2.materials and components 2. technical principles

2. MATERIALS AND COMPONENTS

-1-

2.

Technical Principles:

Materials and Components

The authors have attempted to use images that are free of copyright restriction however if there are omissions or inaccuracies please inform us so that any necessary corrections can be made. The authors are also grateful to those businesses and agencies including Dyson, Blackpool Creative, Rob Law CEO Trunki (images and text provided by Trunki.co.uk), PROTO 3000 and Matthew Cooke that have given permission for images from their websites to be used in this work.


-2-

NATURAL - DEFINITION

Natural material is derived from plants, animals or ore [ground].

It is possible to categorise natural materials into organic

materials such as wood or fibres or inorganic materials such as

stone, or ore. [metallic ore to produce metals such as copper,

iron, lead and gold.

COMPOSITE—DEFINITION

When two or more materials are bonded or combined together

it creates a composite material. Usually the new material has

improved properties than the original materials. The main

components of a composite material are the strengthening

material and the bonding matrix [glue or resins]. Usually these

type of materials have excellent weight to strength ratios. [Much

stronger than other materials compared to the same weight]

SYNTHETIC - DEFINITION

The term synthetic is used to describe materials that have been

created by man via a scientific process. It is possible to mix

materials or chemicals to create a new material. In some

instances chemicals are mixed together to simulate or copy

natural materials, the leather look for example.

SMART - DEFINITION

The term ‘Smart material’ is used to explain the properties of a

special range of materials. Smart materials can react to its

environment when introduced to outside stimuli without the

interference of humans. These materials have given designers

opportunities to design products that a few years ago would not

be possible.

REGENERATED—DEFINITION

Materials that have been re used or processed into a different

type of product such as wood waste processed into chipboard or

MDF. This material would have different properties to the

original material.

MATERIALS


-3-

Working Properties of Materials Different materials have different working characteristics. This is essential

to the designer when selecting a specific material for a particular

component that needs to perform in a certain way.

Listed are key characteristics materials will exhibit.

Conductivity

This is the ability of the material to conduct heat or electrical energy.

Strength

This is the ability of the material to withstand impact or force without

deforming or breaking.

Elasticity

This is the ability of the material to bend or deform and return to its

original shape.

Plasticity

This is the ability of the material to permanently change its form or

shape.

Malleability

This is the ability of the material to be deformed or bent in all directions

without breaking.

Ductility

This is the ability of the material to be stretched without breaking.

Hardness

This is the ability of the material to resist scratches, indentation and

withstand wear.

Toughness

This is the ability of the material to withstand sudden impact or blows

without breaking.

Durability

This is the ability of the material to withstand constant wear.


-4-

Mat

eri

al C

lass

ifica

tio

n

- N

ATU

RA

L

Material

Mat

eria

l

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

Co

tto

n

Ab

sorb

s sw

eat.

Dra

pes

wel

l an

d is

com

fort

able

aga

inst

th

e sk

in.

T-sh

irts

To

wel

s

B

ed s

hee

ts

So

cks

Co

pp

er

Red

dis

h p

ure

met

al.

No

n f

erro

us

met

al.

Mel

tin

g p

oin

t o

f 1

10

0oC.

Go

od

ele

ctri

cal c

on

du

ctiv

ity.

Go

od

hea

t co

nd

uct

ivit

y.

Go

od

res

ista

nce

to

co

rro

sio

n.

Ver

y m

alle

able

—ca

n b

e b

ent

and

sh

aped

ove

r an

d o

ver

wit

ho

ut

bre

akin

g.

Ver

y d

uct

ile -

can

be

stre

tch

ed t

o a

th

in w

ire.

El

ectr

ical

wir

e

Sa

uce

pan

s

C

op

per

wat

er p

ipes

Wo

ol

Com

es fr

om

shee

p.

Go

od

th

erm

al q

ual

itie

s.

Go

od

res

ista

nce

to

fir

e.

The

fib

res

can

be

spu

n in

to

yarn

s an

d k

nitt

ed in

to

garm

ents

.

Ju

mp

ers

W

oo

l Car

pet

s

NA

TUR

AL

MA

TER

IALS

Mac

hine

-was

habl

e.Dr

y-cl

eana

ble.

Good

stre

ngth

.


-5-

Mat

eri

al C

lass

ifica

tio

n

- N

ATU

RA

L

Material

Mat

eria

l

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

Silv

er

Pu

re M

etal.

Wh

ite

lust

re p

reci

ou

s m

etal.

Bes

t m

etal

fo

r el

ectr

ical

an

d

hea

t co

nd

uct

ivit

y.

Qu

ite

exp

ensi

ve.

Tarn

ish

es q

uit

e q

uic

kly.

Ver

y m

alle

able

an

d c

an b

e

shap

ed a

nd

ben

t to

intr

icat

e

shap

es a

nd

fo

rms.

•Je

wel

lery

•H

igh

val

ue

•Ta

ble

war

e

•El

ectr

ical

co

nta

cts

•P

lati

ng

of

chea

per

met

als

such

as

bra

ss

•M

irro

rs

Silk

N

atu

ral

fib

re f

rom

th

e co

coo

n

of

the

mu

lber

ry s

ilk w

orm

th

at

can

be

wo

ven

into

tex

tile

s.

