GRAP1051

Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Industrial Design Engineering
Materials, Mechanics, Processes and Principles of Production
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Content
Introduction to Lecturers
Why are we here?
What are we going to teach you?
Semester Outline
History of Materials
Material Classifications
Material Properties
How do products get into the market?
Who buys products?
Design Considerations
Process Classifications
Next Week
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Margaux Hayes
Product Design Engineering degree from Swinburne
Internship with DEAM, designing tools for keyhole surgery
Now freelancing for both private clients and a product
development consultancy
Set up a community workshop and studios called NORM
Board member for the Brunswick Tool Library
Design, construction and curating of a portable performance
venue called The Tabernacle
Occasional work in wider fields such as construction, sound
and lighting design
Currently working on evacuation equipment, wearable
technology, furniture.
Uses SolidWorks, Adobe Suite
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Prue OConnor
Product Design Engineering degree from Swinburne with honours
Spent 4
th
year in The Netherlands 6 months Uni, 6 months work at
Phillips
Graduated and worked for 3 years at Nylex
Worked on Wheelie Bins, Eskys, Water Tanks, Agricultural Tanks etc
Experience with Injection Moulding, Blow Moulding and Rotational
Moulding
Started my own design consultancy in 2005
Worked with many companies on small blow moulded bottles, spas,
medical products, outdoor blinds and awnings, baby bottles,
automotive transport cases, graphic design
Experienced with testing to Australian Standards and ISO Quality
Systems
Uses SolidWorks, Photoshop, Illustrator and InDesign
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Why are we here?
So you want to be an Industrial Designer?
How do you decide what to design?
How do you decide what to make it from?
How do you decide how to make it?

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
What are we going to teach you?
How products function and how they are made
How to choose and specify materials and a suitable
manufacturing process
How to communicate to engineers, toolmakers,
manufacturers etc (and to some extent sales people
and marketers) in their language
How to express how you want a product to be made
(using presentations, technical drawings and reports)
How to consider and balance the many aspects of
product design. Including ethical, social, economic and
environmental concerns, not just the manufacture.


GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
What are we going to teach you?
So all that technical stuff is good, but what about
loving what you do?
Enjoying the process of understanding which
materials and processes to use
Look at the world around you the desk, your
phone, chair, building etc
Question how it is made? Why that way? What
is it made from?
This will come naturally overtime, curiosity is key

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
What is considered good design practice?
Good design insists that a product:
Is innovative and functions correctly and efficiently
is intuitive and suits its target market
enhances the users lifestyle
saves time and/or money
is manufactured in an environmentally friendly way
or which helps the environment as its primary function
is easily assembled and disassembled using minimal parts
is reliable and durable and thought out to the last detail


GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Where will you end up?
Design Consultancy?
Manufacturing Company?
Sculptor/Artist?

http://www.abc.net.au/acedayjobs/cooljobs/profiles/s2320502.htm


GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Example: Plastic Chair in Wood
Designed by Maarten Baas
Commissioned by Contrasts Gallery
Made from Elm Wood
2008
Maarten took the
traditional injection
moulded green
plastic patio chair, and
redesigned using Elm
Wood and made by
Chinese woodcarvers
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Example: Chindogu
the Japanese are of creating something useful yet useless at the same time

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
We want to teach you:
> Co.Design on Elizabeth Whelan
> Richard Feynman on Challengers o-rings
Imogen Houldsworth
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Semester Outline
week 1 Intro Materials and Design C4
week 2 Form Follows Material - Materials and Design C6
week 3 Product breakdowns, reverse engineering and project 1
week 4 Polymers
week 5 Metals
week 6 Ceramics, Glass, Fibres, Natural materials
week 7 Assignment 1 Presentations
week 8 Product Case Studies Materials and Design C8
week 9 Shaping Profiles
week 10 Joining Profiles. Assignment 2 Submission
week 11 Surface Profiles
week 12 Overview. Assignment 3 Submission
week 13 No Classes
week 14 Combined Assignment Submission
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Materials in history
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Materials production now
4.17 Raw Materials World Production
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Material Classifications
4.5 Material groupings by
mechanical similarity
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Metals
- Combination of metallic elements
- Non-localised electrons (they can move)
- Good electrical and thermal conductors
- Opaque
- Strong yet deformable

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Metals
- Ferrous vs. Non-ferrous
- Alloys


GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Ceramics
- Typically a combination of metallic and non-metallic
elements
- Includes clay minerals, cement, glass
- Typically insulative
- Resistant to high temperatures and harsh environments
- Typically very hard but brittle
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Ceramics
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Polymers
- Includes plastic, rubber, etc
- Typically organic compounds: based on carbon, hydrogen
and other non-metallic elements
- Large molecular structures
- Low densities
- Can be extremely flexible
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Composites
- Combinations of metals/ceramics/polymers
- Designed to display a combination of the best
characteristics of both materials

