Modelling & Testing
Once the design development stage is complete you should have a clearer understanding of what your final idea will look like. However before you can begin manufacturing your design you will need to test your idea by producing a variety of models. These models can either be scaled down or be full scale and they will allow you to experiment with different materials and see if those chosen work. If not changes can be made.
These should be documented with both images and annotation to explain the process that you have taken. Modelling can be either practically or as a CAD model. Ideally both should be used. Any practical tests that you completed can be documented and used as evidence for criteria 2.
These should be documented with both images and annotation to explain the process that you have taken. Modelling can be either practically or as a CAD model. Ideally both should be used. Any practical tests that you completed can be documented and used as evidence for criteria 2.
Materials, Manufacturing & Workshop Skills Building.
As part of criteria 2 you will be continuing your confidence and skills building by completing a series of workshop activities in how to join materials (wood, metal and plastics).
All of the practical activities you complete and demonstrate in your work booklet can be used in your controlled assessment course work as testing and development work. This is graded within criteria 2.
These will be documented via write ups, photographs and a 3D isometric drawing.
You will be completing the following:
Wood Joints.
- Butt Joint
- Mitre Joint
- Halving Joint
- Dowel Joint
- Lap Joint
- Housing Joint
- Finger Joint
Plastic
- Line bender
- Polyfusion
- Vacuum Forming
Metal
- Aluminium laser etching
All of the practical activities you complete and demonstrate in your work booklet can be used in your controlled assessment course work as testing and development work. This is graded within criteria 2.
These will be documented via write ups, photographs and a 3D isometric drawing.
You will be completing the following:
Wood Joints.
- Butt Joint
- Mitre Joint
- Halving Joint
- Dowel Joint
- Lap Joint
- Housing Joint
- Finger Joint
Plastic
- Line bender
- Polyfusion
- Vacuum Forming
Metal
- Aluminium laser etching
Workshop Skills Building Booklet.
gcse_workshop_skills_builder_student_booklet_-_2015_version.pdf | |
File Size: | 1003 kb |
File Type: |
Workshop Skills Theory.
In lessons you will be shown a theory video clip, a teacher demonstration & theory step by step worksheet which will enable you to complete the skills task. This will be documented by you in your booklet, which will be marked by your teacher and then re-typed up with corrections by yourself. Supporting photographs and isometric 3D sketches will allow you to provide sufficient evidence for criteria 2.
Dowel Joint.
Theory & video on how to make a Dowel joint.
Lap Joint - Strong wooden joint.
Housing Joint.
Dovetail Joint.
Materials Modelling & Testing [CHECK LIST]
To be successful in this section you will need to include the following in your coursework.
1)Initial card models *3 (Photographs added, testing with a light, annotation & a manufacturing table)
2)Development modelling (of chosen design) using appropriate materials. Testing different types of acrylic [frosted, tinted and matt] against the light fitting.
3)Testing of the design itself. Such as cut outs, etching, inserts etc against the light fitting. Test using liquid solvent cement/insert size testing [no glue/exact fit]
4)Materials and finishes testing [spray paint, wood varnish, bees wax, applying wood veneer onto wood and coloured wood stain] Photographs and annotation.
5)Sublimation research and testing. Another skill, even if not used on the final product. You will sublimate on both wood and acrylic. Photograph and annotate.
6) Image transfer using PVA glue, a printed image and wood. Photograph and annotate.
7) Laser etching on acrylic plastic using the laser cutter. Photograph and annotate.
8)Feet and toppers modelling [Initial sketches and CAD to manufacture on the CNC lathe]. Scope to model out of modelling clay also and test with their wooden dowel models.
1)Initial card models *3 (Photographs added, testing with a light, annotation & a manufacturing table)
2)Development modelling (of chosen design) using appropriate materials. Testing different types of acrylic [frosted, tinted and matt] against the light fitting.