Nat

ura

l sh

ine

and

lu

stre

w

ith

smo

oth

tex

ture

.

Go

od

ab

sorb

ency

th

at m

akes

it c

om

fort

able

to

wea

r in

ho

t

clim

ates

- c

oo

ling

effe

ct.

On

e o

f th

e st

ron

gest

nat

ura

l

fib

res

bu

t lo

ses

20

% o

f it

s

stre

ngt

h w

hen

wet.

Dra

pes

wel

l.

•Sh

irts

an

d

Blo

use

s

•U

nd

erw

ear

•P

yjam

as

Lin

en

Lin

en

is a

tex

tile

mad

e fr

om

th

e

fib

res

of

the

flax

pla

nt.

Val

ued

fo

r it

s ex

cep

tio

nal

coo

lnes

s an

d f

resh

nes

s in

ho

t

wea

ther.

Fib

res

wo

ven

into

a t

exti

le.

Hig

hly

ab

sorb

ent

and

a g

oo

d

con

du

cto

r o

f h

eat,

hen

ce

com

fort

able

to

we

ar in

ho

t

wea

ther

.

•U

nd

erw

ear

•Sh

irts

•Tr

ou

sers

•Ja

cket

s

•B

lou

ses

NA

TUR

AL

MA

TER

IALS


-6-

Mat

eri

al C

lass

ifica

tio

n

- N

ATU

RA

L

Material

Mat

eria

l

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Uses

Exam

ple

s

SOFT

WO

OD

Red

Ced

ar

Hig

h r

esis

tan

ce t

o r

otti

ng

and

we

ath

er.

Ver

y ex

pen

sive

to

bu

y.

Use

d f

or

ou

tsid

e w

ork

, lik

e

furn

itu

re o

r sh

eds.

•G

ard

en S

hed

s

SOFT

WO

OD

Sco

ts P

ine

Wh

itish

/cre

am c

olo

ure

d w

oo

d

wit

h c

oar

se g

rain

patt

ern

. Can

hav

e a

lot

of

kno

ts.

Mu

ch c

hea

per

th

an H

ard

wo

od

s.

Mu

st b

e tr

eate

d if

use

d o

uts

ide.

Qu

ite

eas

y to

cu

t an

d s

hap

e.

No

go

od

fo

r ca

rvin

g

bec

ause

of

its c

oar

se g

rain

pat

tern

.

•B

uild

ing

Ind

ust

ry

NA

TUR

AL

MA

TER

IALS


-7-

Mat

eri

al C

lasi

fica

tio

n

- N

ATU

RA

L

Material

Mat

eria

l Pr

oper

ties

Use

sEx

amp

les

Mat

eri

al

Ch

arac

teri

stics

HA

RD

WO

OD

Ash

Bec

ause

of

its

flex

ible

qu

alit

ies

it's u

sed

fo

r to

ol h

and

les,

ham

mer

, sp

ades

,

sled

geh

amm

ers.

Tu

rned

wo

rk B

ow

ls e

tc.

Exce

llen

t w

oo

d f

or

turn

ing

on

a

lath

e.

Spri

ngy

/ f

lexi

ble

qu

alit

ies

.

HA

RD

WO

OD

Oak

V

ery

tou

gh a

nd

du

rab

le.

Go

od

res

ista

nce

to

ro

t an

d

dam

p e

nvi

ron

men

t.

H

igh

qu

alit

y fu

rnit

ure

inte

rio

r an

d

exte

rio

r.

Wo

od

en fl

oo

rin

g.

Fen

ce p

ost

s an

d gat

es.

B

ecau

se it

is s

o h

ard

it's

very

go

od

for c

arvi

ng

wo

rk.

Ver

y h

ard

an

d t

ou

gh a

ndd

ifficu

lt t

o c

ut

and

sh

ape.

HA

RD

WO

OD

Mah

oga

ny

Red

/ B

row

n in

co

lou

r, w

ith

goo

d q

ual

ity

grai

n p

atte

rn.

H

igh

qu

alit

y in

teri

or

furn

itu

re.

Hig

h q

ual

ity

fin

ish

es c

an b

e

app

lied

.

Stra

igh

t gr

ain

ed—

easy

to

car

ve

and

wo

rk.

HA

RD

WO

OD

Bal

sa

Ver

y lig

htw

eigh

t an

d s

oft

.C

an b

e ea

sily

sh

aped

an

d

cut.

No

t su

itab

le f

or

trad

itio

nal

furn

itu

re.

M

od

el m

akin

g.

Mo

del

air

craf

t b

ecau

se it

so

ligh

t.

HA

RD

WO

OD

Teak

V

ery

Tou

gh w

ith

a n

atu

ral o

ily

fin

ish

.

Exce

llen

t re

sist

ance

to

dam

p

envi

ron

men

ts a

nd

ch

emic

als.

O

utd

oo

r ga

rden

furn

itu

re.

W

ork

top

s fo

r b

ench

es in

lab

ora

tori

es.

NA

TUR

AL

MA

TER

IALS

Ope

n-gr

aine

d, to

ugh

and

flexi

ble.

Teak

has

a v

ery

attr

activ

e st

raig

ht g

rain

and

is re

sista

nt

to m

oist

ure,

fire

and

aci

d.


