GCSE D&T Textiles Knowledge Organiser Commercial Processes Scales of Production Circular Knitting Machine Batch Weaving Loom One Off Mass
Flat Bed Knitting Machine
Manufacturing Processes - Wastage, Addition, Forming Composite/Lamination Wastage Addition Forming Composites are materials made from two or more different materials Dyeing and Printing Pleating and combine the properties of the materials they are made from. Cutting/Shearing Sewing Quilting Gore-Tex Carbon fibre reinforced Batik plastic Screen printing Shears Computerised Embroidery Gathering Quilting Bonding fabric Rotary Cutter Laminated fabrics are made when two or more layers of fabrics are Fastenings Applique bonded together using a polymer film, this is what creates the Laser cutting Tailoring laminate material to have its shiny effect.
Piping GCSE D&T Textiles Knowledge Organiser Tools & Equipment Techniques and Processes Laser cutter Tailor’s Chalk
Hot Press Wood blocks for Mannequin printing Rotary Cutter
Screen Printing – screen and Overlocker squeegee Pinking Shears
Shape & Form Production Aids Computerised Double Embroidery Machine Templates Plain French Seam Machine Dressmaking Patternmaster Seam Stitched Pattern Seam Fabric Shears Pinked Edge Curved Seams Inverted pleat
Wax pot & Tjanting Overlocking Embroidery Hoop Accordion Pleat Gather Knife pleat Zig Zag edge Dart Box Pleat Block Patterns GCSE D&T Textiles Knowledge Organiser Fibres, Yarns & Fabrics Textiles & their working Sources & Origin properties Absorbency - soaks up water/sweat Strength – strong, doesn’t break easily Elasticity – has some stretch Warming/cooling – traps air/air flows through Flammability – ability to catch fire Durability – hard wearing Crease resistance – does not crease Comfort – soft against skin Drape – hangs well Water repellent – ability to repel water Shrink resistance – will not shrink when washed Thermoplastic – will soften when heated and can be heat-set into new shapes that it will maintain when cooled (synthetic fibres) Lightweight – not heavy/dense Texture – smooth or coarse Fabric Construction Knitted Woven Non Woven
Types of Weaves Weft
Warp Selvedge
Bias Plain Twill Satin GCSE D&T Knowledge Organiser Scales of Production
Name/ Type How many it makes Key Info Examples of Products
• Also known as Bespoke or Prototype manufacture • Custom-made products • Towers / Bridges One-off Production 1 • Specialist workers/ skills • One-off Houses • Specialist machines and materials • Custom made clothes • High Quality but expensive
• Uses a mix of workers and machinery • Baked foods • Uses jigs, moulds and templates to help make identical products • Limited edition car Batch 10s-1000s • Stations of workers e.g. cutting station, painting station, etc • Socks • Can have some variation e.g. colour, finish, flavour • Chairs
• Big assembly lines (and sub-assembly lines) • Cars • Heavily automated • Bottles Mass 10,000s - 100,000s • Standard and identical products • Microchips • Little worker input • Plain shirts
• 24/7 production • Energy • Heavily automated • Water Continuous 100,00s + • Standard and identical products • Paper • Little worker input • Plastic
One-off Production Batch Production
Advantages Disadvantages Advantages Disadvantages
• High storage costs • Lower cost than one-off • Jugs, moulds and templates have to be • Custom made • Time consuming • Jigs, moulds and templates help products checked • High Quality Materials • Specialist training for workers look identical • Workers can become bored on their • High Quality Craftsmanship • Expensive to buy • Can have some variety station
Mass Production Continuous Production
Advantages Disadvantages Advantages Disadvantages • Initial starting costs are high • Initial starting costs are high • Large amounts made at once • Large amounts made at once • If production line stops, the product can’t • If production line stops, the product can’t • All products are identical and to same • All products are identical and to same be made be made standard standard • Workers become bored monitoring • Workers become bored monitoring • Using automation reduced human error • Using automation reduced human error machines and repetitive tasks machines and repetitive tasks Fibres and Fabrics Knowledge Organiser
