Cambridge National R105 R109 engineering design and manufacture revision notes.

1. Manufacturing
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2. Choice of Material & Manufacturing
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The choice of material
will dictate limitations
on the choice of
Manufacturing process.
The shape of the product
Can also affect the
Choice of process.
If a particular method
Of manufacture is to be
Used then this will
Dictate the choice of
Material.

3. Material Selection
The choice of material is determined by the properties Of the
material required for the product but also Limited by the
range of manufacturing processes available.
Selection Charts like these can help design engineers select
The appropriate material based on the specification.
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4. Manufacturing Process Selection
The choice of manufacturing process is determined by
The material chosen. Some methods of manufacturing are
More appropriate to some materials than others.
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5. Forming Methods
There are three methods of forming or shaping material.
Forming through wastage, cutting/removing material to
shape.
Forming through fabrication, joining material to
shape.
Forming through redistribution, reshaping or
reforming the material to create shape sometimes
known as deformation.
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6. Tools & Machinery for forming through Wastage
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Wood
Tenon Saw
Chisel
Arbour
Glass Paper
Band Saw
Drill
Router
Sanding Disc
Laser Cutter
Metal
Hack Saw
Files
Emery Cloth
Wire Wool
Band Saw
Drill
Grinder
Lathe
Mill
Laser Cutter
Plasma Cutter
Plastic
Coping Saw
Hand Drill
Files
Emery Cloth
Wire Wool
Band Saw
Drill
Lathe
Mill
Laser Cutter

7. Tools & Machinery for forming through Fabrication
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Wood
Joints
Adhesives
Wood Screws
Coach Bolts
Metal
Flanges
Adhesives
Screws
Nuts & Bolts
Clips
Pop Rivets
Soldering
Brazing
Welding
Plastic
Adhesives
Screws
Nuts & Bolts
Clips
Pop Rivets
Sonic Weld

8. ian.bates@franklin.ac.uk
Wood
Laminating
Steam Bending
Metal
Hammering
Planishing
Folding
Forging
Sintering
Extruding
Plastic
Line Bending
Blow Moulding
Vacuum Forming
Injection Moulding
Extrusion
Compression Moulding
Tools & Machinery for forming through Deformation

9. Exercise – 20 minutes - Pairs
Product – In flight teaspoon for British Airways 1st
Class
Product Specification:-
• Aesthetic
• Carry embossed logo
• be of high quality
• Functionality
• Ergonomically comfortable
• Environmentally sound
• Manufacturing
• Mass produced
• Environmentally sound
Choose an appropriate material and manufacturing method.
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Material Specification
• Cost = £1/Kg
• Energy Content <=100 MJ/Kg
• Recycle Fraction > 0.5
• Stiffness 1 MNm/Kg
• Strength 10 KNm/Kg

10. Example answer
Thin stainless steel –
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Material Specification
• Cost = £1/Kg
• Energy Content <=100 MJ/Kg
• Recycle Fraction > 0.5
• Stiffness 1 MNm/Kg
• Strength 10 KNm/Kg

11. http://www.youtube.com/watch?v=diTlfZUy1vk
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12. Aesthetic
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