-8-

Mat

eri

al C

lass

ifica

tio

n

- S

YN

THET

IC [

Man

mad

e]

Material

Mat

eria

l Pr

oper

ties

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

Acr

ylic

A

vaila

ble

in m

any

colo

urs

as

wel

l as c

lear

.

Go

od

res

ista

nce

to

ch

emic

als.

Scra

tch

es m

uch

eas

ier

than

glas

s.

Can

be

bri

ttle

on

imp

act

bu

t

less

like

ly t

o b

reak

th

an

no

rmal

gla

ss.

Ther

mo

pla

stic

can

be

mo

uld

ed a

nd

sh

aped

wit

h

hea

t.

C

rash

hel

met

Vis

ors

C

ar H

ead

lam

p c

ove

rs

Si

gns

Epo

xy R

esin

Th

erm

ose

ttin

g p

oly

mer

.Ex

celle

nt

elec

tric

al a

nd

hea

t

insu

lati

on

qu

aliti

es.

Co

mes

in t

wo

par

ts R

ESIN

&

HA

RD

ENER

.

P

ain

t an

d c

oat

ings

mu

st b

e

cure

d b

efo

re u

se [

Hea

ted

in a

Kiln

]

W

hit

e p

ow

der

co

atin

g o

n

wh

ite go

od

s [e.g. w

ash

ing

mac

hin

es, d

ish

was

her

, fri

dge

s]

A

dh

esiv

es [

Ara

ldit

e]

PTF

E [T

eflo

n]

Acc

iden

tally

cre

ated

by

Ro

y P

lun

kett

in 1

938

Typ

e o

f P

oly

mer

mad

e

fro

m c

hem

ical

s.V

ery

low

fri

ctio

n.

Use

d a

s co

atin

gs o

n

mat

eria

ls.

C

oat

ing

on

no

n st

ick

pan

s

B

eari

ngs

or

surf

aces

th

at c

om

e

into

co

nta

ct

SYN

THET

IC M

ATE

RIA

LS


-9-

Mat

eri

al C

lass

ifica

tio

n

- S

YN

THET

IC [

Man

Mad

e]

Mat

eria

lM

ater

ial

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

Poly

amid

e (N

YLO

N)

Ver

y to

ugh

an

d d

ura

ble

Bea

rin

gs in

mac

hin

ery

C

asto

rs o

n p

ort

able

equ

ipm

ent

Cel

lop

han

e O

bta

ined

fro

m n

atu

ral c

ellu

lose

wo

od

pu

lp o

r fi

bre

.

Usu

ally

a t

hin

cle

ar fi

lm u

sed

fo

r

foo

d p

acka

gin

g

100

% B

iod

egra

dab

le.

Can

be

wat

erp

roo

f b

ut

bre

ath

able

at

the

sam

e ti

me.

Se

llota

pe

or

adh

esiv

e

tap

es

Fo

od

pac

kagi

ng

Sw

eet

pac

kagi

ng

B

ecau

se it

is b

reat

hab

le

Poly

pro

pyl

ene

Th

erm

op

lasti

c p

oly

mer

th

at is

avai

lab

le in

man

y co

lou

rs.

Ver

y m

alle

able

, can

be

ben

t o

ver

and

ove

r w

ith

ou

t b

reak

ing.

Suit

able

fo

r cr

eati

ng

nat

ura

l

hin

ges,

fo

lder

s o

r D

VD

cas

es.

Ver

y h

igh

ten

sile

str

engt

h.

Can

be

mo

uld

ed in

to s

hap

e.

R

op

es

Fo

lder

s

D

VD

Cas

es

Sc

ho

ol c

hai

r b

od

y

PV

C [P

oly

vin

yl C

hlo

rid

e]

Ther

mo

pla

stic.

Qu

ite

flex

ible.

Can

be

extr

ud

ed in

to lo

ng

pro

file

d s

hap

es.

W

ind

ow

Fra

mes

G

utt

erin

g

SYN

THET

IC M

ATE

RIA

LS

Sunl

ight

resis

tanc

e an

d ex

celle

nt a

bras

ion

resit

ance

.


-10-

Mat

eri

al C

lass

ifica

tio

n

- S

YN

THET

IC [

Man

Mad

e]

Mat

eria

lM

ater

ial

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

AB

S V

ery to

ugh

an

d d

ura

ble

Ver

y rig

id a

nd

sti

ff.

Hig

h im

pac

t re

sist

ance

.

Go

od

fin

ish

an

d c

olo

ur

ran

ge

Can

be

mo

uld

ed in

to

com

ple

x sh

apes

.

Can

be

recy

cled

.

C

asin

gs f

or

Mo

bile

ph

on

es

C

asin

gs f

or

com

pu

ters

C

om

po

nen

ts f

or

Dys

on

Vac

uu

m c

lean

er

Elas

tan

e [L

ycra

]

[PER

FOR

MA

NC

E

MA

TER

IAL]

A c

om

po

site

of

syn

theti

c

mat

eria

ls d

evis

ed b

y D

uP

on

t in

195

9 t

o c

reat

e a

mo

der

n f

abri

c

that

rev

olu

tio

nis

ed t

he

texti

les

ind

ust

ry. E

last

ane

is r

eco

gnis

ed

as it

s b

ran

d n

ame

– Ly

cra

or

Span

dex

. Usu

ally

it c

an b

e m

ixed

wit

h w

oo

l, n

ylo

n o

r co

tto

n.

