The document provides a design brief for a universal bread bin. It outlines the problem of lack of kitchen workspace due to clutter and proposes a design for an airtight bread bin with a pull-out bread board and knife storage. The design requirements specify that the bin must be movable, airtight, safe to handle, able to fit most décor, and easily cleanable with knives safely stored. Research is then presented on materials, existing products, joining techniques, and finishes to inform the design.

1. Name: Oliver Derham Candidate Number: Lord Wandsworth College Centre Number: 58433 Resistance Materials Edexcel GCSE Year 2010 Page Number: 1

3. Must be airtight to keep bread fresh

4. Must be safe to handle – so not cumbersome, i.e. not too heavy, and must not have sharp edges for health and safety reasons

5. Must to be able to fit most people’s home décor

6. Must be able to be easily cleaned

7. Knives must be kept in safe storage and not sticking outPage Number: 2

8. Analysis of Design Brief Wood could come from softwoods as it grows quicker, thus replenishing trees cut down Metal could be recycled So bread doesn’t go off Wood could be recycled Lid must not slam down in case of hand injury i.e. round edges Buffing machine + polish for finish Knives must be in protected casing in case of hand injury No sharp edges Materials must be environmentally friendly Bread must be kept airtight Knives must not blunt easily Acrylic Whole unit must be of a compact size Must be easily cleaned Steel Lid must not break off Must not dent easily Acrylic Former Each item of the product must be easily accessible Cad/ Cam To agree with specification Strip heater Mild Steel Seal must not disintegrate Aluminium Ingot Forge User Requirements Safety Sand Caster Must have chopping board for meat and bread Equipment sustainability Aluminium Metal could be recycled Steel Must keep bread fresh Acrylic Universal Bread Bin Materials Wood could come from softwoods as it grows quicker, thus replenishing trees cut down Performance Requirements Must keep kitchen tidy Hard or soft wood, i.e. pine or oak Finishes i.e. paint or varnish Form Must hold knives Must hold a variety of breads and amounts Finish Components Function Contemporary version of classic cottage bread bin Wood could be recycled Research To keep kitchen less cluttered i.e. have chopping board and knives, storage for condiments and bread bin area To be a universal bread bin To keep bread fresh Pictures Body Bread board Knives Home stores Handles Internet Home owners Feet Varnished, polished, brush finish on metal, spray paint i.e. Tesco, Homebase, e.t.c. Temporary fixings, such as wood screws, nuts and bolts and other fixings such as glue Page Number: 3

10. Price- £101.52

11. Style- Retro

12. Colour- Orange powder coat

13. Components- Sheet steel body, Tempered steel rod handle, piano hinge

15. Price- £20

16. Style- modern

17. Colour- jet black and brushed steel

18. Components- Chrome plated tempered steel formed handle, Aluminium Lid, Aluminium Base, Two pivot hinges

20. Style- Classic/ modern

21. Colour- Natural white oak

22. Components- White oak body, white oak lid, white oak knob handle

24. Price- £71

25. Style- modern

26. Colour- jet black and brushed steel

27. Components-Aluminium Base, Bendy Plastic sheet for lid with magnetic strips for lid to seal

28. Special Features- Materials thin but durable to allow optimum bread capacityPage Number: 4

30. Pull off lid,the most reliable system, it involves a lid with a projection. All that needs to be done is for the lid to pull off

31. Cupboard hinge, a variation on a door hinge, usually found in cupboards. Slightly difficult to fit and tends to become loose on its own. Medium priced

34. Block, This requires less manufacturing processes as it is purely a block of a specific size. Can be made from wood or metal and is very cheap and easy to manufacture

36. Meat- seasoning (of varying sorts), salt, pepperBased on this data collected, the storage space must be tall and deep enough to fit a number of these items. The design will provide this for the smaller sizes of them, but the butter should be kept in the fridge for obvious reasons Page Number: 5

38. can be used for crumbs to fall to a separate tray

39. Has a variety of shaped holes

40. Manufacture leaves no waste products

41. Light

43. Can be stained

45. Needs to be treated properly

46. Blunts tools quickly

48. Is a thermo plastic and therefore can be formed to most desired shapes and can be recycled

50. Can dent easily

51. Can shatter easily

53. Easily fixed

54. Easily shaped

56. Can tear

57. Heavy use can break the Foam X upCan be used as lid, Base/ frame, handle or decorative features Can be used under the base as a way of friction Page Number: 6