Natural Fibre Products Manmade Fibre Products (synthetic) Property Definition Found in Traditional fibres from plants and animals. Modern fibres manufactured using polymers. wool, cotton, Wool: Fibres from sheep’s wool are spun into Strong and durable manmade polymer fibre. limen, non- yarn and can be woven and knitted. The Nylon: absorbent A fabric’s ability to hold moisture. Has a wide range of applications, as a clothing woven fabrics fibres can also be spun into finer yarn which such as felt is turned into cloth. Absorbent, soft or coarse fabric and in other uses where durability is handle, not durable. important. Warm to wear, non-absorbent and good drape. Can be made with soft or coarse handle. A fabric or yarn made from a mix of natural and manmade fibres, Used in yarn form in knitwear, scarves, blended purposefully created to use the features of both. gloves, bags, dresses and suits. Used in wide range of clothing in pure and blended form. Waterproof coats, tents. A fabric that uses specific fibres and weave that allows air to pass sportswear breathable through the clothing, thereby preventing heat and moisture build- blended fabrics, up. line, cotton, wool Cotton: Thread is spun from fibres from the Polyester: Very durable polymer fibre, non-absorbent cotton plant. Used widely due to its good and cool to wear. Often blended with cotton to durability and soft handle. Can be machine produce low cost, breathable fabrics and used widely The way a fabric looks when it is hanging down. Clothing designers washed, but requires ironing as creases in place of pure cotton. drape must consider the drape of a fabric when choosing the material for all fabrics easily. Highly-absorbent. a garment. Used in canvas, muslin, calico and denim, Used in clothing and home furnishings, industrial clothing, home furnishings polyester used for ropes, seat-belts. Hard-wearing, stain resistant. Man-made fibres are mainly more nylon, polyester, durable, and are therefore blended with natural fibres to create durable denim, lycra Silk: Natural fibre from silkworms, woven Organza: A lightweight, sheer fabric traditionally more durable products. into fine fabric, which has a high sheen or made from silk, although more often now made lustre. Cool to wear. from polyester. Its decorative properties make it What a fabric feels like to the touch, for instance: smooth, rough, Used in high-class clothing and home popular for embellishments on clothing. handle all fabrics furnishings in Satin form. stiff. Used in home furnishings, hat decorations, wedding dresses. silk and synthetic satins, polyester Linen Made from fibres of the flax plant, sheen A smooth and slightly reflective surface finish to a fabric. linen is a traditional fabric. Does not products, some cause allergies and is cool to wear. Highly Lycra (brand name for spandex/elastane): A 20th leathers absorbent. century ‘wonder material’, Lycra is commonly found organza, voile, Used in home furnishings, summer clothing. in sportswear due to its breathable and elastic qualities. Excellent shape retention. When blended sheer Fabrics that are flimsy and semi-transparent. muslin lingerie with natural fibres, clothing with the feel of natural products fire, and the elasticity of Lycra can be achieved. Leather: Made from animal skins, leather lycra and lycra A fabric’s ability to keep its shape and not become deformed through is not strictly a fabric. Comfortable in both Used in tight-fitting sports wear, stockings and shape blends, leather, hot and cold conditions. Untreated, leather leggings, blended in denim, woollen clothing. retention use. is absorbent but can be treated with a range polyester, nylon of finishes to improve its effectiveness and durability. Tough and elastic. Photo courtesy of (@flickr) Mediamatic Hybrid Wearables - granted under creative water- Non-absorbent. A fabric’s natural ability, or manufactured finish, polyester, nylon, Used in clothing, car upholstery, home commons licence - attribution. furnishings. Photo courtesy of (@flickr) Those Who Affected Me - granted under creative repellent allowing water to not penetrate through the weave. leather commons licence - attribution
Smart Fabrics This acupuncture therapy shirt allows the wearer to receive specific therapy at the same time as getting on with their job. Advancements in modern technology have implications for fabrics and design. Wearable technology and performance enhancing textiles are This light emitting fabric is an example of how designers can use fibre-optics to create high- important strands of sports and fashion design in the modern age. impact visual clothing and accessories.