Hig

h E

lasti

city

pro

per

ties

an

d

is a

mat

eria

l th

at c

an b

e

stre

tch

ed. I

ts p

oss

ible

to

stre

tch

th

e m

ater

ial u

p t

o

600

% m

ore

th

an it

s o

rigi

nal

size

bef

ore

it w

ill b

reak

.

Ver

y Li

ght

mat

eria

l.

Res

ists

ab

sorp

tio

n o

f sw

eat.

Sw

imm

ing

suit

s [F

asts

kin

]

K

eep

fit

clo

thin

g

C

yclin

g cl

oth

ing

Poly

este

r M

ade

fro

m n

atu

ral o

ccu

rrin

g

chem

ical

s in

pla

nts

, an

d is

usu

ally

cate

gori

sed

as

a Th

erm

op

lasti

c.

Can

be

wo

ven

into

sh

eets

of

fab

rics

. Can

be

pro

cess

ed a

nd

use

d a

s P

ET b

ott

les

[po

lyet

hyl

ene

tere

ph

thal

ate]

.

Ver

y h

igh

ten

sile

str

engt

h.

Less

nat

ura

l fee

l th

an n

atu

ral

fib

res

such

as

cott

on

.

Less

like

ly t

o w

rin

kle.

Can

be

ble

nd

ed o

r m

ixed

wit

h o

ther

nat

ura

l fib

res

such

as c

ott

on

to

ach

ieve

a m

ore

nat

ura

l fee

l.

B

ed L

inen

Sh

irts

B

ott

les

C

urt

ain

s

Ta

rpau

lins

Fi

lms

Sa

fety

bel

ts

SYN

THET

IC M

ATE

RIA

LS


-11-

Mat

eri

al C

lass

ifica

tio

n

- C

OM

PO

SITE

Mat

eria

lM

ater

ial

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

Kev

lar

[PER

FOR

MA

NC

E

MA

TER

IAL]

Hig

h r

esis

tan

ce t

o im

pac

t.

Hig

h r

esis

tan

ce t

o a

bra

sio

n

Mad

e o

f w

ove

n f

ibre

.

Bu

llet

Pro

of

Ves

ts

Fi

re R

esis

tan

ce c

loth

ing

P

erfo

rman

ce T

yres

on

bik

es o

r ra

cin

g ca

rs

P

rote

ctive

mo

torc

ycle

clo

thin

g

Car

bo

n F

ibre

M

ade

of

Wo

ven

car

bo

n fi

bre

s w

ith

Res

in m

atri

x to

so

lidif

y fo

rm o

r

shap

e.

Hig

her

str

engt

h t

o w

eig

ht

than

ste

el.

Can

be

form

ed t

o

com

ple

x fo

rms

and

shap

es.

C

ano

e sh

ells

R

acin

g C

ar B

od

y sh

ells

R

acin

g cy

cles

Go

rete

x

[PER

FOR

MA

NC

E

MA

TER

IAL]

A P

TFE

bas

ed p

oly

mer

mat

eria

l th

at

is w

ater

pro

of,

win

dp

roo

f an

d

bre

ath

able

. Th

e m

ater

ial h

as m

inu

te

po

res

[ho

les]

20

,00

0 ti

mes

sm

alle

r

than

wat

er d

rop

lets

so

wat

er c

an’t

pen

etra

te t

he

mat

eri

al. T

he

po

res

are

big

en

ou

gh f

or

wat

er v

apo

ur

to

esca

pe

[sw

eat

] m

akin

g th

e m

ater

ial

bre

ath

able

.

Wat

erp

roo

f -

du

e to

min

ute

po

res

in t

he

mat

eria

l wh

ich

are

mu

ch s

mal

ler

than

wat

er

dro

ple

ts, w

ater

can

’t

pen

etra

te t

he

mat

eri

al.

Win

dp

roo

f –

du

e to

th

e

laye

red

co

nst

ruct

ion, w

ind

can

no

t p

enet

rate

th

e

mat

eria

l.

Bre

ath

able

- T

he

min

ute

po

res

allo

w w

ate

r va

po

ur

or

swe

at t

o e

scap

e th

rou

gh t

he

mat

eria

l.

O

utd

oo

r cl

oth

ing

CO

MP

OSI

TE M

ATE

RIA

LS


-12-

Mat

eri

al C

lass

ifica

tio

n

- R

EGEN

ERA

TED

/ C

OM

PO

SITE

MA

TER

IAL

Mat

eri

al

PR

OP

ERTI

ES

Mat

eri

al

Ch

arac

teri

stics

USE

S Ex

amp

les

MD

F

Med

ium

Den

sity

Fib

reb

oar

d

Mad

e o

f ve

ry fi

ne

was

te w

oo

d

par

ticl

es b

on

ded

to

geth

er u

nd

er

pre

ssu

re w

ith

ad

hes

ive.

Bro

wn

pla

in c

olo

ur.

Ver

y h

eavy

an

d d

ense

.

Smo

oth

fin

ish

.A

vaila

ble

in la

rge

shee

ts.

Ver

y st

able

will

no

t w

arp

or

twis

t.

Can

be

fin

ish

ed a

nd

pai

nte

d

to a

ver

y h

igh

qu

alit

y.