58. Forming Materials Can be used to make a multi-coloured acrylic body or lettering Adhesives: Process- Araldite, Place the desired pieces needed to be fixed together in front of you On a separate board, squeeze out the need amount of glue and needed amount of hardener so that they are not touching When reading, using a rod of some sort, mix the two together, then place onto the fixing area on the material Hold together firmly for a few minutes The pieces are now fixed Solvent Cement, Place the desired acrylic materials needing to be fixed in a bench clamp Using a pipette, drip the solvent along the edges of the acrylic By capillary action, the solvent should soon cover the area being joined It should then harden quite quickly Remove from clamp PVA/ Wood Glue, Add to surface and evenly spread Join together Sand Casting: Process- Create a solid mould of the desired component out of wood or plastic e.t.c. Place the mould into the drag/ cope then pack sand around and on top of it. Then remove the mould leaving the sand compact in the desired shape Make a channel in the drag and cope to allow the molten aluminium ingot to flow into the mould Leave for about an hour to cool then remove the cope and drag The shape has been formed Finally sand blast the component to remove flash and texture of the sand Finish This could be used to form lettering to go on outside of the breadbin Can be used to give body of breadbin a different shape Can be used to join different types of wood together for body Metal former Process- Place metal on former Use the machine handle to bend the metal around the former (round, square, e.t.c.) Do this to desired degree of movement The metal will now have a shape and not be flat This could be used to mark the holes for lettering and hinges Joints- Box Joints: Process- Comb/ finger Joint, Take the two pieces of wood needing to be joined Using a pencil, metal rule and marking gauge mark out the length for the fingers Mark out a sort of castle ramparts Cut out the alternate fingers using a tennon saw so that both pieces will fit together snuggly Use an adhesive to fix together Centre punches: Process- With a metal rule and pencil, accurately mark a centre point for a chosen hole to be drilled Place a centre punch on this mark Hit with a hammer Check that it is in the right place Then hit a few more times, but more firmly than the previous This acts as a guide for the drill bit Page Number: 7

59. Finishes Varnish- wood: Process- Using a suitable sized brush, apply a layer of varnish to the surface as if like paint Once dry, repeat twice more Advantages- Nice look Seals grains from moisture damage, i.e. rot This can be used to give the product a nice finish and look Protects wood and makes it easy to clean Brush and polish- metal Process- Once specific shape is ready to be finished, it can be smoothed down using emery paper (like sand paper to wood) This gets rid of dirt, oil and possible scratch/ cut marks If left after this process a brush effect is created If shiny surface is wanted, polish can be used after this process using polish and a rag of some sort Surface coatings- metal: Cellulite paint- Process- Apply to surface Spray Paint- Process- Apply to surface Plastic Dip- Process- Apply to surface Protects surface from chemical changes, i.e. oxidation, and makes it look good This can be used to Get rid of burr and give the wood a smooth finish Hand Jig Saws, palm sanders, sand/ glass paper, wet and dry and files and rasps- wood/ metal: Process- Jig saws, Draw desired shape on material Clamp material onto two workbenches to leave gap in middle, using G clamps Carefully go around the shape with the saw The shape should fall out Files and Rasps, Place material in clamp Depending on shape locate a suitable rasp/ file (i.e. round, half round, flat, e.t.c.) File the edges where cut marks or in accurate cuts have been made (rasps are more effective for this Once suitable go to sanding stage Palm sander and sand/ glass paper and wet and dry, Place material in bench clamp Going from roughest to softest grain of paper go over cut, dent or scratch marks Carry on until completely smooth edges form and possibly rounded edges If acrylic, wet and dry can be used to buffer the edges (and similarly for metal) Stains- wood: Process- Using a suitable sized brush, apply to wood as if like paint Once dry it may need another coat or two Advantages- Gives depth of colour Comes in a variety of colours Goes deep into the grains Can change most woods to desired colour of product Page Number: 8

60. Detailed Existing Product Analysis Overview: the product generally has a modern/ futuristic look to it, as when you first look at it you do not suspect that it is a cheese/ bread bin. The design for each segment is also very clever in the way it all folds down to save space when opened. This could be very good at the dinner table or at parties when serving particular food stuffs as not only does it look good and save space, but it also is very mobile. Name: OLLI Derham Candidate Number: Centre Number: 58433 Page Number: 9

