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1. Organic 1 Sam Naylor GCSE Resistant Materials Candidate Number 5686

2. Organic – Contents Page Pages- Pages- -Construction techniques -List of Specifications -Final design -Engineering drawing -Manufacturing plan -Diary of manufacture ensuring quality/ mistakes made -Evaluation 40 41 42-44 45-46 47-48 49-53 54-61 -Planning -Problem analysis -Design Brief and Major Specifications -Research plan -Market research -Product analysis -Mood board -Initial ideas -Size research -Modelling – Diary of Manufacture -Development- function -Design proposal one -Development- ergonomics -Development- aesthetics -Design proposal two -Research- Materials and Finishes 3 4-5 6 7 8-11 12-15 16 17-25 26-27 28-30 31-32,34 33 34-35 36-37 38 39 Sam Naylor | GCSE Resistant Materials | Organic 2

3. Planning Introduction Method On this slide, I have presented the plan for my project in the form of a Gantt Chart. It is veryimportantto plan your work well as it helps you to recognizeall the importantstages, to allocate an adequate amount of time to complete each stage, and keep your project up to date inallareas. In order to construct the Gantt Chart, I first listedthetasksneededto complete the project. Once I listed each of the tasks, I was able to put them in to a logicalorder. I then estimatedandassignedeach with the necessary time frame to complete each task. I then linked these times together and as a result, was able to estimatethetotaltimeneededto complete my project. Finally I had to regulatetheplanningto fit into the desired time specified. Design Process Planning is the act or process of drawing up plans or layouts for a project or enterprise and it is an industrial practice. I used the design process model as illustrated below to help myself construct the Gantt Chart as shown on the right. I also used the Design process when attempting to identify all of the major stages of my project. Gantt Chart Conclusions In conclusion, I am going to use this Gantt chart to make sure that I keep upto date with all of my work, ensuring that I complete every bit of work in ontime. 3 Sam Naylor | GCSE Resistant Materials | Organic

4. Design Problem and Problem Analysis Introduction On this slide, I have presented my design problem and problem analysis. In order to identifytheproblemI have lookedat existing problems in products already in the market. Throughout the product analysis I hope to identify the design specifications that must satisfy my product in order to be successful. Figure 2 Design problem When boiling an egg, I discovered a number of problems. First of all, one has to be careful that they do not place their hands too close to the water or saucepan – in order to avoid burning. Also, one must be careful not to crack the egg when placing it into the saucepan, as this would ruin the egg. One must also be careful that they do not overcook their egg, as this may cause the egg to crack or be too hard. Figure 1 Figure 2 shows that it can be quite difficult to manage tobalance an egg on a spoon when taking it out of the saucepan. This would be especially hard for an elderly person wishing to make themselves a boiled egg. As well as this, you also have to take each egg out one by one, which is not a very practical way of taking them all out. As well as this, it is very hard to be able to tell when an egg is cooked, but there are methods of doing so. Obviously, everyone knows that there is time, which can give a rough answer as to whether the egg has been cooked, by knowing how long it has been boiling for. However, another method is by taking the egg out, and watching for condensation around the egg, and if condensation does occur, then it is cooked, if not, then it is still undercooked. It is very hard to do this and balance the egg on the spoon in the meantime. Figure 1 shows me about to try to spoon out a boiled egg from a saucepan. This is a very awkward step when the water is boiling, as first of all, you have to be careful that you don’t burn yourself while placing the spoon in the saucepan, as the saucepan is very hot. You also have to be careful that you don’t place your hand to close to the boiling water, which adds to the difficulty. It is also important that the egg is not overcooked – in which case, the egg would crack when boiling. Conclusion Through this problem analysis I have developed a number of major specifications that my product must satisfy these are as follows: It must be able to provide easy means of removing an egg from a saucepan. It must also be able to determine when an egg has boiled. 4 Sam Naylor | GCSE Resistant Materials | Organic

5. Design Problem and Problem Analysis Figure 4 Figure 5 Introduction On this slide I have continued toanalyse the design problem. Figure 3 Figure 5 shows an existing product alreadyon the market. I found this image on the internet, and I found that yes, it does provide easy means of boiling your egg, however, I was able to think of a few flaws in the design. First of all, while all it does to help the consumer know how cooked the egg is, it doesn’t help the user to remove the egg from the saucepan. The time that it takes to take the egg out may be considered valuable by some as they may wish for there egg to be cooked for a very specific amount of time. Figure 4 shows another existingproduct already on the market. However, despite it being similar to the product shown in Figure 5, it has a completely different function, in that it helps the user remove the eggs from the saucepan. This product solves the problem shown in figure1 and 2, of having to remove the egg from the saucepan, without touching the water or saucepan. It solves this problem as when the consumer uses it, the first thing that they do is they place 1-3 eggs on the product, and then they place the product into the saucepan, whilst holding the top of the product. This helps the user, as this way, the user doesn’t need to get too close to either the saucepan or the boiling water. However, a problem with this solution is that the part of the product from which the user is meant to grip it from is very thin, and therefore would be quite difficult for some people to get a firm hold of. Figure 3 shows me trying to place the egg into an egg cup. This is made very awkward, as again, I am having to balance the egg on the spoon, and in the meantime, place the egg in the egg cup without it falling on the floor. I have to do so as once the egg is boiled, it is too hot to handle, and I would burn myself if touched. Conclusion Now that I have completed identifying a problemin different products, I can now list any other specifications needed to be included in the making of my product. It should be able to hold at least 2 - 3 eggs. It must be able to provide an easy way of removing an egg from a saucepan. 5 Sam Naylor | GCSE Resistant Materials | Organic

7. Be able to hold at least 3 eggs so that if for example the consumer wishes to boil 6 eggs, they don’t have to boil 2 eggs on 3 occasions.

8. Be able to be used in a range of different sized saucepans so that the consumer doesn’t have to have a specific sized saucepan when using the product.

9. Be able to keep the consumer safe from burning themselves on either the saucepan, or the boiling water.Figure 1 shows my drawings of my first initial ideas for my project. The drawing on the left hand side shows the side view of my product. The drawing on the right hand side shows a 3D drawing of my initial idea, along with annotation giving an explanation of the drawing. The handle must be heat-proof, so that the consumer won’t burn their hand when they want to remove the egg from the saucepan. It also gives an idea of how many eggs it will be able to fit inside it when in use. As well as this, it shows how the product will be able to attach itself to a saucepan. Finally, it explains that there would be small holes in the side of the product so that boiling water will be allowed in to the holder. Conclusions I have now created my brief and my major specifications and therefore will be able to look back and use this page to direct me through my project. Next I will move onto my research plan. 6 Sam Naylor | GCSE Resistant Materials | Organic

10. Research Plan On this page, I have presented a research plan for my project. A research plan is important as it helps me to identify all of the areas of research I must investigate. This research plan contains 11 questions concerning my product. It gives me a question, the data source, what type of source the answer has come from and what kind of information this is (Qualitative/Quantitative). This plan aids me when identifying the areas that I will need to look into, but also provides a logical and original structure to follow. Introduction Conclusions From the analysis of my research I will develop a list of design specifications that my product must satisfy. These design specifications will provide me with a foundation upon which to base my initial design ideas. I will now start the research section with the market research and look to identify the consumers needs and wants. 7 Sam Naylor | GCSE Resistant Materials | Organic