3)Testing of the design itself. Such as cut outs, etching, inserts etc against the light fitting. Test using liquid solvent cement/insert size testing [no glue/exact fit]
4)Materials and finishes testing [spray paint, wood varnish, bees wax, applying wood veneer onto wood and coloured wood stain] Photographs and annotation.
5)Sublimation research and testing. Another skill, even if not used on the final product. You will sublimate on both wood and acrylic. Photograph and annotate.
6) Image transfer using PVA glue, a printed image and wood. Photograph and annotate.
7) Laser etching on acrylic plastic using the laser cutter. Photograph and annotate.
8)Feet and toppers modelling [Initial sketches and CAD to manufacture on the CNC lathe]. Scope to model out of modelling clay also and test with their wooden dowel models.
Manipulative Skills (Part of Criteria 2)
As part of criteria 2 (Developmet of design proposals, including modelling) you will achieve the top mark band if you experiment with a varied range of materials and processes. These need to be documented in your controlled assessments through photographs, manufacturing logs and annotation explaining what you did and whether you would use it in your final manufactured product.
gcse_materials_&_processes_student_booklet..pdf | |
File Size: | 1096 kb |
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Sublimation Printing (Acrylic & Wood)
Sublimation printing is a useful manufacturing process of transferring an image onto a material such as wood or acrylic using heat from a heat press. This method of manufacturing is useful in testing but could be used for the lamps wooden base or acrylic sections for transferring an image or pattern.
Laser Etching
Laser etching is a useful process as part of your testing and understanding of different materials and processes. Taking a piece of acrylic either white or frosted and spray painting a colour a grey-scaled bitmapped image can be etched off to create an usual effect when under a light.
Laser Etching Onto Aluminium.
On the laser cutter and with a bitmap grey scale conversion image you can also etch onto aluminium. This provides another material finish that you could use and incorporate into your design using both CAD & CAM.
Polyfusion.
Polyfusion is a method similar to sublimation of using heat from a heat press to fuse (melt) several pieces of Polypropylene together to create an unusual design. Using certain colours you can create a usual effect when held against a light. This is another manufacturing process which can be documented in your materials testing section.
Line Bender.
Line bending is used to make simple bends in a sheet of thermoplastic polymer such as acrylic. In terms of your final manufactured product for your controlled assessment this could be manufacturing process that you use.
Line bending involves heating the material along a line, using a heating element. The plastic softens as it heats, allowing it to be bent. As the plastic cools it will retain its shape. A wooden former is often used to ensure accurate bending.
Vacuum Former.
Vacuum forming allows you to use thermoplastic to heat and shape using a pre-manufactured mould. Moulds are created to allow for multiple copies to be manufactured. In terms of your final manufactured product for your controlled assessment this could be a method that you use and certainly for testing/modelling would show a high level of skill.
PVA image transfer onto wood.
An image can be transferred onto a material using sublimation as a process. That requires the image to be printed on specific paper and with specific inks. This can often be costly and in terms of mass production of your lamp in industry. Another method of transferring an image which is more affordable is using PVA glue. Glue is applied to the wood surface and a coloured image placed on top. This is smoothed and a clamped until dry (minimum 24 hours). Then carefully using water the paper is rubbed off revealing the image clearly printed onto the piece of wood. Left to dry for a further 24 hours a layer of PVA glue can be painted on top and left to dry to give a shiny, high quality glossy finish.
Wood Veneering.
Wood veneering is method of applying a thin layer of wood onto a piece of man-made board such as MDF to improve its appearance. Companies such as IKEA use this process when manufacturing flat-packed furniture. In terms of your final, manufactured product if you didn't wish to spray paint your wooden base you could use this method to improve its final appearance. Another useful method in your materials and testing section of criteria 2.
Spray Painting
Spray painting is a method of applying colour and a high standard of finish to a piece of wood. In terms of your final product you could apply simply one colour (matt or glossy). You could even use masking tape to section off and create patterns for a decorative finish.
SETTING OUT YOUR E-PORTFOLIO SLIDES [A GUIDE]
Student Examples
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