Describe how a CFRP part is made by lay-up.

Sheets of pre-preg, fibre already impregnated with resin, are laid into a mould in planned orientations. The lay-up is vacuum-bagged and cured under heat and pressure in an autoclave.

Justify the use of CFRP for a racing bicycle frame.

CFRP gives a very light, stiff frame, so more of the rider's effort drives the bike forward. The fibres can be oriented to add stiffness where the loads are highest.

Why is CFRP difficult to recycle?

The thermosetting resin cannot be remelted, so the fibres cannot simply be separated and reused. Recovered fibres are usually shorter and weaker than new ones.

CCEA A-Level Technology and Design 8900

Material Selection and Wood

Topic overview Material selection criteria Physical and mechanical properties Hardwoods, softwoods and timber stock sizes Pine, ash, beech, oak and mahogany Manufactured boards Wood finishes, veneers and laminates

Metals

Topic overview Ferrous and non-ferrous metals and alloys Metal stock forms and sizes Aluminium, copper, brass and zinc Carbon steels and stainless steel Finishes for metals

Plastics

Topic overview Thermoplastics and thermosetting plastics HDPE, LDPE and PET Polystyrene and PVC Acrylic, nylon and ABS Melamine-formaldehyde and epoxy resins

Composite and Emerging Materials

Topic overview Thermochromic and photochromic materials Phosphorescent pigments, reflective films and holograms Liquid crystal displays PEEK, PPSU and graphene

Processing Materials

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Product Analysis and Design Communication

Topic overview Form, function, performance and aesthetics Cost, materials, manufacture and environmental issues Target audience, anthropometrics, culture and safety Design briefs, research and specifications Creativity, innovation and sustainability in design Freehand sketching and mixed media

Design for Manufacture, Quality and Safety

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Electronic Control SystemsOption A

Topic overview Control systems, feedback and electronics safety Resistors, Ohm's law and power ratings Capacitors and RC timing Potential dividers, sensors and comparators Switches, pull-up and pull-down resistors Output devices and LEDs Transistors, Darlington pairs and thyristors Logic gates, truth tables and flip-flops 555 monostable and astable timers

Microelectronic Control SystemsOption A

Topic overview Microcontroller systems, ADCs and DACs Strain gauges and bridge circuits Optical switches, encoded discs and Schmitt triggers Op-amp amplifiers and gain Zener diodes and voltage regulators Karnaugh maps and binary counters Seven-segment, LCD and dot matrix displays PIC flowcharts and programming DC motors, stepper motors and driver circuits

Mechanical and Pneumatic ComponentsOption B

Topic overview Open and closed loop mechanical and pneumatic control Safe working with compressed air and mechanisms Levers, linkages and moments Gear types and gear trains Pulleys, belts, chains and shaft fixings Cams, cranks and converting motion Compressed air supply and pneumatic valves Cylinders, shuttle valves, restrictors and reservoirs Pneumatic circuits for logic, timing and speed control

Mechanical and Pneumatic SystemsOption B

Topic overview Hydraulics, system limitations and plant safety Torque, work, power and air consumption Vacuum handling, proximity sensors and 5/3 valves Sequential and cascade pneumatic circuits Cam profiles and follower displacement diagrams Gear geometry, pulley blocks and ratchets Toggles, treadles, shafts and couplings Friction, brakes and clutches Bearings, lubrication and seals

Designing and Manufacturing ProductsOption C

Topic overview Research, questionnaires and specifications Idea generation, critiques and computer simulation Manufacturing planning and product evaluation CFRP, GRP, Kevlar and tungsten carbide Smart materials, nanotechnology and biophotovoltaics Isometric, perspective and assembly drawing Laminating, steam bending, cutting and printing processes Risk assessment and product safety law Scales of production, JIT and cell production Quality assurance, ISO 9001 and continuous improvement Design influences and intellectual property rights

Product Design in Industry and SocietyOption C

Topic overview Life-cycle environmental impact and climate change The 6Rs, waste and environmental legislation Sustainable metals, plastics and degradable polymers Product life cycles, consumer types and relaunches CAD, CAM, 3D scanning and quick-change moulding Market pull, technology push and market strategy Price, place and promotion Jigs, fixtures and ICT in quality control Design for maintenance, inclusion and scale production Rendering, typography and presentation Dyson, Baylis, Memphis and Apple

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Topic overview Choosing a product to redesign Analysing the function and fitness for purpose of existing products Materials, manufacture and sustainability of existing products Ergonomic and aesthetic analysis Redesign modifications, sketching and viability Modelling, testing and evaluating a redesign

Product and System Design and Manufacture

Topic overview Clients, end users and design briefs Researching existing solutions and writing a specification Generating and appraising design proposals Developing a concept with numerical analysis, ergonomics and aesthetics Working drawings and planning manufacture Testing and evaluating a prototype

Designing and Manufacturing Products

CFRP, GRP, Kevlar and tungsten carbide

3 things to know
AS 1 Paper 2

Overview

CFRP lay-up, anisotropy and recycling, GRP hand lay-up and gel coats, health risks of resins, Kevlar in body armour and other products, and tungsten carbide cutting tips.

What you need to know

Answer each one before you reveal it.

Your recallNot started

Key term

What is carbon fibre reinforced plastic (CFRP)?

Key term

Describe the properties of CFRP.

Key term

Why is CFRP described as anisotropic?

Questions from this subtopic

Each one with the model answer underneath.

1
What is carbon fibre reinforced plastic (CFRP)?
Model answer
CFRP is a composite of strong, stiff carbon fibres embedded in a polymer matrix, usually epoxy resin. The fibres carry the load and the resin holds them in position.
2
Describe the properties of CFRP.
Model answer
CFRP has a very high strength-to-weight ratio and high stiffness. CFRP is also corrosion resistant but expensive, and it can fail suddenly under impact.
3
Why is CFRP described as anisotropic?
Model answer
CFRP is strongest along the direction of its fibres and much weaker across them. Layers are laid at different angles so the part is strong wherever loads act.
4
Describe how a CFRP part is made by lay-up.
Model answer
Sheets of pre-preg, fibre already impregnated with resin, are laid into a mould in planned orientations. The lay-up is vacuum-bagged and cured under heat and pressure in an autoclave.
5
Justify the use of CFRP for a racing bicycle frame.
Model answer
CFRP gives a very light, stiff frame, so more of the rider's effort drives the bike forward. The fibres can be oriented to add stiffness where the loads are highest.
6
Why is CFRP difficult to recycle?
Model answer
The thermosetting resin cannot be remelted, so the fibres cannot simply be separated and reused. Recovered fibres are usually shorter and weaker than new ones.

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Material Selection and Wood

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