DescriptionA ‘swirling’ light shade made from sheet materialfitted over a cylindrical core.

MaterialsShade - polyethylene - low density

Process of manufactureShade - stamped and formed

Method of assemblyShade - riveted

Questions ?1 Explain how the sheet of polyethylene wouldhave been manufactured.

2 Fashion can strongly influence the design of aproduct. With reference to the light shade explainhow fashion has possibly influenced its overall‘look’.

3 Describe the process of riveting, use sketchesto illustrate your answer.

4 Describe how the light shade could have beenmanufactured from wood.

5 State three considerations a company wouldhave to make if the material for the shade wasswitched from plastic to wood.

6 Function and durability are two important designfactors. Describe two aspect of function anddurability which the designer would haveconsidered in the design of the light shade.

AssignmentThe shade is made from a flat piece of PE , cut toshape and then opened up.Produce a design solution for a table lamp wherethe shade is manufactured in the same way buthas a different overall shape.

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DescriptionThis set of storage drawers come in unfinishedplywood allowing them to be coloured to suit theirsurroundings.

MaterialsCase - birch plywoodDrawer - birch plywoodLabel holder - steel / nickel plated

Process of manufactureCase - laminated / veneerDrawer - laminated / veneerLabel holder - pierced, blanked and pressed

Method of assemblyCase - finger joint and glueDrawer - finger joint and glueLabel holder to drawer - riveted

Questions ?1 Explain why plywood is a suitable material forthis product .

2 The label holder could be described as astandard component. Explain why using standardcomponents in products is common practice.

3 Name and describe a suitable joint for fixing thedrawer sides together. Use diagrams to illustrateyour answer.

4 Explain where the designer would haveconsidered physiology in the design of this product.

5 Describe two aspects of the design which couldhave been evaluated by user trials.

6 Explain how the designer would have used theinformation gathered during the user trials.

AssignmentTo extend the range the drawer will be replacedby a hinged door. The door must be made ofsimilar birch plywood.Produce a design solution for a door which couldbe attached to the unit in place of the drawer .

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DescriptionThis cooking spatula is made entirely of plastic.The single hole in the handle allows the spatulato hang on a rack.

MaterialsHandle - polypropyleneBlade - polyamide plastic

Process of manufactureHandle - injection mouldingBlade - injection moulding

Method of assemblyMoulded together

Questions ?1 Explain why a polyamide plastic was chosen asthe material for the blade of the spatula ?

2 Describe the process of injection moulding.Sketches should be used in your answer.

3 Describe the spatula in terms of its aestheticappeal and state its possible market niche.

4 State three aspects of safety the designer wouldhave considered in the design of the spatula.

5 The handle could have been manufactured fromhardwood. State the name of a suitable hardwoodand explain how this change in material couldchange the market niche of the product.

6 State two aspects in the design of the spatulawhere the designer would have consideredanthropometrics.

AssignmentThe spatula has been selected as a product forpossible redesign.State and justify three aspects of the design whichcould be evaluated.Describe the strategies which could be used toevaluate these three aspects.

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DescriptionA chunky white soap dish in steel, fixed to thewall with four screws.

MaterialsTray - polyethyleneHolder - steel tube / lacqueredFixing plates - steel / lacquered

Process of manufactureTray - injection mouldedHolder - formedFixing plates - pierced, blanked and formed

Method of assemblyTray onto holder - placedFixing plates onto holder - welded

Questions ?1 State three pieces of evidence found by visualinspection of the tray which would establishinjection moulding as the manufacturing process.

2 The holes in the fixing plate have been piercedand not drilled. State one piece of visual evidencewhich establishes that the holes have been piercedand not drilled.

3 Explain why piercing is the preferred processfor manufacture in this case.

4 State the name of a metal which could havebeen used to manufacture the tray.

5 Describe a suitable process for the manufactureof the tray using your chosen metal.

6 The soap dish is described as chunky. Describethree ways in which the designer could make thesoap dish look less chunky.

AssignmentThe tray has to be redesigned to allow water todrain from it. Produce three design solutions forthe tray.

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DescriptionThis wall mounted cabinet has a portal windowand hinged door.

MaterialsCabinet - MDFDoor - MDFWindow - acrylicWindow frame - aluminium

Process of manufactureCabinet - machinedDoor - machinedWindow - cut from sheetWindow frame - blanked and pressed

Method of assemblyCabinet - bolted/steel dowelsDoor to cabinet - hingedWindow and frame to door - push fit

Questions ?1 State three properties of MDF which make it asuitable choice for the manufacture of the cabinet.