11. Market Research Questionnaire Introduction On this slide, I have presented the questionnaire for my Market Research. Market Research looks specifically at what the consumer would desire from a product. One way of discovering this information is by using questionnaires and surveys. Google defines Market research as: Research that gathers and analyzes information about the moving of good or services from producer to consumer. Method Producing and handing out a questionnaire is an industrial practise. I will start my Market Research by carrying out a survey using a questionnaire. It will consist of questions on the current methods of boiling an egg. Those asked to participate in the questionnaire will be people who have experienced boiling an egg, and be those who regularly come across the problem. At the bottom of the questionnaire, I will leave a space in which the person filling in the questionnaire may sketch any of their own ideas concerning the aesthetics and function of the product. Conclusions On the following slides, I will present the results from the questionnaire using piecharts, graphs and any other methods that I deem necessary. It is hoped that through the analysis of the results, detailed design specifications will be formed. 8 Sam Naylor | GCSE Resistant Materials | Organic

13. manufactured from stainlesssteel

14. designed to fit into a saucepan with a diameter of around 6-7 inches

15. aesthetically pleasingAnalysis The majority of people chose stainlesssteel as the material that they believe would be best to manufacture the product from. I believe that this material was chosen because it is a hard and durable material, resistant to heat and is good aesthetically. Analysis The majority of people also said that when they boil an egg, they usually use a saucepan with a diameter of about 6-7 inches. This is because they would rarely need a saucepan to fit more than around 5 eggs within it. 9 Sam Naylor | GCSE Resistant Materials | Organic

16. Results of Market Research - Sketches Introduction On this page I have presented the design ideas people who answered my questionnaire gave me. The eggs would be placed in a vertical rack. Figure 2 Figure 1 Conclusions Figure 1 shows a basket like product, with holes in that would simplyaid the user place and remove about 4 eggs into and out of a saucepan. This design is certainly the more complex of the two. This first of all is because it would have a rack that rests on top of the saucepan whilst supporting about three eggs. Conclusions Now that I have a good idea about what people would want my product to look like, I can now start to think of things that I could include in my designs. There is not that much from either of these two designideas that I would wish to incorporate with my final design. However, I will be considering some of the aspects of the design idea shown in figure 2. For example, I may consider having two parallel strips which would rest on the saucepan. 10 Sam Naylor | GCSE Resistant Materials | Organic

18. able to hold at least three eggs

19. small enough to fit into a regular sized saucepanFigure 1 shows a very small and compact product, which is very useful, as it provides the consumer with easy means of storage when the product is not in use. However this means it does not hold very manyeggs at a time, and can actually only hold a maximum of 3 eggs at any one time, which would be very impractical if the consumer needed to boil more than three eggs at once. 11 Sam Naylor | GCSE Resistant Materials | Organic

20. Product Analysis Introduction On this slide, I have presented the product analysis of a colander.Product Analysis is vital for all designers because it helps you practise thinking about design and it helps develop your understanding of manufacturing methods. As well as this, it helps develops one’s use of different materials. It also gives you ideas for use in your own designs and encourages you to evaluate examples of good design and manufacture. Finally, it allows you to make better judgements about the products and services we buy and how they are marketed. Figure 1 The table above will be very useful for me as I progress in the productanalysis stage of my project. It will be very helpful for me as it offers a wide range of different focus areas of the colander, which I can cover and look back to. Figure 1 shows the product I have chosen to study. I chose this product as it is one kind of product that can be used to help someone boil an egg. It is made out of stainless steel, which is very heat resistant and aesthetically complements the kitchen environment. Conclusions Next, I will move on to the analysis of the product, starting with the materials that the product is made from and how it was made. Sam Naylor | GCSE Resistant Materials | Organic 12

21. Product Analysis – Materials and Manufacture Figure 3 Introduction On this slide I have presented the analysis of the materials the product has been made from. I will also look into why the materials were used and whether or not they are appropriate. I will also analyse the manufacturing process of the product and assess whether it is a suitable way to make my product. Figure 1 Figure 2 Manufacture of the product To manufacture this product, two manufacturing process’ could have been used – the first one would have been presswork. Presswork would have been used so that there were holes made for water to be able to flow into the product. A pre-cut blank of stainlesssteel would have been profile cut, punched and crack raised in one power press operation. The next manufacturingprocess could have been CNCspinning, to form the actual shape of the product. The pre-cut blank would have been spun around a mould, in order for it to form into the final shape desired by the manufacturers. Conclusions Analysis of Figures 1, 2 and 3 The material used to make this product was stainlesssteel. This material was used to make he product as first of all, it is very malleable, and can be formed into a very complex shape without fracturing. As well as this, it is a very tough material, and would be able to stay in one piece if it were to be dropped, or if a large amount of pressure was exerted on it. Another thing about stainless steel is that it doesn’t corrode, so acidic substances would not effect it in any way if they were to make contact with the product.` Three different stages of the presswork manufacturing process Two different stages of the CNC spinning process Conclusions On the next few slides I will be continuing with the product analysis section and will be looking at the aesthetics of the colander. From this slide, I have been able to come up with a major specification: 1) I would benefit from making the product out of stainless steel. Sam Naylor | GCSE Resistant Materials | Organic 13

22. Product Analysis - Aesthetics Introduction On this slide have analysed the aesthetic qualities of my colander. Aesthetics are ultimately to do with how easy a product is on the human eye, and whether or not the product looks good. Essentials of aesthetics may include; color, shape, texture, form or other features of the product. Also on this slide I have analysed the finish of the product. Shape and form The shape of the colander is bowl-shaped. This design could be quite practical for boiling things with as the product has many small holes in it (with a diameter of approximately 4mm). However, it is quite difficult to clean the colander in some places. The edges of the product are curved so that the consumer is in no danger of being cut by the product. Fromanaestheticspointofview it is quite a good-looking product.. The handles of the colander are curved and rounded, however are not comfortable to use as the edge of the colander digs into ones hands when being held. Also the circular base provides stability when placed on a flat surface. Texture The texture of the colander is smooth, however, the small holes on the colander slightly affect the feel of it. However it is quite tricky to hold the colander by its handles, as if one has sweaty or wet hands, then they may find it difficult to grasp a firm grip of it. A benefit of its smooth texture, is that it is Size The size of this colander means that it is slightly awkward to store when not in use. This means that the consumer of the product must have an adequate amount of storage space available to them, which in some cases would be a down side of the product. Colour It has a shiny, reflective, silvercolour, and has a fairly modern look about it Figure 1 Figure2 Conclusions From my productanalysis, I have come up with a number of design specifications: The egg holder must have small holes – to allow boiling water to enter within holder. There must be no sharp edges on the egg holder, so that the user of the product does not manage to cut or harm themselves. The egg holder must be aesthetically pleasing in shape, colour and texture. The productmust be well finished, and be durable. Sam Naylor | GCSE Resistant Materials | Organic 14

23. Product Analysis Ergonomics and Function Introduction On this slide I have presented the analysis of function and ergonomics of the colander. I will try to discover any problems that one may come across when using the product. I will also try to discover how the product fits in with the environment that it will be in. I will therefore investigate why the colander has been shaped in the way it has. Ergonomics The colander has been specifically shaped and modified so that once the user doesn’t need water within it, the water drains to the bottom of the colander and through the small circular holes. However, in many cases, the water does not drain through the holes at the base of the colander, as shown in Figure 2. It has also been made in the shape of a bowl so that it is easy to clean after use, as if the product had corners, then it would be difficult to access them (Figure 1). Nevertheless, it does have some corners and they are very difficult to get in to with a standardwashing-up brush (Figure 5). The handles on both sides of the colander are relatively difficult get a good, firm grip of, and from my experience of using it, they are not comfortable to hold (Figure 3). Figure 1 Figure 2 Function The function of the colander is quite easy to understand. It works by providing a large bowl-shaped structure in which the user may place whatever they wish inside. The small holes within the colander allow for water to flow in and out of the colander with little delay. The colander has two handles, however, when the colander is being used, it is not possible to use them both if the user wishes to hold something within the colander (Figure 4). The flat base attached to the bottom of the colander allows for it to be placed on a flatsurface without tipping from side to side. Figure 3 Figure 4 Figure 5 Conclusions From my productanalysis, I have come up with a number of specifications. The product must: 1) Not have many, if any corners. 2) Be easy to clean after use. 3) Be easy to hold, (with one hand if necessary). 4) Allow water to flow through it with ease. Sam Naylor | GCSE Resistant Materials | Organic 15