Can

no

t b

e jo

ined

in

trad

itio

nal

fas

hio

n.

Ver

y p

oo

r in

dam

p o

r w

et

situ

atio

ns

inte

rio

r u

se o

nly

C

arca

ssin

g o

f fu

rnit

ure

—

usu

ally

ven

eere

d t

o h

ide

surf

ace

Fu

rnit

ure

Sh

op

dis

pla

ys

Blo

ck b

oar

d

Stri

ps

of

wo

od

stu

ck t

oge

ther

sid

e b

y si

de

wit

h t

he

grai

n

goin

g in

th

e sa

me

dir

ecti

on

.

Laye

rs o

f ve

nee

r ar

e st

uck

on

top

in o

pp

osi

te d

irec

tio

n t

o g

ive

stre

ngt

h.

Ava

ilab

le in

larg

e sh

eets

.C

ann

ot

be

join

ed in

trad

itio

nal

way

s.

Can

be

ven

eere

d t

o g

ive

a h

igh

qu

alit

y fi

nis

h.

Fu

rnit

ure

Ply

wo

od

La

yers

of

wo

od

wit

h g

rain

of

each

laye

r at

90

deg

rees

to

pre

vio

us

laye

r.

[La

min

ate

d]

Ava

ilab

le in

larg

e sh

eets

.

Ver

y st

able

will

no

t w

arp

or

twis

t.

Ver

y st

ron

g in

all

dir

ecti

on

s.

Can

no

t b

e jo

ined

usi

ng

trad

itio

nal

met

ho

ds.

Can

be

ven

eere

d t

o g

ive

a

bett

er s

urf

ace

fin

ish

ing.

Can

be

ben

t o

r la

min

ated

to

form

sh

apes

e.g

. bo

at

bu

ildin

g.

D

raw

er b

ott

om

s

B

oat

bu

ildin

g

CO

MP

OSI

TE M

ATE

RIA

LS


-13-

Mat

eri

al C

lass

ifica

tio

n

- R

EGEN

ERA

TED

Mat

eria

lM

ater

ial

Prop

ertie

s

Mat

eri

al

Ch

arac

teri

stics

Use

sEx

amp

les

Ch

ipb

oar

d

Larg

e p

arti

cles

of

was

te w

oo

d

bo

nd

ed u

nd

er p

ress

ure

wit

h

adh

esiv

e.

Ver

y ch

eap

an

d a

vaila

ble

in

larg

e sh

eets.

Can

no

t b

e jo

ined

in

trad

itio

nal

fas

hio

n.

Ver

y p

oo

r in

dam

p o

r w

et

situ

atio

ns.

Inte

rio

r u

se o

nly.

C

arca

ssin

g o

f ch

eap

furn

itu

re

U

sual

ly la

min

ated

wit

h

mel

amin

or

Form

ica

to

imp

rove

ap

pea

ran

ce

K

itch

en w

ork

top

s

Pap

er

Pap

er is

a t

hin

mat

eria

l pro

du

ced

by

pre

ssin

g to

geth

er m

ois

t fi

ber

s,

typ

ical

ly c

ellu

lose

pu

lp d

eriv

ed

fro

m w

oo

d, r

ags

or

gras

ses,

an

d

dry

ing

them

into

fle

xib

le s

hee

ts.

Stro

ng

in t

ensi

on.

Ava

ilab

le in

diff

eren

et

thic

knes

ses

[gsm

] an

d in

size

s A

1, A

2, A

3 e

tc.

Ava

ilab

le in

dif

fere

nt

colo

urs

W

riti

ng

pap

er

C

lean

ing

tiss

ues

P

acka

gin

g

G

rap

hic

Des

ign

P

ho

togr

aph

y

Car

d

Car

db

oar

d is

a g

ener

ic t

erm

fo

r a

hea

vy-d

uty

pap

er o

f va

rio

us

stre

ngt

hs,

ran

gin

g fr

om

a s

imp

le

arra

nge

men

t o

f a

sin

gle

thic

k

shee

t o

f p

aper

to

co

mp

lex

con

figu

rati

on

s fe

atu

rin

g m

ulti

ple

corr

uga

ted

an

d u

n-c

orr

uga

ted

laye

rs.

Ava

ilab

le in

diff

eren

t

thic

knes

ses

and

siz

es. M

uch

stif

fer

and

str

on

ger

than

pap

er.

M

od

el m

akin

g

P

acka

gin

g

REG

ENER

ATE

D M

ATE

RIA

LS


-14-

Stock Forms of Materials

Metal

Plastics

Materials are available in many different dimensions

and profiles which are suitable for different

applications.

Metals are available in sheet, flat and round bar,

extruded profiles such as tube, box section, hexagonal

and channels form, wire and ingots ready to be cast

wire.

Wood

Natural wood is available in standard stock form in

different lengths.

Manufactured boards [Bonded material] such as

Plywood, MDF, Block board and chipboard are available

in large sheet form e.g. - 1200mm x 2400mm suitable for

large wooden panelling or large surfaces where the use of

natural wood would be unsuitable or too expensive to

use.

Plastic materials are available in many different forms ready

to be used or processed. Like metal and wood they are

available as sheet form or as extruded profiles.

They are also in granules or powder form ready to be

moulded or formed under heat.