Page 1 of 2 visit twinkl.com Fibres and Fabrics Knowledge Organiser
Wasting Addition Deforming and Reforming
Fabrics are a compliant material and are relatively easy to cut and Addition by hand-stitching Deforming by tailoring shape. They are, however, an unforgiving material, and an incorrect All projects will require some degree of hand-stitching. This may Once the pattern and fabric pieces have been cut, the main tool cut will be often difficult to undo or disguise. be to add a button, join one piece of fabric over the top of another, for shaping an item of clothing is a tailor’s dummy. Re-forming, Cutting: Fabric is normally cut with textile shears. The blades are such as in applique, or embroidering by hand. There are a range of adjustment and fitting can be done whilst seeing the overall 150mm long and the lower handle is always bigger. This allows for stitches which can be done using a needle and thread: shape of the product. Because fabrics are compliant materials, a steadier, longer cut. Rotary cutters are used for cutting non-woven they deform as part of their nature. Imagine wearing a pair of • Running stitch: Quickly joints two fabrics along a line fabrics such as felt. skinny jeans which didn’t deform as you moved! • Overstitch: Loops over the edge of the fabric preventing fraying. Shearing: Although shearing and cutting are the same force and Deforming by pleating and gathering movement, pinking shears give a zig-zag edge to their cut. This • Blanket-stitch: Ornamental stitch effective on decorative work. Shape can be created and accentuated through the use of prevents woven fabric from fraying • Back stitch: Stronger that a running stitch and good for seams. gathering. Pleating can create a strong visual effect and allow for Wasting Fabrics with CAD/CAM movement in a garment. Zips, buttons, hook and eye, press-studs and Velcro can all be added Sections of fabric can be wasted effectively using a laser cutter. A to fabrics and used to add and fasten pieces together. Pleat: Repeated folds in a textiles product, usually stitched at the pattern can be created using CAD software such as 2D Design and top. Addition by machine-sewing used to control the laser cutter. Identical patterns can be created very Gather: To shorted a piece of fabric by drawing it together, like quickly using this method with a high level of accuracy. The correct method for joining fabrics is dependent on the type of the top of some curtains. fabric being used, and the loads and stresses that will act upon the Seam Allowance join. An overlock machine is good for professional looking products Deforming by heat and liquids Fabrics require a seam allowance; the material where the stitch joins as it binds the seam inside the join. Sewing machines are required to Heat treatment: Some specially laminated fabrics can be formed two pieces of fabric together. This means fabric must be cut larger add fasteners such as zips. into shape using heat. This is useful where the designer needs than the size needed by approximately 10mm on all sides where a join Addition by computer sewing machine parts of a design to hold a shape without support, such as is required. collars. Many jobs can be completed by a programmable CAM sewing machine. Blocking: Traditionally, moulded hats, for both men and women have been created by deforming felt on wooden blocks. A felt Some schools have embroidery machines. A design is created on hood or cone is placed on the block and a liquid stiffener is a computer, before being uploaded to the embroidery machine. applied. A steam iron is then used to shape the felt around the Decoration, detail and personalised names can be added to a panel of block before shaping the brim and cutting off waste material. a product this way.
Page 2 of 2 visit twinkl.com GCSE D&T Knowledge Organiser Work of others and Customer Research Work or Others Image/ Designer Design Key info Example Movement Research
• British designer in 1880s • Simple natural crafts Arts and Case studies William Morris • Useful and beautiful Crafts Product Analysis products (wallpapers, cushions, etc) Interviews
• Scottish designer in 1860s – 1920s What methods of • Known for light and research can be used Charles Rennie shadow to find information? Art Nouveau Mackintosh • Created stained glass and furniture Questionnaires and • Inspired by nature and surveys geometric lines Materials testing • Italian designer in the Social media and email 1950s/60s • Enjoyed making everyday Ettore Stottas Memphis objects wacky and bold Research can be divided into 2 categories; Primary Research and Secondary • Used lots of bold colours Research. and black lines Primary is research you complete yourself. Secondary is research from resources others can gathered e.g. books, magazines and Image/ Example Brand Key info internet
Primary research is generally more reliable as it is done by the person using it and • Italian Design Company can double-check the data • Homeware and kitchen utensils Alessi • “Post-modern” style Another key piece of research, is Anthropometrics and Ergonomics. This helps • Phillipe Starke is a major designer develop the sizes of products, etc to make sure it fits the User
The study of measurements of the human body. • USA-based tech company • Famous for iconic designs of iPod and Anthropometrics E.g. Knowing the grip width of a palm, if designing a iPhone Apple new travel coffee cup • Steve Jobs and Johnathon Ive are major designers The application of anthropometrics to ensure products • Known for innovative and modern design are safe and comfortable to use. This can also include; size, material, appearance, brightness, sound and texture. • British engineering company Ergonomics • Famous for vacuum cleaners and Dyson innovative technology E.g. making sure the travel cup is the correct size, and • James Dyson is a major designer an insulating smooth material to make it comfortable to hold for long periods Paper and Board Knowledge Organiser Properties and Definitions of Paper and Boards Compliant/ Resistant Materials
Virgin Products Property Definition Found in
