Design and Manufacturing Process

1. LECTURE-3
DESIGN & MANUFACTURE

2. Working with manufacturers
Integrating design and manufacture
Selecting Materials

3. Common Materials
CERAMICS an inorganic, nonmetallic solid prepared by the
action of heat and subsequent cooling.
Traditional ceramic applications include tiles, whiteware
such as toilets and sinks and pottery.
Technical ceramic applications that take advantage of the
high thermal conductivity of ceramic include heat sinks for
electronic circuitry.

4. Stoneware
High fired clay is usually grey to brown in color due to the
presence of iron and other impurities in the clay.
It differ from earthenware in that it has very little moisture
absorbency once fired.
Stoneware is commonly used or tableware when glazed

5. Earthenware
Low temperature fired clay , usually red or orange color.
Used to make pots industrially as well as large sculpture and
architectural forms
Fired at normally low temperature leaving the body porous if
not glazed

6. Porcelain
 The wondrous white translucent ceramic is fired at a high temperature to fuse
the glaze and clay body together to produce a highly refined material.
 Made by firing a pure clay and then glazing it with different colors
 sonorous, nonporous
 It is mainly used for utilitarian wares and artistic objects.
 China clay or Kaolin

7. COMPOSITES
Engineered materials made from two or more components.
However, within the composite you can easily tell the different
materials apart as they do not dissolve or blend into each other
Natural composites exist in both animals and plants. Wood is a
composite – it is made from long cellulose fibers (a polymer) held
together by a much weaker substance called lignin
The bone in your body is also a composite. It is made from a hard
but brittle material called hydroxyapatite (which is mainly calcium
phosphate) and a soft and flexible material called collage(which is
a protein).

8. Making composites
Most composites are made of just two materials. One is the
matrix or binder. It surrounds and binds together fibers or
fragments of the other material, which is called the
reinforcement.

9. FIBREGLASS
The first modern composite material was fiberglass. It is still
widely used today for boat hulls,sports equipment, building panels
and many car bodies. The matrix is a plastic and the
reinforcement is glass that has been made into fine threads and
often woven into a sort of cloth.
On its own the glass is very strong but brittle and it will break if
bent sharply. The plastic matrix holds the glass fibers together and
also protects them from damage by sharing out the forces acting
on them.

11. CARBONFIBRE
Some advanced composites are now made using carbon fibres
instead of glass. These materials are lighter and stronger than
fibreglass but more expensive to produce. They are used in
aircraft structures and expensive sports equipment such as
golf clubs.
Consists of woven carbon-fiber yarn, combine with resin to
produce a mouldable sheet material
Material has high strength to weight ratio.

12. Honeycomb
These composites consist of a core hexagonal structure name
after its visual resemblance to a bee’s honeycomb, skinned
either side by a sheet.
Produce mostly as a sheet material in aluminum and
glassfibre
Advantage of stiffness combined with low weight and are
often used for architectural and light weight structures.

13. Why use composites
The biggest advantage of modern composite materials is that they
are light as well as strong. By choosing an appropriate
combination of matrix and reinforcement material, a new material
can be made that exactly meets the requirements of a particular
application. Composites also provide design flexibility because
many of them can be moulded into complex shapes. The
downside is often the cost. Although the resulting product is more
efficient, the raw materials are often expensive

15. LAMINATES
This group of material is commonly defined by its layering of
materials together using adhesives.
Plywood is common example of a laminate made up of layers
of the same material.
The process of lamination enables such materials to be
surfaced with colored polymer sheets such as formica or
metal finishes.

16.  Withstand high temperatures up to 400 degree & thermal stresses, owing to its
low thermal expansion coefficient
 High resistance to chemical agent
 Hard glass, less dense from normal glass
 Uses:
Neon tubes
Industrial pipes & columns
Telescope mirror
Resistance to sudden fall in temperature is low.
GLASS, Borosilicate (PYREX)

17. Glass, Coated
1. Metal deposition
Surface treatments-( Aesthetic or technical reasons)
 Deposits are applied in a vacuum or by direct coating
 Self-cleaning glass
Self-cleaning glass is a specific type of glass with a surface which keeps
itself free of dirt and grime.
 Self-heating glass
 One way mirrors

18. Laminated glass

19. Glass toughened or Tempered
Tempered glass, or toughened glass, is glass that has been
heat-treated to make it stronger, more resistant to heat and
break in a way to prevent injury.

20. Cut the glass into the desired shape first. This has to be done before the glass is tempered,
as the tempering process will weaken the glass if it is cut or etched afterward and may increase
the likelihood of breakage.

21. Inspect the glass for imperfections. Cracks or bubbles may cause the glass to break during
tempering; if any are found, the glass cannot be tempered.

22. Sand the cut edges smooth. This removes any burrs created during cutting or etching.

23. Wash the glass. This removes any tiny grains of glass deposited during sanding, as well as any
dirt that may interfere with the tempering process.

24. Heat the glass in a tempering oven. Glass may be fed in batches or continuously.The oven
reaches temperatures of over 600 degrees Celsius (1,112 degrees Fahrenheit), with the industry
standard being 620 degrees Celsius (1,148 degrees Fahrenheit).

25. Quench the glass to cool it. The heated glass is subjected to seconds of high-pressure blasts of
air at various angles.The rapid cooling causes the outer surfaces of the glass to cool and contract
faster than the center, giving the tempered glass its strength.

26. Plastics/ Thermoplastics
Acrylonitrile butadiene styrene:
Highest impact resistance
High mechanical strength
Better resistance to heat and chemical agents
Light weight
Applications:
Cars dashboards,radiator grills
Electronic industry ( telephone and tv set cases)
Vacuum cleaner bodies
Toys and office furniture
Poor resistance to UV

28. Acrylic
Transparent material also known as polymethylmethacrylate
(PMMA)
Used as alternative to glass
Use in lighting, aircraft windows and spectacle lenses, where
its rigidity and hardness are necessary. It is recyclable and
non toxic

30. Polypropylene (PP)
Semi-crystalline thermoplastic
Good chemical resistance
Excellent electrical insulation
High fatigue resistance ( hinges, repeated bending)
Low coefficient of friction
Good impact resistance
Very sensitive to UV
High shrinkage when moulded
Average mechanical strength

32. POLYSTYRENE
 Amorphous thermoplastic
 Transparent and good appearance of crystal form ( smooth, shiny surface)
 Easy to use with adhesives or to weld
 Easy to mark, decorate, print on, easy to color
 Sensitive to impact and scratching
 Very sensitive to chemical agents

33. Pvc (Polyvinylchloride)
Amorphous thermoplastic material
Flexible or rigid
Chemical resistance
Good electrical insulation
Self-extinguishing so still useful in buldings
Sensitive to uv
Limited chemical resistance when transparent
Poor impact resistance at low temperature