Using materials more than once. Milk bottleMeans you don’t have to produce new ones, raw materials etc.

Recover energy from waste› EFW – Energy can be recovered from waste› WTE – Waste can be converted into energy in the form

of heat or electricity. › This can be used to heat homes and reduces the need

for oil and gas.› Incineration emission must be controlled.

Recycle materials and products and use recycled materials› Processing used material and products into new

materials or products. Reduce the demand for new materials, reduce energy consumption and reduce air pollution. Less waste – no landfill.

Glass, paper, metal, textiles and some plastics can be recycled. These are not recycled into new, pure products they reused in lower quality products – cardboard, lower-grade metals and plastics.

Salvage› It involves stripping out materials – gold, lead from

batteries. Only used for high value

CAD/CAM› Computer Aided Design/Manufacture –› CAD plugs into CAM – using CNC – computer

numerically controlled machinery to make products automatically, quickly and accurately.

Virtual modelling and testing› A computer model of a physical object – visualisation

purposes› Used for testing – air flow, stress analysis and fatigue

testing Laser testing

› Edges require little surface finishing. CNC milling and turning

› Great accuracy and speed. A milling machine uses a cutter that moves up and down vertically while the work which is fixed to the table moves backwards, forwards and from side to side. Cut curves and 3D shapes

Lathes› Turn products in the round. Work held in the chuck, the

tool post moves to turn cylindrical products. Tools changes can be automatic. Some have automated chucks and material handling – so non-stop production is possible.

Rapid prototyping› Automatically creating physical objects by adding

materials in layers to build up a 3D object.› CAD model broken into slices. › Allow prototype in hours not days and £ hundreds not

thousands.› Time to develop products much quicker and cheaper.› 6 months form 2 years.

Bluetooth› Wireless transmission of data using radio waves.

Exchange data over short distances between mobile and fixed devices. PAN (personal area network)

Videoconferencing› Two or more people in different locations to have an

interactive video and audio conversation.› Relay pictures and sounds in a virtual meetings. › Video input – video camera or webcam› Video output – computer monitor, TV or projector› Audio input – microphone› Audio output – loudspeakers› Data transfer – LAN, digital telephone line or internet.

Look at the table for advantages etc.

Used to communication and transfer data from one system to another.

Email› Quicker and cheaper communication – across the world

in seconds. › Pictures, spreadsheets can be sent by attachment.› Changed, saved and resent› Client responds quickly – lots of time savings.

Email marketing and sales› Emails to sell products – new products, promotion› Customers have to register their products – direct

access to information. EPOS – Electronic Point of Sale

› Think Tesco’s – tills are used to gather and record information.

› Barcode is read by a laser scanner.› 13 numbers give information about the product

More EPOS› Intelligent Till – sales are recorded on a computer. They

monitor sales across the store. › Stock levels are known and reorders automatically› Analysis of sales and stock levels – know sales and

allows monitor of wastage, theft and damage. EPOS in manufacture

› Stock control principles – products are give a unique barcode

› Fixings in boxes are barcoded in batches and then when they are need they are scanned in and can then make sure that replacements are ordered in time.

› Monitor product assembly more carefully – don’t need a large stock of bought-in components.

Health and safety at work act 1974› Remember PPE, COSHH, Risk Assessment, Ventilation

You need to be able to describe safe working practices.

Identify workshop hazards and precautions.

Magic words – Jigs, templates and patterns. Jig –

› A work-holding device that is made specifically to suit a single component or a device to help when making identical components.

› Use them to drill holes for dowel joints or cut a dovetail joint. See pictures in book.

Patterns -› Used to mark out or make a number of identical components. Sand

casting patterns are used to be able to repeat the process – they tend to me made from wood or epoxy resin.

This is good for your design question, remember the whole idea is to allow products to be repeated easily.

Varnish, wax polish, stain, paint, plastic dip-coating, electroplating.

Why?› Aesthetics, functional properties and depends on the material

Prepare the materials – clean ferrous with emery cloth or sand and clean wood surfaces.

Varnish – plastic varnish (synthetic resins) – much harder, tougher surface over natural varnish. Heatproof and waterproof.

Wax polish – dull gloss shine. Beeswax + turpentine. Seal the surface before application with meths.

Stain – enhances the natural grain. Water, spirit and oil. Spirit and oil are flammable well ventilated area. Lots of colours.

Paint – Decorative colour and protective layer. Indoors and outdoors.

To paint wood, seal knots with knotting (don’t ask me). Then a primer, undercoat and then apply a top coat. Polyurethane is much tougher.

Paint metal – prepare, oxidation must be removed. Red-oxide paint can to reduce oxidation. Then a primer and undercoat before the top coat. Rub down between layers.

Plastic Dip-coating – suitable for most metals. Hanging baskets, brackets, heated to 180c and placed in a bath of fluidised powder. Smooth, glossy finish. Crack and peel off over time.

Electroplating – mainly brass and copper coating to decorate and durable metal such as silver or chromium. Using electrolysis. Expensive and time consuming.

Metal changes colour to match the temperature. Hardening and tempering Annealing Case Hardening Hardening and tempering

› Increasing hardness of steel for things like the end of scribers, drills and punches. Only used for medium-carbon or silver steel.

› Heat to 720C (dull red) and quench it immediately in water or oil.› Metal is too brittle so reduce the hardness to produce a more elastic,

tougher material that will retain a cutting edge. This is called tempering.

› Heat the product well behind the cutting edge and the heat reaches the edge then quench it in water.

Annealing – As metal is worked or deformed its hardness increases and becomes difficult to work. The process restores the initial structure of the material by relieving internal stresses.

Metal changes colour to match the temperature. Hardening and tempering Annealing Case Hardening Hardening and tempering

› Increasing hardness of steel for things like the end of scribers, drills and punches. Only used for medium-carbon or silver steel.

› Heat to 720C (dull red) and quench it immediately in water or oil.› Metal is too brittle so reduce the hardness to produce a more elastic,

tougher material that will retain a cutting edge. This is called tempering.

› Heat the product well behind the cutting edge and the heat reaches the edge then quench it in water.

Annealing – As metal is worked or deformed its hardness increases and becomes difficult to work. The process restores the initial structure of the material by relieving internal stresses.

Heat the metal and then allow it to cool gradually.

Case Hardening› Harden mild steel as it has less than 0.4% carbon you have to case

harden the product. This gives it a carbon-rich skin. › Heat the metal to cherry red, dip it in carbon powder and leave it to

cool. Repeat three or four times. Used for tool holders and driveshafts.

Adhesives remember not glues PVA, contact adhesive, epoxy resins and Tensol cement. PVA