Craft and Design

1. Craft and Design Your need to know

2. Design Aesthetics. What things look like. If a designer wants to change the Aesthetics of this chair, they could try some the following things Design brief Analysis of brief Specification Investigation/research Idea generation Planning for manufacture Manufacture Evaluation Design process Change the colour of the chair. Bright, dull, contrasting. Anthropometrics. Measuring and recording the sizes of people. Change the shape of the chair. Circles, triangles, curves. Anthropometric data table. You can use this instead of doing all the measuring yourself. Change the texture of the chair. Rough, smooth, furry. Change the material of the chair. Wood, metal, plastic, concrete. Ergonomics. How things are designed to suit the sizes of the human body If you measure the height of the whole population you will get a few small people, a few big people, and a lot in between. We cant design for everyone, so we forget about the smallest 5% and tallest 5% of the people. So we design for people between the 5th and 95th percentile. If you want to design something for small people use the 5th percentile sizes. If you want to design something for tall people use the 95th percentile. If you want to design for the average size use the 50th percentile. Ergonome. When a designer is working on a product they might use an ergonome. This is a model of a person of average size (50th percentile) Tallest people Smallest people An ergonome being used to design a desk.

3. Wood • Hardwood softwood • Shaping wood • Joining wood • Finishing wood

4. Wood Wood joints Wood glue The main glue used with wood is PVA. A joint glued with PVA need to be tightly clamped and left for 9-12 hours to get to full strength. Types of wood. There are two families of wood; Softwood These come from trees which have needles. They do not have leaves to fall. Softwoods include; Red pine, Cedar, Douglas fir Hardwood These come from trees which loose their leaves in the autumn. Hardwoods include Oak, Beech & Mahogany Manmade boards These are made from wood, but usually cheap or unsightly pieces that cant be used on their own. Butt joint Dovetail joint Rebate joint Mortice and tenon Dowel joint G-Clamp Cross halving Housing joint Knock down fitting. Used so that customer can build their furniture at home. Means furniture can be transported flat instead of built up Stopped housing joint Sash cramp

5. Try square Bradawl Cross pein (Warrington) hammer Shaping Wood 1 Wood Wood turning. Making cylinder shaped objects in wood. Driving centre. Has teeth which bite into wood. This makes the wood spin round Headstock Tailstock Marking gauge Mortice gauge Tool rest Increase the speed of the lathe for the last cut to improve surface finish. Live centre. Spins on ball bearings, and supports the other end of the wood. Dead centre could have been used but this does not spin, so burns the wood. Mortice machine Getting ready Hand router Claw hammer 1. 3. 2. Use smoothing plane to take off the corners to make an octogan. Draw diagonals on each end. Saw down 3mm on each diagonal with tenon saw. Draw circle on each end using dividers.

6. Ferrous metals contain iron Non ferrous don’t. e.g. Cast Iron, Mild steel. e.g. Aluminium, Brass, Copper, Tin. Metal Files Shaping Metal 1 File card. Used to clean teeth of file. Anvil Tongs. Used to hold hot metal Forge work. Where metal is heated and beaten into shape using a large ball pein hammer against the anvil. Drilling Guard Chuck Chuck key to tighten drill bit Table Safety Tie hair back Wear goggles No loose clothing Hand Drill Brazing hearth Heat treatment. We can change the strength of metal by heating it up and cooling it down in different ways. Annealing. Steel is heated up to a dull red colour and left to cool. This makes the steel easier to bend or hammer into shape Hardening. Steel is heated up to deep red and cooled immediately This makes the steel hard but brittle. Tempering. Steel is heated up gently and left to cool. This makes the steel not quite as hard, but much less brittle. Twist drill bit Machine vice Pillar Drill Countersink bit Sawing metal Hand vice. For holding thin sheet metal while drilling Folding bars. For holding sheet metal while it is being bent. Junior Hacksaw Hacksaw Sheet metal work Hide Mallet. For hammering sheet metal to shape. Tins snips. For cutting out shapes in thin metal

7. Shaping Metal 2 Metal Metal lathe Facing off Parallel turning Headstock Chuck Guard If cutting tool is too low you will be left with a small piece in the middle when you have made a cut. This is called a pip. If this happens adjust the cutting tool up and continue. Tailstock Cutting tool is passed across the end face of the work piece to produce a mirrored flat surface. Cutting tool is passed along the length of the work piece to reduce the diameter. Parting off Knurling • Safety. • Wear goggles • Tie hair and clothing back • Make sure chuck key is removed • Make sure guard is in place Bed Tool post Saddle Compound slide. Can be set to any angle. Used to cut tapers. Thin parting tool is passed through the work piece to cut it off from the bar. Lathe is set to slow speed. Knurling tool leaves criss cross print on metal to give it better grip. Cross slide Drilling Taper turning Centre drill Cutting a cone shape. COMPOUND SLIDE ONLY must be used. Use Jacobs chuck in tailstock. Start with centre drill to make pilot hole, then use twist drills to work up to finished size.

8. 1 2 3 Metal Pop Rivet. Quick and easy rivet to form. They can be formed from only one side of the job. Rivet set Electricity is passed between 2 pieces to be joined. This generates a lot of heat, melting the edges to be joined making a strong permanent joint. Riveting Permanent joint Welding Permanent joint Joining Metal Riveted Joint. Snap head both sides Types of rivet head Nut and bolt Can be taken apart Die stock Die Gluing Permanent joint An epoxy resin glue can be used to glue metal together, Tap wrench Using the die. For first cut tighten middle screw and loosen outside ones. Second cut. Loosen middle one and tighten both outside ones. Use taps in this order 1. Taper tap 2. Intermediate tap 3. Plug tap Cutting a screw thread. An inside thread (nut) is cut with taps. An outside thread (bolt) is cut with a die.

9. Crucible Runner Riser Shaping Metal 3 Marking out Metal Metal Casting. A hole is formed in sand using a mould. The mould is removed, and The hole left behind is filled with molten aluminium (650 – 700 °C). Used to make irregular shapes in metal. Odd leg callipers Ball pein hammer Engineers square Marking out Dividers Steel rule Centre punch Scriber Measuring Inside callipers Outside callipers Micrometer

10. THERMO PLASTICS can be heated up and reshaped many times. They have plastic memory; this means they remember they were made in big flat sheets, and will try to go back to this flat shape when heated. Acrylic is a Thermo plastic. THERMOSETTING PLASTICS cannot be heated up and reshaped. They will stay in the shape they were made in permanently. Melamine is a Thermosetting Plastic Plastics • Edge finishing. • Cross file • Draw file • Draw file with wet and dry. • Polish with metal polish Marking out Oven. Used to heat up the whole of a piece of plastic Pen or pencil Vacuum forming This is a process where you heat thin Thermoplastics up and place it over a mould. You then suck out the air (a vacuum) and the plastic takes up the exact shape of the mould. Click on the picture of the Vacuum forming machine below to see a Youtube video of it. You will not be able to watch this in school! Strip heater. Used to heat a thin area of the plastic to make precise line bends. Cutting Fluidising tank (Dip coating machine.) Coping saw Dip coating. Puts a plastic coating onto metal. It makes metal tools more comfortable to use, and stops steel from rusting. Vacuum forming mould. Must have sloping sides to allow the mould to be removed from the plastic this is called draw. It must also have rounded corners to stop the plastic splitting as it stretches over the mould.

11. Wood Measuring Casting. A hole is formed in sand using a mould. The mould is removed, and The hole left behind is filled with molten aluminium (650 – 700 °C). Used to make irregular shapes in metal. Dividers