Technical Principles

• 'Cold working'

  bending, rolling or hammering. Improves tensile strength and hardness.
• Annealing


  Undoes work hardening, heat metal and slowly cools it.
• Case Hardening


  Hardening the surface of steel <0.4% carbon. Carburising:- Heated to 950C then added with carbon and then quenching.Quenching:- fast cooling of water to shock it. Keeps the hardening surface.
• Hardening


  Makes a material harder but leaves it brittle.
• Tempering


  Reduces the hardness of a material to make it more ductile. Heat to below critical point.
• Embossing


  Raised design on the surface of a material
• Debossing


  The opposite of embossing
• Foil Blocking


  Debossing and heating a metallic sheet
• Screen printing


  Use of a squeegee and spreading of the ink
• Flexography


  Four colour process (CYMK)
• Acrylic Spray prints


  Acrylic paint is fast drying, water soluble and water resistant.
• Overmouldings


  TPE used as a secondary part. Eg a polypropylene toothbrush and a TPE.
• Electroplating


  To coat a cheaper metallic material with a more expensive one eg stainless steel with silver coating
• Polymer Dip coating


  Metal heated to 230C then dipped into a fine polymer
• Metal Coating


  Galvanising - Coating in zinc 460C
• Powder coating


  Statistically charged paint particles (negative) onto a positively charged material eg cars or bikes
• Varnish(metal)


  Add to an expensive material to give it a clear finish. Protection.
• Sealants (metal)


  Tough polymer-based coating to protect surface from decay and tarnishing
• Preservatives (metals)


  Temporary or long term coating on surfaces, mainly on moulds
• Anodising


  Used for aluminium products, enhances natural oxide layer.
• Cathodic Protection


  Sacrificial anode
• Batch Production


  Examples: Pottery, Wooden furniture, high-quality loudspeakers, jet engines.
• Mass Production


  'Division of labour' - to split a task into smaller orders to improve efficiency. Henry Ford with the line production.
• Unit Production Systems (UPS)


  Used in the system for textiles
• Quick Response System (QRS)


  Amount of time between the initiation and completion of a product or part.
• Vertical in-house production


  To minimise the amount of external parts or components that need to be bought outside of the companies factory.
• Just in time


  Parts come onto the production line as needed and only when needed, therefore reduces the need for storage space and wasted materials.Toyota
• Modular/Cell Production


  CAM cells setup to combine with a number of CNC machines. Used with lathes, milling machines, drills and grinders.
• Flexible Manufacturing Systems (FMS)


  Extensive use of modular/cell production. Able to respond to change s manufacturer needs.
• Single minute exchange dies (SMED)

  The changing of dies and presses within single digits thus reducing the down time of machines.
• Standard components


  The use of universal components etc screws and tyres
• Sub-assembly A product that it in itself is a product but then added to your product enhances it


  eg a mud guard for a bike.
• CAM


  Computer aided manufacture
• Laser cutting


  Data converted into computer numerically controlled (CNC)
• Routing


  Spinning bit that cuts into thicker materials
• Milling


  Similar to routers, but are a drill bit
• Computational fluid dynamics (CFD)

  To simulate how a gas or fluid moves around a car or object eg a formula 1 car.
• Finite element analysis (FEA)


  Use of computer modelling to carry out component stress test.
• Rapid prototyping processes


  To use CAD to design a model and then quickly 3D print it to see it used in a real life scenario.
• Electronic point of sale


  To analyse how consumers purchase data. This data is collected via barcodes, the amount of money they spend, how often etc. Used to affect the target market out reach.