How does the scale of production affect the choice of material?

Mass production favours materials that suit fast, automated processes such as injection moulding. A one-off product can use materials worked by hand, such as solid hardwood.

Why must a material suit the manufacturing process chosen for a product?

Each process only works with materials that behave in the right way. Vacuum forming needs a thermoplastic sheet that softens when heated, so a thermosetting plastic cannot be used.

Explain why zinc and aluminium alloys are often chosen for pressure die casting rather than steel.

Zinc and aluminium alloys have much lower melting points than steel. A lower melting point extends the life of the steel die and cuts energy use.

What does corrosion resistance mean when selecting a material?

Corrosion resistance is a material's ability to resist chemical attack from its surroundings, such as rusting in damp air. Outdoor and marine products need high corrosion resistance.

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

Topic overview Wasting with hand tools Manual and CNC machine tools Rolling, blanking, press forming and forging Injection and blow moulding Rotational moulding and vacuum forming Sand casting, die casting and extrusion

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

Topic overview CAD modelling, virtual imaging and rapid prototyping CAM and CIM Factor of safety and tolerances Testing and inspection of products Risks in workshop and manufacturing processes

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

Product Development

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

Material Selection and Wood

Material selection criteria

3 things to know
AS 1 Paper 1

Overview

Functional requirements, properties against working characteristics, scale of production and process, corrosion resistance and stability, stock forms, true cost, joining methods and why selection is a compromise.

What you need to know

Answer each one before you reveal it.

Your recallNot started

Evaluation

Evaluate aluminium alloy as a material for the frame of a lightweight camping chair.

Key term

Why must a designer consider functional requirements when selecting a material?

Key term

What is the difference between a material's properties and its characteristics?

Questions from this subtopic

Each one with the model answer underneath.

1
Why must a designer consider functional requirements when selecting a material?
Model answer
A material must have the properties the product needs to work, such as strength, stiffness or electrical insulation. The wrong properties lead to failure in use.
2
What is the difference between a material's properties and its characteristics?
Model answer
Properties describe how a material responds to forces, heat or electricity, such as hardness or conductivity. Characteristics describe qualities such as colour, texture, grain and ease of working.
3
How does the scale of production affect the choice of material?
Model answer
Mass production favours materials that suit fast, automated processes such as injection moulding. A one-off product can use materials worked by hand, such as solid hardwood.
4
Why must a material suit the manufacturing process chosen for a product?
Model answer
Each process only works with materials that behave in the right way. Vacuum forming needs a thermoplastic sheet that softens when heated, so a thermosetting plastic cannot be used.
5
Explain why zinc and aluminium alloys are often chosen for pressure die casting rather than steel.
Model answer
Zinc and aluminium alloys have much lower melting points than steel. A lower melting point extends the life of the steel die and cuts energy use.
6
What does corrosion resistance mean when selecting a material?
Model answer
Corrosion resistance is a material's ability to resist chemical attack from its surroundings, such as rusting in damp air. Outdoor and marine products need high corrosion resistance.

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Material Selection and Wood

Metals

Plastics

Composite and Emerging Materials

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