24. Mood Board Introduction On this slide I have presented the Mood Board for my project. A MoodBoard is a selection of images of products that relate to the problem in some way. These products may give oneself inspiration in the design of their product. Conclusions I based my decision when choosing which images to use on quality, shape and relativity to my product. I like the idea of kitchen utensils being made out of stainless steel, as I believe that it gives the product a more aesthetically pleasing look, and they always are made to a high quality finish. Sam Naylor | GCSE Resistant Materials | Organic 16

25. Initial Ideas – Buzz Page Introduction On this page, I have presented my Buzzpage of initial ideas. To produce this page, I worked with my class-mates, explained the design brief to them then asked them to draw an initial idea of their own, in order to solve my design problem.This process is an industrial practice. Figure 1 Figure 2 Figure 3 Figure 4 Figure 7 Figure 5 Figure 6 Figure 8 Figure 9 Conclusion This page of designsenabled me to get a wider perspective on possible design solution for my product. This buzz page is the basis of ideas for the final product. More detailed designs will be drawn, which will be accompanied by CAD drawings. From the ideas that some of my classmates proposed, I may choose to develop the ideas shown in figures 3,5 and 8 further. However, I will not be developing any of the other ideas proposed any further. Sam Naylor | GCSE Resistant Materials | Organic 17

26. Initial Idea 1 Introduction On this slide, I have presented my first initial idea. My first initial idea is a shape similar to that of an up-side-downumbrella, with five slots each capable of holding one egg each. It has a rubber handle, in order to prevent the user getting burnt, whilst the mainbody and shaft is made out of stainlesssteel. The product is designed to fit into a regular sized saucepan. Figure 1 Analysis Pros: It is a unique design It would hold a sufficient amount of eggs for a family of five. It has a modern, and slick look. Due to it having a unique method of gripping it, when it is lifted, the centre of gravity of the product is in the centre of it, so it doesn’t tip to the sides. Cons: The eggs may get pushed out of the slots by bubbles when they are being boiled, and therefore defeat the object of the product. The eggs may not boil quickly, as the product may insulate the bottom of them. Water may not drain through the slots for the eggs. Sam Naylor | GCSE Resistant Materials | Organic 18

27. Initial Idea 1 (continued) Introduction On this slide I have continued to present my firstinitialidea. As you can see, I have presented it using CAD, in order to give a better representation of what it would look like if it were to be manufactured from stainless steel. Figure 4 Figure 2 There are five slots, which would all be capable of holding one egg each. Figure 3 The handle of the product would be made out of rubber, to prevent the user from burning themselves. Conclusions I have decided that I will be modelling this initial idea, as I believe it has some very uniquecharacteristics, and is very aesthetically pleasing. I will model it using CAD, and then using the CNCmiller in order to machine it. The diameter of the product at its widest point would be small enough to fit into a saucepan with a diameter of 170mm or more. Sam Naylor | GCSE Resistant Materials | Organic 19

28. Initial Idea 2 Introduction On this slide, I have presented my second initial idea. My second initial idea is a shape similar to that of my first initial idea, however, there were some features which I decided to change. A different shaped handle has been used to try and help improve grip and control of the product. I also changed the way in which the product holds the eggs, by getting rid of the individualslots for the eggs. Figure 1 Analysis Pros: It is a unique design It would hold a sufficient amount of eggs for a family of five. It has a modern, and slick look. It is capable of holding at least 3 eggs, which satisfies one of my major specifications previously mentioned. Cons: If the user is only boiling one or two eggs, then the product would not balance well. The eggs may not boil at the same heat throughout them, as the product may insulate the bottom of them. Water may not drain through the slots for the eggs. Sam Naylor | GCSE Resistant Materials | Organic 20

29. Initial Idea 2 (continued) Introduction Figure 3 Figure 1 On this slide I have continued presenting my second initial idea. However, as you can see, I have done so using CAD. Figure 2 Conclusions I have decided that I will be modelling this initial idea. I will be doing so as I would like to test and compare the different features of my first and my second initial ideas due to them being quite similar in terms of size and shape. I will model it using CAD, and then using the CNCmiller in order to machine it. In figure 1, you can see the height of the shaft relative to the base of the model. You can also see from the orange part of the model that the handle of the product would be made out of rubber. Figure 3 shows the 3D view of my second initial idea. The arrow below Figure 3 demonstrates the diameter of my second model, which is 140mm wide. This means that it would be able to fit into any saucepan with a diameter larger than 140mm. Figure 2 shows the planview of my second initial idea. From this view, you can see that their would be sufficient space for at least 5eggs. You can also see that the shaft of the model is based right in the centre of the model, in order to give the user as much balance possible when they hold the product. Sam Naylor | GCSE Resistant Materials | Organic 21

30. Initial Idea 3 Introduction On this slide, I have presented my fourth initial idea. My fourth initial idea is an egg holder with a rack which would hold a maximum of four eggs, and a long z-shaped handle which would provide the user with sufficientleverage to lift the holder. When placed on a flat surface, the egg holder would be able to balance well without the aid of any support. The slots which would be used to hold the eggs would have very smooth edges, so that the eggs inside would be in no danger of cracking. This idea also has a rubber grip attached near the handle, which would allow the product to stay secure when in the saucepan. Figure 1 Analysis Pros: The egg holder would be able to balance on a flat surface without any support The egg holder would be able to firmly attach itself to the rim of a wide range of sizes It would securely hold four eggs Cons: It would not be able to fit comfortably in a saucepan with a diameter of less than 190mm. Sam Naylor | GCSE Resistant Materials | Organic 22

31. Initial Idea 3 (continued) Introduction On this slide, I have presented my third initial idea. To do so, I used CAD, as shown below in figures 1,2,3 and 4. Figure 1 Figure 2 Figure 3 The user of the product would be able to comfortably hold the product, due to the handle being made out of rubber. Also, the shape of the handle would suit the user well, as the user would be able to easily grip it using their thumb, index and middle fingers. In figure 2, you can see that there would be a rubber gripwhich would be capable of holding the product firmly onto a saucepan. Figure 1 shows my third initial idea from a front on perspective. As you can see, it has 4 slots, each capable of holding one egg each. Figure 4 Conclusions I have decided that I will not be modeling this initial idea. This is for several reasons Sam Naylor | GCSE Resistant Materials | Organic 23

32. Initial Idea 4 Introduction On this slide, I have presented my fourth initial idea. My fourth initial idea is similar to that of a basket, except there are small holes on the sides of it (each 10mm wide) which allow water to easily flow within it. When placed on a flat surface, the egg holder would be able to balance well without the aid of any support. The main frame of the product would have a very slick interior and exterior, and very smooth edges so that the eggs inside would be in no danger of being damaged prematurely. Due to the rest of the product being made out of stainless steel, the handle would be made out of rubber, in order to prevent the user from being burnt. Figure 1 Analysis Pros: The egg holder would be able to balance on a flat surface without any support Once within a saucepan, there would be no issues, concerning balancing the product within the saucepan. Cons: It would not be able to fit easily in a saucepan with a diameter of less than 175mm. It is moderately aesthetically pleasing. Sam Naylor | GCSE Resistant Materials | Organic 24