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Composites
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Material Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Mechanical Properties
Compressive strength Maximum stress a material can withstand before compressive failure (MPa)
Ductility Ability of a material to deform under tensile load (% elongation)
Fatigue limit Maximum stress a material can withstand under repeated loading (MPa)
Fracture toughness Energy absorbed by unit area before the fracture of material (J/m^2)
Hardness Ability to withstand surface indentation (e.g. Brinell hardness number)
Plasticity Ability of a material to undergo irreversible deformations (-)
Poisson's ratio Ratio of lateral strain to axial strain (no units)
Resilience Ability of a material to absorb energy when it is deformed elastically (MPa)
Shear modulus Ratio of shear stress to shear strain (MPa)
Shear strain Change in the angle between two perpendicular lines in a plane
Shear strength Maximum shear stress a material can withstand
Specific modulus Modulus per unit volume (MPa/ m^3)
Specific strength Strength per unit density (Nm/kg)
Specific weight Weight per unit volume (N/m^3)
Tensile strength Maximum tensile stress a material can withstand before failure (MPa)
Yield strength The stress at which a material starts to yield (MPa)
Young's modulus Ratio of linear stress to linear strain (MPa)
Coefficient of friction (also depends on surface finish)
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Mechanical Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Mechanical Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Electrical Properties
- Conductivity/Resistance

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Electrical Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Thermal Properties
Thermal Expansion
Flammability
Melting point
Specific heat
Thermal conductivity
Glassy transition point
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Other Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Material Failure
Fracture
Fatigue
Creep
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Optical Properties
Colour
Glossiness
Transparency
Reflectivity

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Optical Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Acoustic Properties
Resonance
Absorption (insulation)
Pitch
Timbre

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Acoustic Properties
Federation Bells
at Birruang Mar
By Neil McLachlan
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Tactile Properties
Temperature
Texture
Hardness
Stiffness
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Emotional/Cultural Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Emotional/Cultural Properties
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
How do products get into the market?
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Push Example
Pull Example
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Who buys the products?


Who is your target market? They are the ones who should be!
Your target market, audience, client, whatever you want to call them is who your are
primarily designing for
The more precise you are in defining a target the more suitable your product will be
However, in direct contrast to this, if you are too specific, you are also limiting your
ability to sell to a wider audience

Consider the following to help define your target market:
Category: Example:
Age 20-50 years old
Gender male
Location Australia (metro areas)
Socio-economic status high $100k+
Occupation lawyer, doctor, engineer
Personality conservative
Marital Status single
Lifestyle eats out, likes to play sport
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Who buys the products?
Example:
Would you use high end materials for a watch that is for a child?
Would you use a cheap plastic material that will break easily for a chair?
Would you make power tools in pink?
Would you make a hand held blender too big for the average person to hold?

Some people buy with emotion or impulse
Some are first in, must have the latest and greatest gadget
Others will wait until the product has been around for a while and
prices are lower
Others will choose not to buy a product unless they have to
There are real psychological reasons behind buying the products we do
Is it from necessity? luxury? need or a want?
People use their senses when buying. How does it look? feel? sound?
It is important to try and incorporate these factors when designing
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
What do we think of before starting product design?
What must we consider when designing?
What is essential to make the product successful?
How do we balance all the requirements?
How do we decide between what are critical features/functions
and desirable ones?
Who is involved in the process?

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Process Classifications
Throughout the subject we will be using the following
terms (from the text):

Shaping
Joining
Surfacing

GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Shaping
Shaping processes give form to materials
(Ashby, M & Johnson, 2
nd
ed 20120, Materials and Design, Elsevier Ltd, Jordan Hill, Oxford)

Different types of manufacturing processes are used to create the form required,
and different materials can use the same process.
Deciding on which process to use can depend on cost, volume, size and tolerance
required
The following processes, or Shaping methods will be covered during this subject:



GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Joining
The manufacture of a product involves many steps, one of which
is that of assembly
(Ashby, M & Johnson, 2
nd
ed 20120, Materials and Design, Elsevier Ltd, Jordan Hill, Oxford)

How can we join two parts together? How can we join many parts together?
Joining similar materials and joining dissimilar materials
Considerations for disassembly
The following processes, or Joining methods will be covered during this subject:



GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Surfacing
Almost every component of a product has some sort of surface
process applied to it
(Ashby, M & Johnson, 2
nd
ed 20120, Materials and Design, Elsevier Ltd, Jordan Hill, Oxford)

Coating a surface can enhance a products thermal, fatigue, friction, wear, corrosion
or aesthetic properties
Material choice is critical to surfacing success
The following processes, or Surfacing methods will be covered during this subject:



GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Industrial Design Engineering
Materials, Mechanics, Processes and Principles of Production
GRAP1051
Semester 1 2014
Margaux Hayes
Prue OConnor
Week 1 - Subject Intro
Next Week
Homework
Read chapter 4 to reinforce todays lecture
Read chapter 6 in preparation for next week
Organise yourself in groups of 2/3 before next week
Document 5 examples in your environment where
engineering sits behind design

Bring to Class
Phone or tablet camera

Further Reading
Everyday Engineering IDEO book at RMIT Library