Thermoset plastics are available in Resin and woven matting

form that can be moulded into intricate shapes and forms

over moulds.

Metal Stock shapes

Forms of Plastics

Forms of Wood


-15-

SMART MATERIALS SMART materials are those that change in reaction to change in

conditions in their surroundings or in their use when influenced by

controlled factors - such as passing an electric currrent through them.

Modern products increasingly use them as imaginative designers see

the potential they offer. Shirts that change colour with changes in

temperature and thermometers that are in the from of printed strips

use thermochromic inks whilst photochromic inks respond to changes

in light conditions.

Clothing also uses inks that have this characteristic and have patterns

that change with altering light conditions.

Materials that respond to an electric current might be used as component parts of safety valves or as a part of a

functional system that uses the change in shape with current to trigger some other process. These are 'shape

memory alloys' (SMA).

Thermoelectric materials again use electrical current but change temperature - in this way cooling or heating can

take place and this effect is being used to design innovative products.

Polymers that change their shape with changes in temperature are sometimes called 'Intelligent gels' - It is only

imagination that limits the products that might be created as more such materials are developed.

SMART materials have one or more properties that can be dramatically altered. Most everyday materials have

physical properties, which cannot be significantly altered; for example, if oil is heated it will become a little thinner,

whereas a smart material with variable viscosity may turn from a fluid which flows easily to a solid. A variety of

smart materials already exists, and are being researched extensively. These include piezoelectric materials,

magneto-rheostatic materials, electro-rheostatic materials, and shape memory alloys. Some everyday items are

already incorporating smart materials (coffeepots, cars, the International Space Station, eyeglasses) and the

number of applications for them is growing steadily. Each individual type of smart material has a different property

which can be significantly altered, such as viscosity, volume, and conductivity. The property that can be altered

influences what types of applications the smart material can be used for.

For some time now, scientists have been researching materials, which – equipped with sensors and controls –

“behave” similarly to biological systems. Initial successes with these kinds of “smart materials” have already been

achieved. As a result, materials could soon be available which repair themselves or adapt to certain environmental

conditions autonomously.

Thermochromic ink on fabrics which

changes colour when submitted to heat


-16-

Mat

eri

al C

lass

ifica

tio

n

- S

MA

RT

MA

TER

IAL

Mat

eria

lM

ater

ial

Prop

ertie

sU

ses

Exam

ple

s M

ate

rial

Ch

arac

teri

stics

SMA

Shap

e M

em

ory

Allo

y [N

ITIN

OL]

Retu

rns t

o its

orig

inal

shap

e if

defo

rmed

e.g

. fra

mes

for

mem

o f

lex

glas

ses

spri

ng

bac

k in

to s

hap

e if

th

e fr

ames

are

ben

t o

r sa

t o

n a

ccid

enta

lly.

Te

eth

Bra

ces

Fr

ames

fo

r Sp

ecta

cles

Mat

eria

l rem

emb

ers

its

ori

gin

al

shap

e if

def

orm

ed a

nd

will

retu

rn t

o o

rigi

nal

sta

te.

Ph

oto

cro

mic

Gla

ss

This

Gla

ss c

han

ges

colo

ur

wh

en

sub

ject

ed

to

ligh

t.

Gla

sses

th

at d

arke

n w

hen

in

sun

ligh

t. W

eld

ing

Mas

ks t

hat

inst

antl

y d

arke

n w

hen

yo

u w

eld

.

G

lass

on

wel

din

g

mas

ks t

hat

rea

cts

inst

antl

y w

hen

wel

din

g

Le

nse

s o

n e

xpen

sive

sun

glas

ses

The

pig

men

t in

th

e gl

ass

will

reac

t to

ligh

t an

d c

han

ge it

s

pro

per

ty a

nd

dar

ken

.

Ther

mo

chro

mati

c

Mat

eria

l

This

mat

eri

al w

ill c

han

ge c

olo

ur

wh

en s

ub

ject

ed t

o d

iffe

ren

t

tem

per

atu

res.

For

exa

mpl

e ke

ttle

s th

at c

han

ge c

olo

ur

wh

en

ho

t. C

hild

ren

's s

po

on

s. B

ath

plu

gs f

or

bab

ies.

Sm

art

colo

ur

p igm

ent

in p

last

ics

that

rea

ct

to h

eat

SMA

RT

MA

TER

IALS

The

chan

ge in

col

our h

appe

ns

at a

det

erm

ined

te

mpe

ratu

re, w

hich

can

be

varie

d de

pend

ing

on th

e m

ater

ial.


-17-

Mat

eri

al C

lass

ifica

tio

n

- S

MA

RT

MA

TER

IAL

Mat

eria

lM

echa

nica

l

Prop

ertie

s

Use

sEx

amp

les

Mat

eri

al

Ch

arac

teri

stics

Ther

mo

chro

mic

Ink

Ink

pig

men

t th

at r

eact

s to

hea

t. T

his

ink

pig

men

t ca

n b

e

use

d o

n p

rod

uct

s as

ind

icat

ors

of

hea

t.

In

k o

n b

eer

can

s th

at

sho

w if

th

e b

eer

is

cold

.

In

k o

n e

ggs

that

chan

ge c

olo

ur

if e

gg

has

bee

n b

oile

d f

or

lon

g e

no

ugh

Ther

mo

chro

mic

ink

in t

he

mat

eria

l will

ch

ange

co

lou

r w

hen

mat

eria

l is

sub

ject

ed t

o

tem

per

atu

re c

han

ge.

