?

• Just in time is a ‘pull’ system of production, so actual orders provide a signal for when a product should be manufactured. Demand-pull enables a firm to produce only what is required, in the correct quantity and at the correct time.

Just In Time Production (JIT)

Knock Down Fittings

Knock Down fittings or KD joints are the components that fix together flat pack furniture/products. It is a temporary joining method.

A company that sells Flat pack furniture is IKEA.

Why is flat pack furniture cheap to make?

Task:

List the advantages and disadvantages of flat pack furniture

Advantages DisadvantagesGives the consumer a sense of achievement when it has been put together

It may need specialist skills and equipment to put the product together

It is cheaper to buy as the product has not been assembled and takes up less space whilst being transported

Some people perceive this type of furniture as cheap

This product is environmentally friendly as each item takes up less space. More furniture can be transported which cuts down traffic pollution.

The quality of the furniture may not last as long.

Plastic corner block

Scan fittings

Cam lock

You may need to name or draw a specific KD fitting

CAD/CAM

• Use of CAD packages in the school environment for producing drawings and 2D/3D images.

• On-screen modelling and manipulation of images. • Appropriate use of text, database and graphics software

in school and commercial situations • Storing and sharing data electronically • Application of CAD/CAM to the designing and making of

models and prototypes• Be familiar with Computer Numerical Control of machines

(CNC) such as lathes, milling machines, routers, machining centres, laser cutters.

CAD/CAM

CAD (computer aided design)- Use of 2D and 3D design softwareCAM (computer aided manufacture)- Outputting jobs from a computer

generated drawing to a machine, such as CNC lathes, milling machines, routers, and laser cutters

CNC Lathe video and CNC Milling video

MaterialsGo into the exam ready to give specific examples of materials and have an understanding of their properties.

Hardwood Oak Property – Hard, tough, open grained

Non ferrous Aluminium Property – Light, soft malleable

Thermosetting Melamine-formaldehyde

plasticProperty – Hard, strong and scratch resistant

You need to have 2 or 3 examples of each type of material

Task

Name 2:• Hardwoods• Softwoods• Manufactured boards• Ferrous • Non Ferrous• Thermosetting• Thermoplastic

Could you state their properties too?

Can you name two smart materials?

Smart MaterialsSmart materials react to temperature and

light and appear to act intelligently

Polymorph

Photochromic material

Flexiply

How they will ask you about materials

• The exam will either ask you to name a material OR state why a material is suitable.

Name a suitable hardwood for a child’s toy?

Give a reason why beech is suitable for a child’s toy

Properties OR Working Characteristics

• Hardness

• Toughness

• Strength

• Elasticity

• Flexible

• Impact resistance

• Ductility

• Malleability

Elasticity

Hardness/Malleable

Flexible

Material PropertiesPerformance characteristics of different materials have to be

considered when choosing what products should be made of, you need to know the definitions of the following properties;

• Hardness – resist cutting and indentations• Toughness – withstand shocks such as hammering• Strength = 4 types include the ability to withstand...

• Being pulled apart or stretched• Crushed or compressed• Twisted• Sheared as a result of sideways force like scissors

• Elasticity – can be stretched and then return to original length

• Flexibility – bend but not break and return to original shape• Ductility – can be stretched into wire• Durable – can withstand bad weather conditions• Malleability – can be hammered, pressed into a shape

Wood Finishes – Protect or DecorateWood Finish

Details Example Product

Paints Water-based paints are not durable. Oil-based paints are tough, hard wearing and weatherproof. Acrylic paints are quick drying.

Varnishes Polyurethane varnishes give clear, tough and hard-wearing finish = plastic coating that doesn’t go into wood. Can get them in quick-drying. ‘Yacht’ varnish provides waterproofing.

Stains Do not protect wood. Used to enhance the look of wood by showing off grain or colouring it to look like different, more expensive wood or bright colour. Not easy to apply and can look patchy.

Wax Beeswax is sustainable, natural finish for wood that leaves dull gloss shine. It is applied straight on bare wood after it has been sanded and sealed with oil.

Polishing Build up layers of clear polish, sanding between each coat, which enhances look of grain. Also used to seal wood before waxing.

Quality It is important that you know that products need to be a certain quality to be

sold commercially.

• Design – they have to be designed in such a way that they will perform the correct function

• Manufacture – they need to be made so they are both safe and don’t fall apart.

– To do this the correct materials need to be chosen and the product must be made accurately

Quality Control

To help with this process companies will check a certain number of the products. This is called inspection, and would generally include checks on;

– Accuracy of sizes

– Overall appearance

– Surface finish

– The consistency, composition, and structure of the materials

Easy marks to be gained!

Exam tips

• Read all of the questions first before you fill in the answers, especially what they are requiring, such as ‘describe’, ‘explain’, ‘discuss’.

• Underline key words in the questions• Fill in all answers. If you are not sure then

guess!• Look at how many marks are available for each

question• Keep an eye on the time• Always annotate your designs• Do your best