33. Initial Idea 4 (continued) Introduction On this slide, I have presented my fourth initial idea. To do so, I used CAD, as shown below in figures 1,2,3 and 4. Figure 1 Figure 2 Figure 3 Figure 4 The user of the product would be able to comfortably hold the product, due to the handle being made out of rubber. I designed the handle specifically so that the user of the product would be able to easily remove it from a saucepan, as it provides itself with a lot of leverage. Figure 1 shows my fourth initial idea from a 3-Dperspective. As you can see, it has many small holes on the sides of the basket. These have been placed where they are, so that water can easily flow into the product when it is placed in a saucepan containing water. Again figure 2 shows my fourth initial idea, however it does so from a side-on view. It gives a very clear idea of how large the handle is, compared to the basket in which eggs would be placed. Conclusions Although my fourth initial idea has many useful and interesting characteristics, I have decided that I will not model this design. Sam Naylor | GCSE Resistant Materials | Organic 25

34. Research - Size Introduction On this slide, I have presented the size research concerning anything which may influence the size of my project. I will look into the size of eggs, saucepans and the size different types of handles, due to it being a hand held product. It is important that I can out some research on the size of my product, as it has a big effect on how my product will perform when used. Figure 4 Figure 3 Method I took the measurements using a ruler, a vernier, a tape measurerwhen attempting to acquire the most accurate results possible. Figure 1 Figure 2 Figure3 shows an image of myself using a ladle. I chose to look at the size of this ladle as I thought that it would be useful to know how small and thin some kitchen utensils are. Although it is a different type of handle to the one I would be looking to use, I think it is useful to look at how it can be held according to its size. Figure 4 however shows myself measuring the width of the handle. I discovered that it has a width of 13mm, and it has a thickness of 6mm. I think that this is the bare minimum amount of material which could be used for this products particular function, because if it were to be any smaller, it would be too awkward for the user to grip. Conclusion From carrying out this research, I am now able to come up with some more specifications: The handle must be at least 13mm wide. The handle must be no wider than 42mm. Figures 1 and 2 are of myself measuring the dimensions of a handle on a cupboard, in my house. I looked at measuring how wide and how thick the handle was, at the points where the user is meant to grip the handle. It was 42mm wide, and had a thickness of 24mm. I do not believe that the handle which I will use for my product would need to be any wider than that of the handle on this cupboard, as I believe that the majority of people would be able to grip this handle with ease. Sam Naylor | GCSE Resistant Materials | Organic 26

35. Research - Size Introduction On this slide, I have continued to researchsize in order to help me with my project. I will research the size of chicken eggs and saucepans, as these are both significant features relating to my project. I also decided to take dimensions of how much space 2, 4 and 6 eggs would all occupy if they were all placed within the closest possible proximity of each other. I discovered that the maximum amount of eggs that one could place on the base of a saucepan with a diameter of 18.5cm was 8. Size of Eggs 4 Eggs 2 Eggs 6 Eggs To discover what the averagesize of chicken eggs was, I decided to take 5 different measurement from 3 different eggs. I chose these eggs, by determining which 3 eggs, within a box of 12 I deemed to be the smallest, the largest, and the most average size in length and width. The table below shows my results, after carryingout some measurements concerning the different sizes of eggs. Size of Saucepans I also decided to research the size of saucepans. I took measurements of the height of the saucepan, and also the width. I have demonstrated doing so, within figures 1 and 2. After carrying out some research, I discovered that the diameter of the saucepan was 18.5cm and that the height was 10cm. Figure 1 Figure 2 Conclusion From carrying out this research, I am now able to come up with some more specifications: If I decide to place slots in the products, designed to hold an egg each, they must be at least 45mmwide. The product must be no wider than 18.5cm and at least 16cm tall. Length Width 1 Width 3 Width 2 Width 4 Sam Naylor | GCSE Resistant Materials | Organic 27

37. Durability/strength

38. Weaknesses

39. Suitable materials

40. Proportion

41. AestheticsI am also able take the model to a third party, so that they could be given an opinion on the model from another perspective. Finally, it helps when suggesting any other possible improvements that could be made to the product. I used modelling Plaster to model my first initial idea as it is: 1.Very easily cut 2.Relatively strong 3.Its density is reasonably similar to the materials that I have already thought about using for the manufacture of my final product. Figure 1 shows the block of modellingplaster that I started off with. Figure 2 is an image of me when I am measuring the correct thickness that my modellingplaster will need to be, for when it gets CNC machined. Figure 3 shows the planer thicknesser that was used in order to cut my piece of modelling plaster down to the correct thickness. Figure 5 Figure 4 Figure 6 Figure 4 shows me cutting my piece of modelling plaster to the correct length, using the band saw. In order to machine the shaft and handle of my first model, I needed to export them on to an IGES file. Once I had exported my CAD onto an IGES file, I was then ready to CNC mill the handle and shaft of my first model. The result of this is shown above in Figure 5 Conclusions Next I will continue with the diary of manufacture for my two models and evaluate each model against my majorspecifications. Once I had machined both halves of my handle and shaft, I glued them together, and they were then ready to put together with the base of my firstmodel. Superglue, a contact adhesive was used to ensure a secure bond. Sam Naylor | GCSE Resistant Materials | Organic 28

42. Modelling - Diary of Manufacture (continued) Introduction On this slide, I have continued to present my diary of manufacture for my two models. Figure 1 Figure 2 Figure 3 Figure 4 Figure 2 also shows the base of my first model, however I have presented it from a side elevation. To cut the base, I used the CNCmiller. However, to round the edges at the bottom, I used the table router, as it gave me a reasonably accurate result, and it provided a very easy means of dong so. Figure 4 shows myself sanding the handle and shaft of my first model, to give a qualityfinish. Figure 1 shows the base of my first model which I exported into the MDX3Psoftware. As you can see, I machined the base of my firstmodel without the handle and shaft. Figure 3 shows myself sanding the base of my first model, using P120 sandpaper, then P240 sandpaper. These were the first few steps taken in order to give my model a quality finish. Figure 7 Figure 6 Figure 5 Figure 8 Figure 7 shows the handle and shaft of my second model split into 4 parts on an IGESfile. In order to machine these different parts, I had to place them onto an IGES file. Once I had machined the parts, I glued them together. Figure 8 shows the base of my first model in MDX3Pformat. The cut the top of my base, I used the CNCmiller, however in order to cut the bottom side of the base, I used the router. Figure 6 shows the base of my second model which I presented, in the MDX3Psoftware. As you can see, I machined the base of my first model without the handle and shaft. Figure 5 shows my final outcome after constructing my first model. I have presented it in context, demonstrating its purpose in the process. Conclusions This has helped me to learn about how I will build my project. I will use the CNCmiller to machine my finalproduct as I now have sufficient experience using it. Sam Naylor | GCSE Resistant Materials | Organic 29

43. Modelling - Evaluation Introduction On this slide I have presented my Evaluation of my models. Having tested the models, I am now ready to look at any areas for improvement, or any especially weak areas of the models. Using the search engine ‘Google’, I discovered that the definition of Evaluation is: The act of gaining an understanding or fixing the value or worth of something. I will evaluate my models using many different methods. I will evaluate them by : Test against my major specifications Use a 3rd party Discovering the positive and negative points of my models, so that I have a good understanding of what I should and shouldn’t change. Figure 1 Figure 5 Figure 6 Figure 7 Figure 8 Figure 2 Figure 3 Figure 4 Water deposited within the slots designated for the eggs, after being taken out of a saucepan with water within it. By making a second model, I was able to give myself an accurate insight as to what positive and negative points there were to take from this design idea. Pros: 1. The model can securely hold the five medium sized eggs 2. The user can grip the product relatively easily. Cons: 1. When I attempted to hold the model in mid-air, the model tipped slightly to the side, due to the handle being vaguely off of the centre of gravity. 2. When I placed only 3 eggs within the model, they were not held securely within it, and this resulted in one of the eggs cracking prematurely. By developing this model, I was able to discover all of the positive and negative points to do with my model, using a hands on approach. Pros: The model can securely hold the five medium-sized eggs that it is required to hold, as said in my major specifications The handle functions well, and the user can easily grip the product. Cons: I discovered that when I placed the model in a saucepan full of water, it was not possible for the water to drain through the slots in the model for the eggs once the eggs were boiled, and the model was removed from the saucepan (as demonstrated in figure 4). Conclusions As both my models are quite similar, they share positive and negative points. Next, I will look to develop the design on the development of function. Sam Naylor | GCSE Resistant Materials | Organic 30