Pie

zoel

ectr

ic

Mat

eria

ls

Mat

eria

l will

def

orm

wh

en a

smal

l ele

ctri

c cu

rren

t is

pas

sed

thro

ugh

it. I

t w

ill a

lso

pro

du

ce

a sm

all v

olt

age

wh

en

def

orm

ed.

This

mat

eri

al c

an b

e ce

ram

ic o

r

crys

tal (

Qu

artz

) b

ased

.

C

on

tact

sen

sors

A

larm

s

M

icro

ph

on

es a

nd

hea

dp

ho

nes

SMA

RT

MA

TER

IALS


-18-

Mat

eri

al C

lass

ifica

tio

n

- A

LLO

YS

[

NO

N F

ERR

OU

S]

Allo

ys a

re M

ETA

LS t

hat

are

a m

ixtu

re o

f co

mp

on

ents

cre

ated

to

imp

rove

th

e p

rop

erti

es o

f th

e o

rigi

nal

mat

eria

ls.

For

exam

ple

STE

EL is

mu

ch s

tro

nge

r th

an

IRO

N.

Mat

eria

lM

ater

ial

Prop

ertie

s

Use

sEx

amp

les

Mat

eri

al

Ch

arac

teri

stics

DU

RA

LUM

IN [A

lum

iniu

m A

LLO

Y]M

ix o

f A

lum

iniu

m 9

4%, C

op

per

4.4

% &

Mag

nes

ium

1.6

%

Sa

uce

pan

s

A

ero

pla

ne

par

ts

Mu

ch s

tro

nge

r an

d t

ou

gher

than

pu

re a

lum

iniu

m.

Mu

ch li

ghte

r th

an s

tee

l.

Ver

y go

od

res

ista

nce

to

corr

osi

on.

Ver

y d

ucti

le c

an b

e d

raw

n

into

a t

hin

wir

e o

r ro

lled

into

fo

il.

BR

ON

ZE

Use

d m

ain

ly f

or

casti

ng.

Man

y

arti

sts

use

bro

nze

to

cas

t

scu

lptu

res.

Sc

ulp

ture

s an

d

casti

ngs

.

Sh

ip p

rop

elle

rs

B

eari

ngs

Ver

y go

od

res

ista

nce

to c

orr

osi

on.

Mel

tin

g p

oin

t 9

00

oC.

MA

TER

IALS

—A

LLO

YS

http://en.wikipedia.org/wiki/File:Norwid_Relief.jpg


-19-

Mat

eri

al C

lass

ifica

tio

n

- A

LLO

YS

[

FER

RO

US]

A

lloys

are

MET

ALS

th

at a

re a

mix

ture

of

com

po

nen

ts c

reat

ed t

o im

pro

ve t

he

pro

per

ties

of

the

ori

gin

al m

ater

ials

. Fo

r ex

amp

le S

TEEL

is m

uch

str

on

ger

than

IRO

N.

Mat

eria

lM

ater

ial

Prop

ertie

sU

ses

Exam

ple

s M

ate

rial

Ch

arac

teri

stics

LOW

Car

bo

n M

ild S

teel

[Fe

rro

us

Met

al]

Mo

st c

om

mo

nly

use

d

met

al. P

ure

IRO

N m

ixed

wit

h C

AR

BO

N t

o c

reat

e

Stee

l.

C

ar B

od

ies

N

uts

& B

olt

s

B

uild

ing

Ind

ust

ry

N

ails

Fr

ames

Ver

y To

ugh

an

d d

ura

ble

mat

eria

l.

Can

be

shap

ed a

nd

cu

t w

ith

trad

itio

nal

to

ols

.

Will

ru

st s

o m

ust

be

pro

tect

ed

in u

se [

Pai

nt

or

coati

ng]

Hig

h c

arb

on

ste

el

[Fer

rou

s M

eta

l]

Can

co

nta

ins

up

to

2.5

%

Car

bo

n.

D

ue

to h

igh

er

carb

on

co

nte

nt,

stee

l is

har

der

so

is

use

d f

or

cutti

ng

too

ls, b

lad

es,

chis

els

etc

Du

e to

th

e in

crea

sed

car

bo

n

con

ten

t th

is s

teel

is m

uch

har

der

th

an lo

w c

arb

on

ste

el. D

epen

din

g o

n c

arb

on

con

ten

t th

is s

teel

can

be

use

d t

o c

ut

or

shap

e o

ther

low

car

bo

n s

teel

. Use

d f

or

cutti

ng

too

ls.

MA

TER

IALS

—A

LLO

YS


-20-

Mat

eri

al C

lass

ifica

tio

n

- A

LLO

YS

[

NO

N F

ERR

OU

S]

Allo

ys a

re M

ETA

LS t

hat

are

a m

ixtu

re o

f co

mp

on

ents

cre

ate

d t

o im

pro

ve t

he

pro

per

ties

of

the

ori

gin

al m

ate

rial

s. F

or

exam

ple

STE

EL is

mu

ch s

tro

nge

r th

an

IRO

N

Mat

eria

lM

ater

ial

Prop

ertie

sU

ses

Exam

ple

s M

ate

rial

Ch

arac

teri

stics

Brass

Mix

of

Co

pp

er a

nd

Zin

c.