61. 1 2 3 4 5 Specification 6 7 8 9 10 11 12 Page Number: 10

62. What do I need to Research? Must hold a valid amount of bread Knock Down Fittings? Packaging? And Holder Must not be cumbersome Foam- X (for non slip base) Lid Breadboard Base Knives Body Must be within a 500mm x 500mm x 500mm boundary Handle must fit hand shape Aluminium Acrylic Handle Soft Hard Dimensions Storage Space Metals Woods Plastics Flat Pack Components Anthropometrics Are materials recycled? Must not break after heavy use Materials See Page 6 Or 6th form students e.g. Knives, lid hinge, board hinge and dents in the body Tools and Equipment University Students Research Essentials In shared kitchens Sustainability Market Will it be environmentally friendly Polished Any Households Source and strength of materials Age 14+ due to knives Costs Or other Finishes Varnished Production Techniques Joining Materials Together Existing Products Paint Consumer What colours? To be a universal bread bin Brushed To keep kitchen less cluttered Production Unit To keep bread fresh One off prototype Materials Stain Screw fittings What colours? i.e. have chopping board and knives, storage for condiments and bread bin area As cheap as possible Hinges Forged/ welded Predicted to become mass produced Intermediate price for good quality Around 3 times cost of unit to pay for materials, labour and to make a profit Dowel/ Box or comb joints What types? Production + materials Adhesives What types? On production line Page Number: 11

63. Review Page Number: 12

64. Page Number: 13

65. 14 Model Stage The general shape of the lid is flush to the edges of the frame The joints for joining the short side panels to the long side panels were tested, but for the model a simple butt joint was used to give a general idea of the shape of the frame The lid support fits exactly into the top of the frame to hold it in place. It also is a good surface for cutting on The modeling stage helped provide a basis for the actual product as it has developed into a rectangular structure

66. Production Processes 3.Assembly of individual panels to form entire side panels 1. Side Panels Start Start 2. Teak transitional end panel pieces Mark out design for Pine panels with pencil and metal rule and tri- square Start On each individual panel mark the half way point on edge to be joined using a tri square, pencil and metal rule Mark out design for teak pieces using tri square, pencil and metal rule NO Check measurements against design Check measurement against design NO NO Check measurements against design Yes black out areas being cut Yes Clamp the individual panels onto a workbench using G- Clamps Yes black out areas being cut against design Put against bench hook to cut with tenon saw Using a biscuit cutter, cut the slot for the biscuit joint, along the line drawn at the half way point Put against bench hook to cut with tenon saw Sand down all edges and round corners NO Check for smoothness and non sharpness Make sure all components fit flush together Yes Sand down all edges and round corners NO Yes Apply glue to edges to be joined and into the slot. Place the biscuit into the slot and the place resulting panel into several sash clamps to make sure that the joint is strong NO Check for smoothness and non sharpness Yes Finish Yes Yes Finish Yes Finish Yes Page Number: 15

67. Production Processes 4. Finger Joints 6. Mitre Joints for base support Start Start 5. Assembly of Breadbin Frame Mark out 4 mitre joints, 35 x 20 x 110 (mm)using a mitre square and pencil Using a marking gauge set at 20mm, a metal rule and a pencil, mark the ends of the now larger panels Start Prepare an area on the workbench with sash clamps NO NO Check measurements against design Check measurements File finger joints to fit flush together Cut each component out using a tenon saw and bench hook or a mitre saw NO Yes Use a tri square and pencil to mark out fingers for finger joints Make sure that the finger joints fit together properly Black out areas to be cut Yes Use elephant sander to produce flush edges Apply glue to edges to be fixed together NO Check for smoothness Using a tenon saw cut out the fingers to specification on a bench hook Assemble the panels to become a frame If ready, mark out holes in the centre of two edges which will be fixed to frame. Use a centre punch to create a guide for bench drill to create a pilot hole NO Put sash clamps in relevant places so that the frame will be square and strongly fixed together Sand down all edges and round corners NO Check for smoothness and non sharpness Finish Yes Screw the mitre joint s into the bottom corners of the frame Yes Finish Finish Page Number: 16

