2. MATERIALS AND COMPONENTS
-1-
2.
Technical Principles:
Materials and Components
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2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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.
2. MATERIALS AND COMPONENTS
-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
.
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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.
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
.
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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.
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
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ical
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.
MA
TER
IALS
—A
LLO
YS
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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
2. MATERIALS AND COMPONENTS
-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.
2. MATERIALS AND COMPONENTS
-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