Mount Board: A thick, flexible Moulded Pulp Board: Recycled virgin A paper or board product which has been printer paper, board, available usually in black paper and card is turned into made from tree pulp without the addition envelopes, books or white. a pulp and moulded into shape of any recycled or alternative fibres. All etc. which forms protective packaging. true white paper products are virgin. Used in drinks bottles, food Photo courtesy of Creativity103 (@flickr.com) - granted Photo courtesy of John Lodder (@flickr.com) - granted recycled A paper or board product which has been paper towels, toilet under creative commons licence – attribution packaging, cosmetic packaging. under creative commons licence – attribution made using some or all waste material, roll tubes, greetings usually from paper mills. Colour tends to cards, newspapers Corrugated Card: Thick, Foam Board: Thick, lightweight be grey (from the print on the paper used) lightweight and strong, this and stiff. A layer of foam is laminate board is used widely laminated between bleached card. of dyed darker colours. in transit packaging. Normally Can be slotted and jointed to give laminated Layers of paper or card glued together to foam board, only printed on one side and strength to larger constrictions. create stiffer product. corrugated unbleached. Photo courtesy of Creativity103 (@flickr.com) - granted Photo courtesy of Phil Parker (@flickr.com) - granted under creative commons licence – attribution Used in model-making, under creative commons licence – attribution cardboard, mount Used in transit packaging/ architectural prototypes. board warehouse storage. compliant Bends, twists, tears and folds easily and thinner paper and Carton Board: Durable, lightweight card, can have glossy or matt finish. Excellent print qualities without tools. board products. and bends easily into nets. resistant Does not deform easily without tools or thicker/laminated Used in dry food packaging. force. paper, board products
Paper Weights and Uses Photo courtesy of ms.akr (@flickr.com) - granted under creative commons licence – attribution stiffness A material that resists bending, remains foam board, rigid. corrugated card Weight (grams per square metre) Suitable for tough Able to withstand rough handling or corrugated card, 80gsm printing, general use (durable/ treatment. Offers good weather resistance. carton board strong) 90gsm standard printer paper, thick enough to be colour-printed tension A pulling force. Paper and board products glued together 100gsm good quality paper for letters, certificates, drawing when assembled often are glued in tension. packages 120gsm stiff, printable paper, suitable for menus, leaflets, small scale packaging corrugated In card, a rippled middle layer is laminated transit packaging 160gsm light card suitable for printing/cutting/plotting, packaging between two flat layers, thus creating a thick, lightweight yet stiff board.
visit twinkl.com Page 1 of 2 Paper and Board Knowledge Organiser
Wasting Cutter/Plotter White Glue (such as PVA) With research and skill, sophisticated three- dimensional shapes can be created by scoring Most paper and board can be cut and shaped easily Advantages: Advantages: and folding nets or developments. with basic equipment. Allows for repetitive Permanent, strong bond,
Hand Punch flow production, with reliable, even on small tabs. Invisible. Photo courtesy of AaltoFablab Photo courtesy of (@wikipedia.org) - granted identical results. (@flickr.com) - granted under creative under creative commons licence – attribution Advantages: commons licence – attribution Disadvantages: Quick, perfect holes. Disadvantages: Cannot be undone, takes a long time to set. Not suitable for thicker Disadvantages: Temporary Addition Methods: Photo courtesy of (@wikipedia.org) - granted under creative commons licence – attribution Photo courtesy of Shrie Bradford Spangler card products. Limited range of hole (@flickr.com) - granted under creative commons licence – attribution Adhesive Velcro Addition Press Moulding (using paper pulp) sizes available. Not suitable Advantages: Although the finish of press-moulded products for very thin paper or thicker card. Prototype modelling uses a wide range of addition Allows for adjustment. is quite poor, strong inserts can be created for or joining techniques, but often leaves a low- Craft Knife and Safety Rule Disadvantages: products such as food and perfumes to ensure quality finish. Advantages: Photo courtesy of Scott Lewis Expensive, not suitable (@flickr.com) - granted under creative bottles and jars are held tightly inside the Permanent addition methods suitable for high commons licence – attribution No set-up time, good for one-offs for thinner, less stiff materials. container. Because pulp is made from recycled quality finish include: paper, this method can help a product have an Disadvantages: ‘environmentally friendly feature’. Photo courtesy of alice combes Double-Sided Tape Finish relies on the skill-levels (@flickr.com) - granted under creative commons licence – attribution Paper Fasteners of the maker. Not suitable for Advantages: Advantages: repeat-production. Instant, permanent, Easily undone. Quick. strong bond. Invisible. Wasting Paper and Board Using CAD/CAM Photo courtesy of LED Bulbs 123 (@flickr. Disadvantages: com) - granted under creative commons Disadvantages: Photo courtesy of (@wikipedia.org) - granted Thin card can be wasted effectively using CAM licence – attribution Hard to disguise, Sharp under creative commons licence – attribution such as laser cutters and cutter/plotters. Nets are Cannot be undone. Fiddly. edges make it unsuitable for many applications. developed on CAD software such as 2D Design Hot Glue and CorelDRAW. These files are sent to the CAM Advantages: Deforming and Reforming machine for accurate cutting and scoring. Permanent, strong bond. Paper and thin board are compliant materials Laser Cutter and will bend and fold easily in one direction. Disadvantages: Advantages: Photo courtesy of Teacher Resource (@flickr. Stiffer or thicker board requires the use of specific Cannot be undone. Can leave com) - granted under creative commons Allows for repetitive flow licence – attribution techniques. a stringy or thick edge. production, with reliable, Paper Fasteners Scoring and Folding identical results. For most prototype package and models, scoring Photo courtesy of Pete Brown (@flickr.com) - granted under creative and folding is the best method. This can be done Disadvantages: commons licence – attribution by hand but also using CAD/CAM by carefully Not suitable for foam-board designating the lines to be scored a colour which due to the fumes released. controls a lighter, scoring pressure on the cutting head of the machine.