68. Production Processes 7. Base 9. Sandcasting 8. Lettering Start Start Start Mark out design for base on plywood (roughly 360 x 210 [mm]) Compact casting sand into two halves of the die. Pick a font on word and type “BREAD.” Enlarge it to fit whole page and print Check that there are no gaps and that the sand is level NO Stick onto MDF board and cut to form individual letters Check measurements against design File and sand them down On one half, gently push the MDF letters into the sand so that they create an impression Yes black out areas being cut Check size fits onto side of bread bin shell Put against bench hook to cut with tenon saw After removing the MDF letters, use a trowel to dig a small trench between each impression and at either end, to allow the Aluminium Ingot to flow to each. NO Yes Move on to step 9. Sand down all edges and round corners Finish Check for smoothness and non sharpness Then using a conical shaped piece of metal, create a hole at the end of the outer trenches. Yes Yes Yes Yes Fix to the mitre joints and edges surrounding by wood glue NO Continued Next Page Make sure that all the impressions are smooth and that there is no excess sand Yes Yes Finish Yes Page Number: 17

69. Production Processes Yes Using wood glue, rub join the two halves together. 9. Sandcasting Continued 10. Lid …Continue from Previous Page… Measure width and length of the inner pat of the top of the bread bin Start After making sure the Aluminium is molten place both sides of the mould together and place next to the furnace. Carefully pour the aluminium into one of the holes until it comes through to the other hole at the other end Get two rectangular pieces of wood (one pine, one teak) cut to the same width and length of the frame On another rectangular piece of pine mark these measurements on it in order for it to fit perfectly as a guide for the lid NO Use a hacksaw to saw the now aluminium mould into the individual letters Check measurements against design NO Check measurements Use the various needed files to remove any rough edges, shape the lettering and remove any gaps Yes Mark out a diagonal across the same area on both pieces so that they are identical to each other. Yes Cut out the new shape and sand the edges so that they are smooth NO Check the edges are smooth and that they are still within the size constraints Attach to the underneath of the upper section of lid previously made, centrally, using wood glue and 4 screws in each corner Cut using a Yes Find the centre point on the upper section and centre punch Sand and file edges to smooth and shape NO Once finished, use araldite to stick lettering onto one side panel Use a hole saw (roughly hand sized) to drill through to the pine layer. Sand the circular piece down so it is about 20 mm smaller in radius and then re join it in the centre of the hole just made with wood glue. This is now the handle. Yes Use wet and dry paper (with heavier to lighter grains) and WD40 to create a smooth, shiny and brushed finish Check for smoothness and non sharpness Yes Finish Finish Page Number: 18

70. Production Processes Page Number: 19

71. Gantt chart Page Number: 20

72. Health and Safety During Certain Tasks Drilling Hole Saw Sanding Filing Varnishing Sawing Marking Wet and dry with WD40 Gluing Screwing Sandcasting Centre Punching Biscuit Joining Page Number: 21

73. Cutting List Page Number: 22

74. Proof of Manufacture Frame Sand Casted Lettering Other Processes: Transitional Wood Lid Acrylic Handle Page Number: 23

75. 24 Other Tools Used Centre punch for marking holes for bench drill Safety mask and goggles to protect eyes and respiration system from debris Hammer for use with centre punch Scroll saw for cutting MDF lettering for Sand cast moulding Bench drill for drilling pilot holes for screws and for using the hole saw attachment Coping saw to cut parts of comb joints and for MDF lettering Tenon saw to cut panels to initial size and to cut mitre joints Tri- square to get right angled lines when marking Marking gauge for use with comb joint marking Mallet to help compact sand casting sand into moulds File for shaping the wood and sand casted aluminium into the desired shape Work bench clamp to hold materials in place whilst working with them Sash clamps for forming frame Palm sander for sanding edges and faces smooth Varnish for finish and protection of body

76. 25 Finished product

77. 26 Key Features: In Use

78. Test and Evaluate Page Number: 27

79. Page Number: 28 Test and Evaluate

80. Client Feedback Page Number: 29

82. Production Schedule

84. Evidence of Making

85. Manufacturing

87. Evaluation

89. Index *including page numbers

90. Situation (Problem) & Design Brief

91. Analysis of Brief

92. Product Analysis

93. Research

95. Chosen Idea

97. CAD Drawings

98. Models

99. Final Idea