45. Eggs could not be easily removed from their slots.

48. There was a lot of waste material.

49. There was no drainage system within the egg slots.

51. Reduce as much waste material as possible without jeopardising the quality of the products function.Plan view (above) Side elevation By having a cradle-shaped design, there are many benefits that come with it. First of all, there is obviously a large reduction in waste material, so there would be less of an environmentalimpact should the design by manufactured. This also makes the product lighter, and therefore easier to handle. Also, water can flow in and out of the product very quickly and efficiently. Another benefit although perhaps being more minor, is that more eggs could be place within the product than the previous design, as there is no fixed limit concerning how many eggs can be placed inside, due to there being no egg slots. Conclusion On the next slide, I will continue to look at developing the function of my 1stinitial idea, before I start to develop the ergonomics of my idea. 32 Sam Naylor | GCSE Resistant Materials | Organic

52. 1st Design Proposal On this slide I have presented my First Design Proposal. I have made several improvements to my initial idea through modeling one of my initial ideas and developing its function. My major changes which I have made to my initial idea are presented on this slide. Figure 2 Figure 3 Figure 1 Figure 1 shows the trimetric view of my first proposal. The base of the product is a cradle-like shape, which allows for water to flow easily around the eggs. It would be capable of holding approximately 4eggs. Figure 3 is the side-on view of my first proposal. While designing my first proposal, I tried to make sure that the handle of the product was long enough so that the user would not be in danger of burning themselves. The shaft of the handle would be placed right in the centre of the product, so that when the user holds the product in the air, it is relatively balanced. Figure 2 demonstrates the plan view of my first proposal. The holes within the base of the product would 25mmwide, so there would be no issues concerning eggs falling through the base of the product. 25mm is plenty of space as far as allowing water to flow through the product is concerned. However, in the meantime it doesn’t allow eggs to fall through. Analysis Pros: The egg holder would be able to balance on a flat surface without any support Once within a saucepan, there would be no issues concerning balancing the product within the saucepan. Cons: The edges on the product could easily crack eggs within the product The eggs would not be firmly held within the product, so they could crack when being boiled. Conclusion I will now move on to developing the function of my product. Sam Naylor | GCSE Resistant Materials | Organic 33

55. The handle size would be reduced.Sketch work All of the edges on the product would be rounded, making the product easier to clean after use. The removal of waste material will dramaticallyreduce the weight of the product, making it easier to handle. Sam Naylor | GCSE Resistant Materials | Organic 34

58. Largerdiameter holes have been included within the egg slotsFigure 1 Figure 1 shows my proposed alteration of the diameter of the holes within the egg slots. The holes would be 14mm, rather than 5mm, which would allow for faster drainage. Figure 2 Figure 2 shows the sketches that I have done to show one of the ideas I had concerning how I could develop the ergonomics of the product further. I have decided that I will incorporate small finger grooves on the edges of the egg slots. This will ease the removal of the eggs from the product dramatically, whilst in the meantime reducing the amount of waste material on the product. Conclusion On the next slide, I will be presenting the aesthetic development of my product, demonstrating all of the ideas that I came up with in the meantime that I believed would make the product more pleasing on the eye. 35 Sam Naylor | GCSE Resistant Materials | Organic

59. Development - Aesthetics Introduction On this slide I am going to develop the aestheticassetsof the egg holder in an attempt to make it engagingto the consumer market. I will mainly be looking at the designs that will be featured on the egg holder. Using my mood board which I created earlier in my project, I looked at designs from kitchenutensils and other products which relate to my project to influence any aestheticdevelopments to do with my project. I decided to look first of all at the design and shape of the handle. Figure 2 Figure 1 Figure 3 Figure 4 Figure 5 Conclusion By sketching such a vast range of ideas for the handle of my product, I now have a very clear idea of what I would like it to look like. However I will have to take into account the ergonomic impact that each of the designs possess, which may prevent me from developing some of the ideas further. On the next slide I will continue to present the aesthetic development for my product. Figure 1 shows my original design idea for the handle of my product. I quite like this idea due to the simplicity that it possesses. I also believe that is very important for the handle to have a shape similar to that of an egg, as the user can then start to understand its purpose in a much clearer manner. In figures 2 – 5, I attempted to design a more diverse handle, so I chose to alter the original handle that I came up with, however keeping its ‘egg’ shape in the meantime. Figure 2 shows a ‘banana’ shaped hole which goes through one side of the handle, which I believe makes the handle look modern and slick. Figure 3 shows a more simple design, which a ovular shaped hole going through the centre of the handle. However figure 4 is a slightly different idea, in that it is a concaved ring which goes through the lower half of the handle. And finally, figure 5 shows 5 small holes within the handle, which give for a ‘bubbly’ and more diverse look. Sam Naylor | GCSE Resistant Materials | Organic 36

61. Cut threesemi-circularholes around the base of the handle.Figure 1 shows the first idea that I came up with concerning the aestheticdevelopment of the base. As you can see, I have just added a small 2mm deep curved ring around the base of the shaft. I quite like this simple design, as although it is very straightforward design, I feel that it gives for a much more distinctive and unique design than when there is no ring. In figure two, you can see that I have come up with a slightly different design than the one shown in figure 1. This design would simply just have three curved holes which go right through the base. Not only would this design have aesthetic benefits, but also functional benefits. These three holes would allow for air to easily pass from the air pocket underneath the base and through the base. What I like as far as the aesthetics are concerned about this design is that the three holes do not stand out too much in the design, however they do provide the product with a slightly more complexvisual image. Conclusion Next I will present my 2nd design proposal, pointingout any major changes that I have made in the meantime. Sam Naylor | GCSE Resistant Materials | Organic 37

62. 2nd Design Proposal Introduction On this slide I have presented my second design proposal. I have made several improvements to my initial idea through developing some of the function, ergonomics and the aesthetics and later modeling my initial idea. My major changes which I have made to my initial idea are presented on this slide. Figure 1 Figure 3 Figure 4 Analysis Pros: The egg holder would be able to balance on a flat surface without any support The product would be capable of draining water out of it when removed from the saucepan. The eggs would be firmly held within the slots. Cons: It would not be easy to remove the eggs from their slots. I don’t believe the product is as aesthetically pleasing as it could be, as it has a very ‘cubic’ shape. The shaft on the product is possibly slightly too long, which could make it hard for the user to manoeuvre the product. Figure 3 shows the plan view of my 2nd design proposal. The shaft of the product is based in the very centre of the base, in order to allow for balance and stability during use. Figure 4 shows a side-on view of my 2nd design proposal. This image demonstrates the amount of material that has been removed from the under-side of the base. It also gives an idea of how far the users hand will be away from the saucepan when they grip the handle of the product. Figure 2 Figure 1 shows the trimetric view of my second proposal. The base of the product has six circular slots in which eggs can be placed. There has been a lot of waste material removed from the underside of the base, compared to the idea that I came up with when coming up with my initial ideas. Figure 2 shows a close up view of one of the egg slots. As you can see, I have incorporated a small hole within the slot in order to allow for drainage to occur. Conclusion Next, I will start to look at researching the materials, finishes and testing that I will use during the manufacture of my final product. Sam Naylor | GCSE Resistant Materials | Organic 38

64. If it were to be mass produced it would be made from stainless steel by die casting.Sam Naylor | GCSE Resistant Materials | Organic 39