visit twinkl.com Page 2 of 2 GCSE D&T Knowledge Organiser Plastics
Plastics
Plastics come from crude oil. Stock forms are sheets, powders, granules and rods
Primary Processing of Plastics Thermoplastics can be reheated and reshaped and infinite amount of times Crude oil is extracted from the earth and then processes into different types of fuels, etc. This is Material Key info Examples called Fractional Distillation
A process called Cracking then converts the large PET Easily blow moulded, food safe and easily recycled Bottles, packaging, etc hydrocarbon molecules into plastics
PVC Flexible, tough, easily extruded Pipes, tape, hard hats
Containers and yoghurt HIPS Flexible, lightweight, food safe and easily vacuum formed pots
Car lights, baths, displays/ Acrylic Tough, brittle, easily scratched signs
Thermosets once heated and set cannot be reshaped
Material Key info Examples
Melamine Kitchenware and work Food safe, hygienic, hard and brittle Formaldehyde surfaces
Electrical casings, buttons Urea Formalehyde Good insulator, hard and brittle and handles
Polyester Resin Strong, heat resistant, can be transparent Coatings, casings Metals Knowledge Organiser Properties of Metals Resistant Materials ferrous: Metals that contain iron. Besides iron itself, non-ferrous: Metals that do not contain iron. Property Definition Found in all ferrous metals are alloys. aluminium: High strength to weight ratio, light, soft, brittle Hard, but easily broken or cracked. cast-iron, steel with high iron: Heavy and strong, iron is most commonly found difficult to join. carbon content. nowadays in various alloys. Historically, iron was the Used in kitchen utensils, packaging, cans, foils, key material which enabled the industrial revolution window frames. conductor Metal which allows heat or electricity copper, gold, brass. to thrive in the UK. Machines, bridges and weapons to flow through it easily. could all be cast in iron, allowing mass-production. copper: Bright and decorative colour when polished. Corrosion resistant. Soft and easy to work by hand. corrode To become damaged by chemical ferrous metals in the form Used in heavy kitchen skillets, radiators and fireplaces Good heat and electrical conductor. reaction (normally water). of rust, some alloys become in older houses. powdery. The Iron Bridge gold: Soft, malleable, ductile, often alloyed to give corrosion-resistant A metal which resists damage by copper, gold, bronze. (opened 1781) in more strength, doesn’t corrode or tarnish. Used in jewellery, electronics, hi-fi equipment, chemical reaction. Shropshire was dentistry. ductile Can be deformed without losing lead, copper, gold. the first bridge to tin: Soft, corrosion-resistant pure metal. Silver- toughness. use cast-iron coloured and bright when polished. Can be worked by Photo courtesy of Martin Pettitt (@flickr.com) - granted hard Not easily bent or broken. steel, iron, brass. structurally. under creative commons licence – attribution hand. Used to plate other metals. lightweight A metal which has a good strength-to- aluminium, duralumin. ferrous alloys non-ferrous alloys weight ratio. mild steel: General purpose metal for general brass: Corrosion resistant, casts well, work-hardens, malleable Can be deformed by beating, bending or lead, copper, gold, silver, tin engineering. Good strength and cold-forging properties. polishes well. Corrodes quickly without protection. Can be welded pressing into shape. Used in castings, boat fittings, ornaments. and braised. soft Metals with comparatively low melting lead, copper, gold, tin. Used in structural components, general workshop bronze: Corrosion resistant, casts well, work-hardens, temperatures. Easily scratched and projects. polishes well. malleable. high speed steel: Very hard, resistant to frictional heat. Used in castings, boat fittings, ornaments, statues. tensile strength A material with good tensile strength steel, iron, aluminium. Used in lathe cutting tools, drills, milling cutters. pewter: Soft alloy of tin, copper, lead or silver. Low resists breaking under tension. high carbon steel: Very hard, difficult to cut, easily melt temperature makes it ideal for casting projects. joined by carbon treatment. Used in sand-casting, old-fashioned tableware. tough/durable/ Able to withstand rough handling or iron, stainless steel. Used in hand tools, hammers, screwdrivers, chisels. strong treatment. solder: Soft alloy, usually made from copper and tin. stainless steel: Hard, tough, resists wear, corrosion An added substance, called flux, allows the solder to resistant, difficult to cut. flow over other metals when heated. Used in dishes, sinks, teapots, cutlery. Used in jewellery manufacture, electronics.