2 The cabinet is to be manufactured fromgalvanised steel sheet. Explain a process whichcould be used to produce the cabinet. Sketchesshould be used in your answer.

3 State three ergonomic factors the designer wouldhave considered in the design of the cabinet.

AssignmentThe cabinet is to be redesigned with double doorsand no window. Handles have to beincorporated(cut) into the door design.Produce adesign solution for the cabinet with double doors.

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DescriptionA one piece moulded easy chair which can bestacked for easy storage.

MaterialsChair - polypropylene

Process of manufactureChair - injection moulding

Method of assemblyNone

Questions ?1 Explain which properties of polypropylene makeit a suitable choice for the manufacture of thechair.

2 Describe the process of injection moulding.Sketches should be used in your answer.

3 Explain the difficulties which may be encounteredwhen injection moulding such a large product asthe chair.

4 State four aesthetic factors which the designerwould have considered in the design of the chairand describe how they have effected its overalllook.

AssignmentIt is decided to produce a stool/table to accompanythe chair.Produce a design solution for a stool/tablemanufactured using the same material andprocess as the chair.

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DescriptionA light weight stool with very modern stylingavailable at low cost.

MaterialsSeat - polypropyleneLegs - steel / lacquered

Process of manufactureSeat - injection mouldingLegs - extruded tube and formed

Method of assemblySeat to legs - 4 screws / 1 centre bolt

Questions ?1 Describe one functional and one aesthetic reasonfor curving the legs.

2 Explain the effect on the cost/aesthetics of thestool, if the stool had been manufactured entirelyfrom stainless steel.

3 Describe the stool using four aesthetic terms.

4 State the market niche for this product and justifyyour answer.

5 State a suitable metal and process which couldbe used for the manufacture of the seat.

AssignmentThe appeal of the stool is to be improved by theaddition of a low back support. The same materialshave to be used.Produce a design solution for the stool with anadded low back support.

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DescriptionA sculptured watering-can made from a singlesheet of material and available in a range ofcolours.

MaterialsWatering can - polypropylene

Process of manufactureWatering can - injection moulding

Method of assemblyNone

Questions ?1 Aesthetics and fashion are closely linked. Forthis product describe the aesthetic styling whichprove this to be the case.

2 This design of watering can allows for stacking.Explain how this will influence the cost oftransportation and storage for the company.

3 User trials were conducted with the wateringcan before it went into production. State twoaspects of the watering can where user trialswould have proved useful.

4 Explain how the designer would have used theinformation obtained from the user trials.

AssignmentIt is decided that due to the popularity of thewatering-can, the range is to be extended toinclude a plant pot and tray. The plant pot andtray should be manufactured from the samematerial/process.Produce a design solution for the plant pot andtray.

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DescriptionA simple dish for holding a candle with centrespike to ensure the candle does not fall over.

MaterialsDish - aluminiumSpike - brass

Process of manufactureDish - die castSpike - turned

Method of assemblySpike into dish - screwed

Questions ?1 State two pieces of evidence found by visualinspection of the dish which would establish diecasting as the manufacturing process.

2 Describe the process of die casting. Sketchesshould be used in your answer.

3 State two properties of aluminium which makeit suitable for this product.

3 Explain, with reference to aesthetics why brassmay have been chosen for the manufacture of thespike.

AssignmentThe holder is to be redesigned with an alternativemethod for securing a candle.Produce a design solution for a holder which willhold a candle without the use of a spike.

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DescriptionA sconce made from black lacquered steel forthick cathedral candles.

MaterialsBack plates - steel / lacqueredDish - steel / lacqueredUprights - steel rod / lacquered

Process of manufactureBack plates - formedDish - blanked and formedUprights - cut

Method of assemblyAll parts welded

Questions ?1 Describe the process used to manufacture thedish of the sconce.

2 Describe one functional and one aestheticreason for the back plates on the sconce.

3 Describe three features of the sconce whichallow it to be manufactured in this way.

4 Explain, with reference to psychology andaesthetics why black has been chosen for thefinish of this product.

AssignmentThe sconce has to be redesigned to befreestanding.Produce a design solution which will allow thesconce to be redesigned as a freestanding candleholder.

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