65. Research – Construction Techniques and Testing Introduction On this slide I have researched the construction techniques that are most suitable for the production of my product. I have looked into how it would be constructed as a model, as well as if it were to be mass produced. There are some disadvantages however of using the CNC Miller in order to manufacture my product. For example, the 6mm cutter can cut only 50mm into the material, but fortunately, this should not pose any issues towards the manufacture of my product. Also, the CNC Miller cannot cut perfectly smooth curved faces, which is likely to cause some slight issues when it comes to sanding down imperfections on my product. Once I have manufactured all of my parts, I will bond them together using superglue. I will then fill in any dents, gaps or holes with Isopon P38 filler. Die Casting Die casting is the manufacturing process that I would use in order to make my product, should I ever decide to mass produce my product. I would use this manufacturing process as it would allow for my product to be produced using stainless steel. Figure 4 – Base CNC Milling I will use a CNCmiller to manufacture my product, as it is fast and accurate. By exporting CAD work as a stereo lithography file, the CNC miller can import the file and cut the desired shape very precisely. Figure 6 I will manufacture the base on its own. Figure 5 – Handle halves nested Figure 1 Figure 3 Figure 2 Figure 3 shows a model which I produced earlier on in my project. I manufactured it out of modelling plaster using a CNC Miller, which is exactly the same as how I am going to product my final design. By producing this model I have provided myself with some experience using certain machines, which should help prevent me from making any mistakes during manufacture. I will manufacture the handle as two separate parts, and I will also manufacture one spare half, as they will be very delicate and easily damaged. Conclusion I will now move on to present my list of detailed specifications. Sam Naylor | GCSE Resistant Materials | Organic 40

67. It must be easy for the user to remove the eggs from the holder.

68. The product must not have any sharp edges which could harm the user or the eggs placed within it.

70. The product must be able to be stored in kitchen cupboards with ease.

73. For my final product I will use modeling plaster , as it is strong, durable and quite flexible.

75. It must be durable so it resists any knocks which it may endure during use.

76. It must not get damaged at high temperatures (in water).

77. It must not get scratched easily, as this would rapidly decrease its aesthetic quality.

79. It must make the removal of eggs from saucepans very swift and easy.

80. The product must be strong and durable, so it does not break easily when placed into a saucepan.

81. It must also drain water through it when placed in and removed from the saucepan.Conclusion Using the information I have collected I can now evaluate my product. However on the next few slides, I will present my final proposal. Sam Naylor | GCSE Resistant Materials | Organic 41

82. Organic Final proposal The egg holder has been purposely designed, to make it considerably easier to place and remove eggs from a saucepan. The unique shape makes it an attractive product to look at. Sam Naylor | GCSE Resistant Materials | Organic 42

83. Organic Final proposal The holes in the egg slots allow for water to drain through the product when removed from water. The shape of the handle is similar to that of an egg, which aids the product fit in to its designatedenvironment. The small grooves on the edges of the egg slots allow for the user to easily remove the eggs from their slots. Sam Naylor | GCSE Resistant Materials | Organic 43

84. Organic Final proposal Waste material on the underside of the product has been removed. The small ring in the centre of the base of the product provides a diverseaspect to the product. 44 Sam Naylor | GCSE Resistant Materials | Organic

85. Engineering Drawing Introduction On this slide I have presented my engineering drawings for my product. An engineering drawing defines the necessities for a product. This will include the dimensions of the product presented from different views. Also included in an engineering drawing is the material which is to be used, any finishes and finally the colour that is desired. Engineering drawings are used in order to allow for the product to be reproduced accurately, therefore it is an essential process which must be undertaken in industry. This will help me during manufacture, to machine, assemble and plan the final working product and to make sure all material is cut down to the right size when it is being prepared. Material- I will manufacture my parts out of modeling plaster, using the CNC machine to get a accurate finish. I will also use filler and sand paper to give for a smooth end product. If I were to mass produce this product it would be made of stainless steel. Finish- I will finish the product with spray paints to give a faultless, modern look. Colour- The egg holder will be a slightly off-white, in order to allow for the product to fit into a kitchen environment, but in the meantime stand out as a top quality product. 3-D Representation Side elevation Part 1 – Base of holder Plan view (from above) Conclusion I will now go on to show my other engineering drawings of the other parts of my final product. 3-D view Sam Naylor | GCSE Resistant Materials | Organic 45

86. Engineering Drawing (continued) Introduction On this slide I have continued to present the engineering drawings for my product. I have presented the drawings for the handle of my product, and also looked at the drawings for half of the handle, because I will be manufacturing the handle in two parts. Part 2 – Handle of holder Plan view (from above) Conclusion Next, I will move on to produce my manufacturingplan, which will demonstrate all of the steps which I will take during the manufacture of my product. Side elevation of handle 3-D View Side elevation of half of handle Sam Naylor | GCSE Resistant Materials | Organic 46

87. Is the cutter at the right depth? Has it been zeroed? Manufacturing Plan and list of all tools and equipment Introduction On this slide I have presented my manufacturingplan, which demonstrates the stages that I will take to complete my finished product. The manufacturing plan is an industrialprocess. Also in the manufacturingplan I will draw attention to areas where techniques that ensurequality are used, to result in the best possible product. As well as this, I will underline any key tools which were fundamental in the manufacture of my product. The manufacturing plan also helps predict how much time is needed as it points out the stages where I will need to spend the most amount of time. This is vital as far as how efficiently the steps of manufacture go is concerned. The manufacturing plan should be set up alongside my final design and engineering drawings. Start Set the MDX3P software to the right setting for the part (i.e. Correct material and cutter) YES Prepare the material – cut out both blocks of modeling plaster. Base - 150×160×40 in size, handle - 160×160×30 in size. Is the software on the exact settings? Is it set on the right cutter on the right material, whilst cutting the correct side? NO NO Lower the cutter to the correct depth according to the part and material being machinedand move it to bottom left hand corner of the material, setting each axisto zero. Plane material down to the right thickness and measure it using with a vernier calliper. YES Check all the pieces are flat, level and that the thickness is correct. Is the material flat on the bed? NO YES NO Press start on draft cut, and then alter to fine cut. Stick down material to bed with hot gluegun and hold down until glue has dried. YES Stick the material down onto some plywood, that is a similar size, using double sided sticky tape. Once it is finished, blow or brush away any dust and start to remove the plywood and the glue away from the bed, so that it can be used again. I can now use the CNC miller to machine my product. NO YES NO Is there enough tape on the board? Is the board flat? YES Continued on next page… Sam Naylor | GCSE Resistant Materials | Organic 47

89. Plainer thicknesser (although only used by member of staff)

90. Hot glue gun

91. CNC miller

92. 360 sandpaper

93. Isopon P38 filler

94. Grey Primer

95. 1200 wet and dry paper

96. Off-white gloss paint

97. Super glue

98. Vernier

99. Compressed airOnce the base is dry, spray the handle with two coats of gloss paint and leave to dry. Repeatprocess for flip job (if necessary), otherwise start to sand away imperfections using 320 grade sandpaper. Wipe down product with cloth, then spray away dust with high pressure air. Is all of the product covered with a thick coat of gloss paint? Have the majority of the imperfections on each part been sanded away? NO Are there any more imperfections or marks? NO YES YES NO Conclusion I now have a clear and well thought structurewhich provides me with a good basis from which I can work from. Next I will start my diary of manufacture Glue all parts together with super glue, then use Isopon P38 filler to fill in any gaps between the parts. Spray away any dust with high pressure air, then spray product with one coat of grey primer. Slightly sand down any imperfections with 1200 grade sandpaper. YES Finish YES NO Can any imperfections now be seen or felt? Sand away all unnecessary filler from product with 320sandpaper, as well as any marks which may show up when spray painting. Sam Naylor | GCSE Resistant Materials | Organic 48