visit twinkl.com Page 1 of 2 Metals Knowledge Organiser base metal: Pure, non-precious metals, such as Wasting metals by drilling and boring. Adhesives Bending iron, copper and tin. Commonly electro-plated Metals need specially hardened bits for holes to be Some metals can be Thicker rod materials can be bent and shaped with other metals such as chromium to achieve a bored or milled successfully. bonded permanently with when heated to red-hot. higher quality finish. Drilling: Hand drill and solvent adhesives such Quenching the material alloy: Metals which are a mixture of two or pillar drill with high-speed bits. epoxy resin. Photo courtesy of (@wikipedia.org) - granted will harden the bend. under creative commons licence – attribution more elements, at least one of which is a metal. Welding/Brazing The purpose of an alloy is to create a metal with Using high temperatures, Casting improved properties over the original. Photo courtesy of Nottingham Hackspace (@flickr.com) - granted under creative commons licence – attribution welding creates fused joints In industry, casting can produce highly successful precious metals: Pure metals which are valued for products. Some schools Turning: CAM or manual metal lathes can waste which can be as strong as their ductility, colour and lustrous natural finish metal rod accurately by both boring and turning. have sand casting the material. Brazing uses and other properties. Platinum, gold and silver are Milling: Using a flat-ended slot drill, a milling facilities, which allow commonly used in jewellery design. lower temperatures to Photo courtesy of COMSEVENTHFLT (@flickr.com) - machine cuts laterally, giving a high degree of granted under creative commons licence – attribution an alloy to be re-formed melt a soft alloy, control to the three-dimensional wasting of metals. Photo courtesy of (@wikimedia.org) - granted into a three-dimensional under creative commons licence – attribution which flows between Wasting Metals Using CAD/CAM shape. the joint and creates a bond. Computer controlled milling machines and Fixing and Fastening lathes are used in Riveting Riveting gives a quick and clean alternative to Photo courtesy of Bullion Vault (@flickr.com) - granted schools and industry to under creative commons licence – attribution Photo courtesy of Nottingham Hackspace (@flickr.com) - welding. It requires an overlap in the material. waste and shape metals. granted under creative commons licence – attribution Wasting Temporary Fixing Aluminium is the most Wasting metals by cutting and shaping. Nuts and bolts, machine screws, self-tapping common material used to mill in schools. Metals can be very resistant to shaping by wastage screws. Addition and tools require special blades to cut metals Washers are often needed to create a secure, accurately. Permanent bonding vibration proof fastening. Metals require specific joining methods based on Sawing: hacksaw, junior hacksaw, abra file, jigsaw Deforming and Reforming (with metal cutting blade). the type of material and shape of product. Cold Forming Shearing: Thin sheet metal can be marked out and Thin sheet material and narrow-gauge rod and cut with special metal sheers or tin snips. wire can be deformed using a range of cold- Filing: Edge shaping and finishing can be achieved forming processes. Simple bends can be made by hand with a range of metal files. using a vice and ball-peen hammer.
visit twinkl.com Page 2 of 2 GCSE D&T Knowledge Organiser Woods and Boards Natural Timbers
Softwoods are generally cheaper than hardwoods as they are more available, since they Man-Made Boards grow quicker. But because man-made boards are manufactured they are cheaper than timbers. Man-made boards also come in a better variety of sizes since they don’t depend on tree Manufactured boards are made from wood chips/dust/ layers and glue. growth.
