Specialist Technical Principles 30%

• Thermoforming

• Thermosetting

• Soften when Heating

• Can be Reshaped

• More commonly Used in Schools

• Easy to Recycle

• Initially Set by Heat

• Can't be Reshaped/Reformed Once Set

• Extremely Strong & Durable

• Resistance to Heat

• Difficult to Recycle

• Synthetic Compounds: Crude Oil

• Naturally Occurring Compounds: Rubber Tree

• Plant Based Starches: Corn Starch

• Rods

• Sheets

• Squares

• Powder

• Granules

• Foam

• Film or Rolls

1) Crude Oil is Heated

2) Fractional Distillation Occurs in Crude Oil Distillation Unit. (CDU)

Separates Crude Oil into Different Compounds or Fluids

These Fuels contain Large Hydrocarbon Molecules which aren't suitable for Plastics.

3) Refining Process:
Cracking Converts Large Hydrocarbon into Smaller More Useful ones for Raw Material for Plastic Production

4) Ethene and Propane Created for Manufacture of Polymer Granules

1) The Mould is Closed & Tightened

2) Compressed Air is Blown to Expand Plastic

3) Mould is Opened & Bottle is Trimmed

• Hot Wire Cutter

• CNC Router

• Jigsaw

• Hand Tools for Filing

• Drilling

• Jr Hacksaw

• Lazer for Cutting/ Engraving Acrylic Sheet

• Craft Knife for Cutting HIPs

• Used in Prototyping for Model Making

• used for Cutting Expanded Polystyrene or (brand name) Styrofoam

For Cutting Acrylic Sheets

• Forstner Drill Bit-
to Drill Larger Holes

• Countersink 90° Angle- to Create a Seating for Screw Head

• Twist Drill-
Drilling Holes

• Round, Half Round,
3 Square, Flat

• Used for Smoothing Edges or Removing Waste

• Used to Cut Acrylic Rod or Straight Lines

• Hacksaw has Teeth that Point Forward.

• Jr Hacksaw has Finer Teeth

• Keep Tools in Working Order

• Only use Tools been Taught to use

• Don't Run with Tools

• Keep Work Area Tidy & Free from Trip Hazards

• Use Safety Mat & Ruler for Craft Knife

• Never Leave Machine Unatended

• Stay Safe Distance Away from the Machine if Someone is Using it

• Only Use Machines been Taught to Use

• Hair Up & Use Goggles

• Make sure Machines have Appropriate
Guards Down (Drilling & Jigsaw)

• Clamp Work if needed (Drilling)

• For Lazer Cutter Ensure there is
Extraction for Dust & Fumes. Lid must be closed for it to work.

• Tensile Srength

• Tension

• Compression

• Torsion

• Shear

• Bending

Shape or Force into a Curve or Angle

(something straight to curve)

• One Product Made at a Time

• Every Product is Different

• Labour Intensive

• May be Made from Hand or Combination of Hand & Machine

• Can be Expensive

• Just-in-Time (JIT)

• Flexible Manufacturing System

• Lean Manufacturing

• Small Quantity of Identical Products Made

• Jigs & Templates used to Aid Production

• May be Labour Intensive

• Machines Easily Changed to Produce a Batch of a Different Product (yellow mug instead of blue)

• Batches in certain numbers e.g 10, 50

• Hundreds of Identical Products

• Often Involves the Assembly of a Number of Sub-assemblies of Individual Components

• Parts may be Bought from Other Companies

• Some Automation Of Tasks and this Enables a Smaller Number Of Workers to Output More Products

• When Many Thousands of Identical Products are Made

• Difference between this & Mass Production is that production line Kept Running 24 hours a day, Seven Days a Week to Maximise Production and Eliminate Extra Costs of Starting &
Stopping production process

• Process Highly Automated and Few Workers Required

• Prototype/One-off Production

• Batch Production

• Mass Production

• Continuous Flow

• Product Meets Specifications

• Product Meets Standards

• Product Safe to Use

• Guarantees Accuracy

• Prevent Mistakes or Stops Mistakes Happening with Regular Checking

• Go & No Go Tool for Timber Thickness (Go Tool- meant to work, No Go- isn't meant to work)

• Registration Marks in Printing- to show the Colours are the Right colours

• Visually- how fabric matching is done

• Soak Timers for PCB's to check exposer to UV Light
(anything with circuit board)

• Depth Stops for Drills- put turn on drill bit so it only drills like 10 mm down

• Jigs

• Patterns

• Templates

• Reference Points or Datum

Sourcing Materials

• Soil Erosion

• Changes to the Landscape

• Loss of Habitat

• Raw Materials are Used Up

Manufacturing Processes

• Pollution from Manufacture Processes

• Landfill from Waste Materials


Transport Products

• Pollution from C02 Gasses

• Air Miles

1) Resources to Make Product

2) Manufacturing

3) Distribution/Transport

4) Use

5) End of Life Disposal

Resources to Make Product-
Are they..?

• Renewable?

• Recycled?

• Sustainable Sourced?

Manufacturing

•Is Making Process Environmentally Friendly?

• How is Waste Recycled & Reused?

• Is the Energy Used to Manufacture Sustainable?

• Have they used Minimal Material in Manufacture?

Distribution/Transport

• Can it be Sold More Locally?

• Is the Transportation Running on Biofuel or Electrical Energy?

• Is Packaging made of Recycled Materials?

• Is there Minimal Packaging?

Use

• Design Energy Efficient?

• Could it use Less Power?

• Could it use Recycled Batteries?

• Can product be Re-Used?

End of Life Disposal

• Can Parts be Used to Make
Another Product?

• Are the Materials Easy To Recycle?

• Can the Product Be Taken Apart Easily to Be Recycled?

• Are Materials Used Recyclable?

• Source For Eco-friendly Materials.

• Use Bio-Fuel Powered Transportation.

• Use Renewable Energy.

• Design Product can Easily be Recycled at End Of Life.

• Work From Home to Reduce C02 Gasses.

• Design using Lean Manufacturing Methods

• Use Biodegradable Plastics wherever possible.

• Recycle Polymer Waste During Manufacture

• Use Recycled Plastics as Raw Materials

6