100. Diary of Manufacture – Ensuring quality (preparing the material and CNC Milling) Introduction On this slide I have presented how I made my product and the techniques used during manufacture. During manufacture one of my aims was to ensure that quality and precision was maintained throughout. This was important for my project as I was working with a complex shape for my final design. I am focusing on this slide on how I prepared the material, which was an essential stage in making the product. I will highlight areas where ensuring quality was considered. Figure 5 Figure 3 Figure 1 Figure 7 I started by taking a large block of modelling plaster and then cutting it down to size using a bandsaw, as shown in figures 1 and 2. Figure 8 Figure 2 Figure 6 Figure 4 Figure 7 shows the control panel of the CNC miller which is used in order to make the desired set up. The box on the left hand side within the figure shows all of the buttons that are required in order to place the material on the correct part of the bed. The box on the right side of the panel shows where the required buttons are in order to turn on or off the spindle and then higher or lower it. Figure 8 shows the CNC Miller that I used in order to manufacture all of the parts for my product. In that image, I had not yet chosen the cutter that I was going to use. Figure 5 shows the double-sided sticky tape that I placed on the underside of the material before I had peeled off the other side of it. In figure 6, I have peeled it off and it is now ready to be stuck on to the plywood. I used the band saw to cut down the material, until precision was much more vital. In this case, I asked a member of staff to plane down the material using the planer thicknesser, as shown in figure 3. A vernier was used in order to measure the exact thickness of the material, and judge how much more of the material had to be removed. 49 Sam Naylor | GCSE Resistant Materials | Organic

101. Diary of Manufacture – Ensuring quality (during CNC machining of base) Introduction On this slide I am continuing my diary of manufacture, and how I ensured that I produced a quality product, while I was manufacturing the base of my product. Figure 5 From figure 3 you can see I placed it into the white spirit tank in order to ease the removal of the product from the sticky tape on the plywood Figure 3 Figure 1 Figure 5 shows the base of my product once both sides of it had been machined. I was very happy at this stage of my manufacture, as I had managed to perfectly align the base up in the correct place so that it was cut accurately. Figure 4 shows the base of my product being machined. At that point in time, it was carrying out the flip-job for the base, as the CNC miller could not cut out all of the product without it being flipped over to the other side. When flipping the base, I had to make sure that it was turned over into the exact same position, to ensure that quality was maintained. Figure 1 shows the base of my product in MDX 3P format. I used this software to find out the exact dimensions of the base in order to prepare the material. Figure 2 shows the base of my product after the first process of machining was complete. Figure 2 Figure 4 Sam Naylor | GCSE Resistant Materials | Organic 50

102. Diary of Manufacture – Ensuring quality (CNC Milling, bonding, filling and sanding the machined parts) Introduction On this slide I am continuing my diary of manufacture, and how I ensured that I produced a quality product. Figure 2 Figure 4 Figure 6 Figure 1 Figure 6 shows my product fully assembled, along with the filler that I used to fill in any gaps or marks in on the product. Figure 4 shows the three handle halves that I machined. I machined 3 so that I could then choose the 2 best quality parts from them. Figure 5 Figure 3 Figure 1 shows the small icons that appear on the right side of the screen when using the MDX 3P software that is used for the machining of parts on a CNC miller. These are necessary in order to carry out a flip-job on the miller. Figure 5 shows the superglue that I used in order to glue all of my parts together. Superglue is a contact adhesive and it is highly renowned for forming strong bonds in a very short space of time.One of the key properties is that it sets within about a minute or so. This was a key factor that ensured that my product glued together as precisely as possible. Figure 3 shows a piece of 320 grade sandpaper which I used to sand down my product after it had been machined. I cut them into small pieces, so that I could get into small, intricate places, such as the insides of the egg slots – shown in figure 4. Sam Naylor | GCSE Resistant Materials | Organic 51

103. Diary of Manufacture – Ensuring quality (Applying primer, filler and gloss coats) Figure 5 Introduction On this slide I am continuing my diary of manufacture, and pointing out all of the key stages that ensured quality, in the build up towards applying the finish. Figure 2 From figure 3, you can see an image of me holding the spray paint that I used in order to spray my product with the final gloss paint. I sprayed it an off- white colour, shown below in figure 4. I had to spray the base and the handle of the product separately, so that it could rest on a surface while drying, and the paint would not get smeared or marked. Figure 1 Figure 4 Figure 2 shows the extractor fan within the room in which I used to spray my product with the primer and the gloss paint. This was a very importantmachine involved during the spraying process, as it meant that I could spray my product inside, without the risk of breathing in harmful gases. Figure 5 shows my final product after having two coats of gloss paint applied all over the product. Once the second coat was applied, I left the product over night, not only for the paint to dry, but also solidify its surface to make it more durable. As you can see above I decided to place some eggs into some of the slots, to make sure that there were no changes that I had to make, for example if the holes were too small or too wide. I also did this in order to check that the finger grooves on the sides of the egg slots were large enough in order to fit a finger or thumb within them. Fortunately, everything functioned well and there was no need for me to make any major modifications to my product. Figure 4 shows my product resting in a cup which is in a clamp. Only the handle is making contact with any of the surfaces, which is important as it is the only part of the product that hasn’t got wet paint on it. As you can see, the paint offers a very slick, glossy look after being applied. Figure 1 shows my product after having a coat of grey primer applied to it. After applying this coat, I was able to see many more imperfections that before, so I used filler when necessary, then started to sand once more, this time using 1200 grade sandpaper. I had to repeat this process many a time, all in order to give my product a top quality finish. Figure 3 Sam Naylor | GCSE Resistant Materials | Organic 52

104. Diary of Manufacture – Illustrating any mistakes that were made So, I have now realised that modeling plaster was perhaps not the most suitable material to choose in order to manufacture my product, however fortunately, I will not be fully testing my model in boiling water anyway. I will however still check if it fits well into a saucepan, as shown below in figure 1 Spray painting – Gloss coat Unfortunately, on one occasion after I had applied a coat of gloss paint, I lost focus and accidently touched some wet spray paint on the base of my product, leaving a large finger print marking within the paint after it had dried. I left it until it was dry, and then sanded away slightly where I had left my finger print on the base, using 1200 grade sandpaper. It was not a drastic mistake, however it did cost me some time, which could be a much more severe mistake if a similar thing were to happen during mass manufacture. Introduction On this slide I am continuing my diary of manufacture, however I will now be looking at pointing out any of the mistakes that I made. Due to myself modeling my final product out of modeling plaster, it is not an exact representation of what my product should be, because if I were to mass manufacture my product, it would be made out of stainless steel. Figure 1 Material – Modeling Plaster Although I will not be able to properly test my final product, due to it having a gloss paint applied, I can still point out some of the issues regarding the products function. If I were to place my product in boiling water in order to boil some eggs, then it is likely that the gloss paint would be removed from the products surface, so I must not do so. However, I discovered that when I placed a piece of modeling plaster on its own into water, it floats, which would affect the way in which my model would function. I am not sure how many eggs would be needed in order to weigh down the model to the bottom of a saucepan, where the water is at its hottest temperature, however six eggs were placed into the product, then I am sure that the model would not float. Sam Naylor | GCSE Resistant Materials | Organic 53