Stock forms for both include; sheets, dowel, planks, etc Material Key info Examples
Flooring, low-end Prone to chipping but good compressive Chipboard furniture, flat- Hardwoods come from Deciduous Trees. These trees loose leaves in winter and strength. Not-water resistant grow fruit and flowers in spring pack
Material Key info Examples Rigid and stable. Easy to finish. Absorbs Flat-pack furniture MDF liquid easily and kitchen unites Sports equipment Ash Flexible, tough and shock resistant Tool Handles Very stable. Exterior veneer can be used Shelving, Plywood from more expensive woods furniture, toys
Toys, furniture and Beech Fine finish, tough and durable veneers Primary Processing of Papers and Boards Mahogany Easily worked, durable, high quality finish High-end furniture Trees are cut then converted into planks by cut using Balsa Very soft and spongy. Light Modelling saws It is then seasoned to reduce the moisture in the wood. Flooring, furniture This is done by either: Oak Tough, durable and hard and veneers Air-drying – Planks are stacked and air allowed to circulate; causing evaporation Softwoods come from Coniferous Trees. These have thin, needle-like leaves and Kiln-drying – Where planks are put into a kiln and grow all year round. Often have pine cones and sometimes nuts and seeds dried rapidly. This process is more costly than air-drying
Material Key info Examples
Durable, tough, good water resistance and Furniture, flooring Larch finishes well and used outdoors Manufactured boards can be either be made by lamination or compression Cheap furniture, Pine Light, easy to work with but can split construction and Lamination – Layers of woods and adhesive are layered decking and compressed together. Usually with a more expensive wooden veneer on the top Furniture, musical Easy to work with, high stiffness but can Spruce instruments and Compression – Wood is shredded, heated and decay quickly construction compressed with adhesive under extreme pressure GCSE D&T Knowledge Organiser Production Techniques and Systems
CAD Computer Aided Design CAM Computer Aided Manufacture Examples; 2D Design, Autodesk Inventor, Fusion 360, Photoshop, etc Examples; 3D Printing, Laser Cutting, CNC Router, Automated Machines Advantages Disadvantages and Robotics, etc
• Easy to change designs Advantages Disadvantages • Designs are easily saved and • Complex and time-consuming to • Expensive to buy the equipment, sent learn • Faster and more accurate than etc • Can be worked on by multiple • Expensive to buy traditional tools • Training takes cost and time people simultaneously • PCs can crash or be hacked – • Repetitive accuracy/ consistent • Need specialists to maintain and • Can be used for virtual testing causing work to be lost outcomes repair the machines • Can produce high-quality • Takes up PC memory • Machines can run 24/7 • Dependence on CAM can cause designs unemployment
Flexible Manufacturing Systems This is where automated machines are adaptable and can produce Just-in-Time (JIT) Manufacture different products if needed. This is where manufacturers only order materials, parts, etc when If a manufacture is making a product with machines that are just needed. The customer’s order triggers the production process and the dedicated to specific tasks they have to be reprogrammed and re-tooled resources needed for that order are the only ones bought. before changing to a new task. This is time consuming and expensive. This can be used in any scale of production but is particularly useful Examples include; CNC Machines, 3D Printers, Laser Cutters, Robotic for one-off production. arms, etc
Advantages Disadvantages
• Saves on warehouse and Lean Manufacturing • All production stops if a part/ storage costs material is missing • Money is not tied-up in stock • Needs to have a fast, reliable This is where waste and energy is kept to a minimum. • Little/minimal waste and good quality supply chain This helps manufacturers save money and resources in production, as • Customer often pays in to work properly well as helping minimise the environmental impact of producing advance so money is secure • Can be time-consuming products. before production GCSE D&T Knowledge Organiser Environment Repairing products rather than The 6Rs Meaning throwing them away
To use a product again either for the same purpose or a different Reuse Reducing Product Miles buy one making the product in the To have less of material/packaging/pollution when making products country it is sold in Reduce Planting more by making them more efficient trees to reduce Recycle Breaking down and forming the material into another product deforestation What can we do to Customers not buying or supporting products that make an Refuse reduce environmental environmental impact impact or products Designers and customer rethinking their decisions when making and and manufacture? Rethink buying products. Fixing a product rather than throwing it away. Extending its life rather than using more resources to make another Recycling products and Reducing Pollution by using materials Repair Often products are Designed for Maintenance so can easily be less plastics, efficient repaired. E.g. Using screws so even non-specialists can take a manufacture, less waste and product apart, or using components that can easily be replaced like using renewable energy (like Using less finite fuses or batteries solar and wind) resources