Yello

w G

old

en N

on

Fer

rou

s

met

al.

Ver

y B

ritt

le m

etal

, will

hav

e to

be

hea

ted

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-21-

Most products need to be finished, THREE factors must be considered

before carrying out the finishing product.

1. Function

What the product will do and what is it used for. For example, polishing

or super finishing applications to provide low friction for bearing

surfaces, raising fabrics to improve insulation properties. Polyurethane

varnish on a coffee table— can place a hot cup on the table without

marking.

2. Protection

Does the material or product need to be protected from its working

environment, damp, heat, corrosion, dust etc. Anodising, electro-plating

and stove enamelling provides protection against corrosion, fire-proof coating on fabric, wax coatings on fabric. Cars painted to avoid rusting.

3. Decoration/Aesthetics

Making the product look a certain way, a particular colour or texture that makes the product look good. Use of thermoplastic powder coating or

painting, screen printing on fabric, painting a car blue, red or green.

Different coloured iPods available.

Finishing Materials

Finishing processes are important to the final quality of a product as they

provide surface coatings and applications that can greatly enhance the

function, protection and appearance of the product.

Same product finished in different AESTHETIC qualities colouring etc

Different colours will appeal to different people. [Personal Tastes]

Finishing Materials

Mild Steel Brackets Plastic

Coated

Cotton Jacket with

waterproof coating

applied

Car body sprayed with cellulose paint

for protection and aesthetic purposes


-22-

AESTHETICS - SURFACE COATINGS ANODISING

Electrical process of giving Aluminium a

decorative coloured coating. Coloured

coating on iPod.

PROTECTION - SURFACE COATINGS GALVANISING

Mild steel dipped in hot molten zinc for a

coating. Mild Steel Rusts when exposed to

water, zinc does not.

Good protection against rust and corrosion.

Used for farm trailers, gates etc.

PROTECTION - SURFACE COATINGS VARNISH / TEAK OIL / WAX

Garden bench – to protect against theweather

Coffee table – Polyurethane varnish, hot

cup, water resistant.

Enhancing the grain makes the product look

better.

Finishing Materials


-23-

PROTECTION & AESTHETICS - SURFACE COATINGS PLASTIC COATING

Plastic Coating - Mild Steel heated and

dipped in polythene powder. Gives good

protection and is available in different

colours so it will look good. Grips on pliers,

plate racks etc.

PROTECTION & AESTHETICS - SURFACE COATINGS POWDER COATING

Powder Coating - Electrically charged plastic powder that sticks to the metal. Then the metal is placed in a kiln so that the plastic coating cures and sticks to the metal.

PROTECTION & AESTHETICS - SURFACE COATINGS PAINT

– Hammerite paint on gates

Car body sprayed with cellulose based paint

SELF FINISHING MATERIALS SELF FINISHING

No finish needs to be applied to these

materials.

Acrylic, stainless steel.

Acrylic or Plastic based products—the

colour is in the plastic pigment.

Stainless steel for kitchen sinks.

Finishing Materials


-24-

Temporary Joints

These types of joints can be taken apart, and are

usually constructed using:-

Nuts and Bolts

Screws

Clips

Brackets

Permanent joints Temporary joints

Nut & Bolt

Nylon fitting

Welding Brazing

Soldering

Rivets

Screws

JOINING MATERIALS

Joints can be Permanent or Temporary.

Permanent Joints

These types of joints cannot be taken apart. The

following methods could be used to create such joints.

Welding

Soldering

Brazing

Adhesive [Gluing]

Riveting


-25-

Adhesives

Fittings Materials and components can be assembled or joined together using

numerous types of fittings.

Many fittings can be disassembled so that components or parts can be

replaced.

Other types of fittings can be permanent so therefore components or

parts cannot be taken apart.

Both types offer designers advantages and disadvantages

Many different types of adhesives are available on the market that are capable of joining a range of different

materials.

Adhesive have different applications depending on materials that need to be joined and where the job will

need to be used.


-26-

Knock-down fittings are those that can be put together easily, normally

using only a screw driver, a drill, a mallet/hammer and other basic tools.

They are temporary joints although many are used to permanently join

together items such as cabinets and other pieces of furniture that are

purchased in a flat pack.

These have been developed for the flat pack market.

A number of stores sell furniture in flat pack form. Eg IKEA, MFI, B&Q etc.

Usually this type of furniture are made from chipboard which is either

laminated with melamine [type of thermoset plastic, or Formica]. These

are available in a number of different colours, depending on the customer

tastes.

Also they are available covered in veneer, thin layer of wood, so that the

furniture looks like real wood.

Advantages

Furniture is much cheaper - the manufacturers don't have to pay anyone to assemble the furniture.

Takes less space to store in the warehouse - saves money and therefore cheaper product.

Transport costs are lower - able to carry more at one time, cheaper product to the customer.

Customer able to take the furniture home with them straight away.

Disadvantages

Can be difficult to assemble - some people might struggle.

Quality of product in some cases can be poor.

Nylon Corner Block

CAM action fitting

KNOCK DOWN FITTINGS

Nylon Screw plugs

Cylinder with thread

Screw

2.materials and components 2. technical principles

Documents