106. Be easy to clean after use.

108. The product must be well finished and have a smooth, rounded shape.

110. It must significantly eggs the placement and removal of eggs from a saucepan with boiling water within.

111. It must allow for water to drain easily throughout the product.I feel that the case satisfies the specifications created for function. The product can hold more than 4 eggs, it certainly eases the placement and removal of eggs into a saucepan containing boiling water and it has a simple and effective drainage system that could easily drain out any water. Method To evaluate my product the most important thing to see was how successful it is. In order to do this I went through a number of tasks. Firstly I tested the product against my design brief and specifications that I had created after research, during the project. I also carried out a user test and gave questionnaires to a range of people of different ages to get down on paper any possible improvements that I could make to my product. I will also examine any weaknesses in the egg holder and explain what improvements I could make. Figure 1 – Final product in context. Figure 3 – Checking the product fits well into a saucepan. Figure 2 - Testing the egg holder Figure 3 – Handle As I was aiming for, the handle has a smooth egg-like shape, which was something that I specified for during the aesthetic development stage of my project Sam Naylor | GCSE Resistant Materials | Organic 54

113. The product must be able to be stored in kitchen cupboards with ease.

115. It must be durable so it resists any knocks which it may endure during use.

116. It must not get damaged at high temperatures (in water).

117. It must not get scratched easily, as this would rapidly decrease its aesthetic quality.

118. The material used must be suitable for current day lifestyles and the modern market.Obviously, it is a challenging task to test my model against these specifications, as I do not want to damage my product. However, if my model were made out of stainless steel, then I would try to test it against these specifications, and I believe that the design would be capable of satisfying them. Figure 1 – Height of product in context Sam Naylor | GCSE Resistant Materials | Organic 55

119. Evaluation (User trials and testing) Question 1 – Would you say that the product would fit into its surroundings? Analysis of results - According to my results, 7 out of 8 people would say that the product would fit into a kitchen environment. Introduction On this slide I am presenting the results of my questionnaire that I gave out to people. For my questionnaire, 8 people were questioned. This process provides me with excellent first hand feed back on the product. I will represent the results using graphs. Evaluation of ‘Organic’ Questionnaire May you please fill out this questionnaire after testing the product so that I may then evaluate the success of my product. Please circle your rating below according to your opinion. ( 1 being the lowest and 5 being the highest) Q1) Would you say that the product would fit into its surroundings? YES/NO Q2) How much easier does the product make the placement and removal of eggs from a saucepan in comparison to a regular spoon? 1 2 3 4 5 Q3) How attractive is the design and shape of the egg holder? 1 2 3 4 5 Q4) Do you feel that the product provides enough height away from boiling water in order to prevent the user from burning themselves? YES/ NO Q5) How is the finish and manufacturing quality of the product? 1 2 3 4 5 Q6) Would you prefer for the product to be made out of (1) stainless steel or (2) rubber? (1) / (2) Please could you jot down any sketches or comments that you believe would benefit my product, thank you. Question 2 – How much easier does the product make the placement and removal of eggs from a saucepan in comparison to a regular spoon? Analysis of results - According to my results, 1 out of the 8 people gave a 3 out of 5 rating for how much easier it was to place and remove eggs into a saucepan than a standard spoon. 4 out of the 8 people gave it a 4 out of 5 rating and 3 out of the 8 gave in a 5 out of 5 rating. This suggests that my product is very effective at carrying out its function. Sam Naylor | GCSE Resistant Materials | Organic 56

120. Evaluation (User trials and testing) Introduction On this slide I will continue to present the results of my questionnaire, while analysing them in the meantime. Question 4 – Do you feel that the product provides enough height away from boiling water in order to prevent the user from burning themselves? Analysis of results - According to my results, all of the people who participated in the questionnaire believed that the product provided a perfect amount of height above the boiling water for the user to comfortably use the product. Question 3 – How attractive is the design and shape of the egg holder? Analysis of results - According to my results, 7 out of 8 people would say that the egg holder is an extremely attractive product, in terms of its design and shape, while only one person rated it a 4 out of 5. Question 5 – How is the finish and manufacturing quality of the product? Analysis of results - According to my results, all of the people who participated in the questionnaire believed that the product provided a perfect amount of height above the boiling water for the user to comfortably use the product. Sam Naylor | GCSE Resistant Materials | Organic 57

121. Evaluation (User trials and testing) Introduction On this slide I have presented the final slide of the results of my questionnaire. Conclusion of user Trial I have now finished the user trial and testing section of my evaluation and I will now go on to showing what improvementscould be made to made to my product. I was extremely glad with the results that I recorded and got a lot of positivefeedback, it has also helped to reinforce as well as discover any areas that I need to develop. However, one thing that I must take into consideration is that my results could be slightly biased as the majority of the people that participated were friends and family that I have known for a considerable amount of time. So, perhaps the feed back that they gave me concerning my product was slightly more positive than they really intended to give. Question 6 – Would you prefer for the product to be made out of (1) stainless steel or (2) rubber? Analysis of results - The results of question 6 show that all of the questionnaire participants believe that if the product were to be massproduced, they believe it should be made out of stainlesssteel. One of the participants, noted down in the comments section at the end of the questionnaire that they thoroughly believe the product should be made out of stainless steel, as ‘Stainless steel is the material that best fits the kitchen environment’. Sam Naylor | GCSE Resistant Materials | Organic 58

122. Evaluation (Social, Moral and Environmental Benefits) Maintenance The product is also very environmentally friendly as it can be maintained. None of the parts would have to be replaced after a certain amount of time, which would contribute towards reducing the waste material. Introduction On this slide I will be looking at how socially, morally and environmentally friendly my product is. It is important to point out these issues as they are becoming of more and more interest to the public. I will try to make clear all of the different ways that I tried to improve the social, moral and environmental benefits of my product. Disassembly and Recycling Due to the product being made solely out of stainless steel, it would not need to be disassembled before being melted down and recycled when it is no longer required. Reducing material waste When I manufactured my product, I aimed to use as little material as possible, however there were a few occasions at which I used more material than necessary. When designing my product however, there were several parts of the product at which I reduced a considerable amount of waste material. For example, on the base of the product, I cut down a lot of unnecessary material on the underside of my product, as shown in figure 1. I also made the wall thickness as thin as possible, while guaranteeing that the function of the product was not effected, nor the durability (shown in figure 2). I also made the drainage holes as large as possible (figure 1). Ways of minimising environmental impact further There are not any particular areas where I clearly could reduce the environmental impact of my product further. However, I could shell the handle and shaft of my product, which would reduce the amount of material used to manufacture my product further. I could also reduce some of the material on the underside of the base of my product, between the egg slots, as shown below in figure 3.. Figure 3 Figure 2 Figure 1 Sam Naylor | GCSE Resistant Materials | Organic 59

123. Evaluation (Recommended future improvements) Introduction On this slide I will present any suggested improvements for my product through sketch work that was produced by questionnaire participants. I have also come up with some possible ideas that could improve my product further, which have also been illustrated on this slide. Figure 2 Figure 1 Method By looking at the results of my questionnaire, comments left at the end of them and the specifications that had not been entirely satisfied, I was able to identify any areas for improvement on my product. I then sketched some ideas, and have presented them on the right, explaining each one. Figure 3 Figure 2 shows a possibility of having small LED’s and a buzzer that would indicate to the user when the timer has gone off. This would provide the user with a clear signal concerning when they need to take the eggs out of the saucepan, There would be a detachable glass top that would protect the LED’s and the buzzer from getting wet. Figure 1 shows a timer that would be inbuilt into the handle. This would allow for the user to know how long their eggs have been in the saucepan for, and provide them with a way of making sure they take their eggs out at exactly the right time according to their desires. Figure 3 shows an idea that I came up with that involves the product being made out of a smart material, that would change colouras the temperature of it increased. This would provide the user with an idea of what temperature the water is at and how well the eggs are cooking. Conclusion Next I will move on to evaluate what went well during the project as a whole and finally suggest how I could mass produce the product should I so wish. 60 Sam Naylor | GCSE Resistant Materials | Organic

124. Evaluation (What went well and mass manufacture) Final Outcome and Manufacture I am very happy with my final outcome, although there are some areas for improvement, which