Sustainability is maintaining our planet and its resources and making a minimal Life Cycle Assessment negative impact
Infinite Resources Finite Resources Can be re-grown and re-bread. Will not This is when a designer looks at the Will run out of eventually environmental impact a product run out of makes over its life time and how it could be reduced. Including: Plastics Paper
• Impact of materials Metals Boards
• Impact of processes Polymers (Textiles) Natural Timbers
• Product Miles (how far a product Cotton has to travel to get from factory to consumer) Leather
• Impact while in use This is where products “die” after a certain amount of time. E.g. Disposable cups, Phones, Lightbulbs, Printer Ink, etc • Impact when disposed of (6Rs) Planned Obsolescence This can have a big environmental impact as customers are throwing away lots of products, and resources are being used to create new ones. GCSE D&T Knowledge Organiser Finishes, Standard Components,
Accuracy and Process Orders Finishes Tolerances Finishes are used to improve the aesthetics and durability of products • The total amount a specific dimension or property is permitted to vary This can apply to hole depth, length, angle, thickness, weight and elasticity Material Type Finishes Used A gauge can be inserted into a gap or hole to check if the sizes fall within tolerance • Paints • Plastic coating If parts do not fit within the specified tolerances they are discarded or recycled Papers and Boards • Varnishes • Wax coating • Laminating • Paints • Staining Quality Control and Quality Assurance Timbers and Boards • Varnishes • Oil • Wax and Polish • QC is product oriented Quality control is where products are regularly tested (during and after • Painting • Polishing manufacture) to ensure they meet the defined set of quality criteria • Lacquering • Plastic Coating Metals and Alloys • Electroplating • Powder Coating • QA is process oriented • Galvanzing Quality assurance is ensuring that the processes used to test the product have been done correctly and consistently • Polishing You can test a product all you like, but if the tests are wrong/ inconsistent with Plastics • Painting each other than the results are invalid • Decals (stickers) • Below are examples of Quality Assurance symbols:
Standard Components Standard components are parts or components manufactured in the 1000s+ They are readily available, don’t require specialist knowledge or tools to replace them and are universally recognised European Conformity BSI Kitemark Lion Mark Registration Mark
Material Type Components used Process Orders • Staples Papers and Boards • Clips • Split pins An Input is A Process is process An Output is a information/ of transforming response to the • Nails • Panel Pins Timbers and Boards stimuli that enters information into an stimuli • Screws • Hinges a PC Output An example would • Nuts and bolts • Rivet Metals and Alloys An example would An example would be speakers, text on • Screw • Washer be keyboard, be a PC a screen, alarm, sensor, mouse, etc lights, etc Plastics • Plastic hinges GCSE D&T Knowledge Organiser Production Processes
Name of Diagram Material Products Made Key info Process
Screen printing places paint on top of a screen. The screen has a stencil Screen- Posters, signs and embedded in it, so when the paint is passed across it the desired shape is printed Papers and Textiles printing t-shirts underneath. Good process in one-off and batch production as often done by hand
Rollers containing the colours and water go onto the plate cylinder. The water Offset Papers and card Posters, stops the colours sticking to certain places, creating the shape. The shape is Lithograp (thin, flexible newspapers, transferred between rollers and onto the material. hy plastics) plastics bags Can be used at batch and mass production
Material is placed between the tail stock and the headstock and spun at high Chair legs, Lathe speed. The material is then cut using specialist tools (either by hand or my Wood and metal baseball bats Turning automated machinery) to the desired shape. )(cylindrical items) Can be used in one-off and batch production
Molten metal is poured into a chamber and a plunger forces the metal through the Die Car parts, engine Metal nozzle into the mould. Unlike sand casting, the mould is reusable. Casting components, etc Good process for both one-of and batch production
Plastic granules are poured into the hopper and onto the screw. The screw moves the material towards the heater where it turns into a liquid. The liquid is then Injection Plastics Chairs, toys, etc forced into the mould, cooled and released. Moulding Great process for mass production as it makes 100s+ of products at once, to a identical standard.
A Plastic parison is heated and put into the mould. The parison is then filled with Blow air (like blowing up a balloon) and is forced to fit the mould shape. It is then Plastics Plastic bottles Moulding cooled and then released. This is a great process for mass producing bottles.