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INSPIRATION PRODUCTSAna Oropeza Prof. John Schaffeld IDUS325 - Emerging Materials

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The intent of this project is to research and explore a diverse range of material properties and manufac-turing processes and apply them to innovative product designs.

Phase 1A: From the required reading: Materials For Inspirational Design, Develop 2 product concepts for each of the 5 material categories listed in the Contents section: Ceramics, Glass, Metal, Plastic and Wood. You will then present the 10 concepts, including composite and exploded assembly views for each one showing how it would be manufactured and assembled, along with a brief narra-tive explaining why your designs are ideally suited for each material you selected. From these 10 concepts, you will be assigned to further develop and refine 1 in a way that is truly inspired and highly innovative. Your goal is to demonstrate a comprehen-sive understanding of each material and show how they could be effective-ly applied to mass- produced consum-er products.

Phase 1B: From the required reading: Making it: Manufacturing Techniques for Product Design, Develop 2 product concepts for each of the 6 manufacturing types listed in the Contents section (sections 1 through 6). Example: ‘Section 1 Cut from

Project Objective: Project Outcome:

Project Description:

Solid’, you might choose ‘Machining’ and ‘Turning’, and then develop one product concept for each of those two processes. ‘Section 2 Sheet’, you might choose ‘Sheet-Metal Forming’ and ‘Metal Spinning’, and then develop one product for each of those two processes and so on. You will then present the 12 concepts, includ-ing composite and exploded assembly views for each one. Your goal is to demonstrate a comprehensive under-standing of how each design would be manufactured by sighting the manufacturing processes and appro-priate materials, and providing a brief narrative explaining why your designs and the materials you’ve specified are ideally suited for each of the two process you selected. From these 12 concepts, you will be assigned to further develop and refine one in in a way that is truly inspired and highly innovative. Your goal is to demon-strate a comprehensive understanding of the manufacturing methods you’ve elected to study, and show how each concept could be executed as a mass-produced consumer product.

Phase 2: Using the required reading text book: Manufacturing Processes for Design Professionals, fully explore all aspects of tooling, fabrication, processing, finishing and assembly associated with the approved final design proposal for each of your two consumer product designs (Phase 1A and 1B). Both concepts should be documented to the level that a manu-facturer could use your information to tool and produce the final product.

Project Deliverables:

The documentation should include the entire conceptual development process, refinement and final render-ings, screen shots of all 3D CAD documentation, material specification and call outs for any necessary fasteners or ancillary hardware needed to assemble the product. No physical 3-dimensional models are required. Your final presentation will be delivered in the form of two separate, high-quality printed process books; one based on the Materials exploration (Phases 1A and 2), and one based on the Manufacturing Process exploration (Phases 1B and 2). PowerPoint/pdf files for the process books must also be submitted.

• 15-minute research and concept presentation for Phase 1. Power-Point/pdf only.

• 15-minute final concept presentation showing detailed illustration and part design, (2) Printed process books and associated PowerPoint/pdf files.

• Extra credit for material acquisition and experimentation up to 10 POINTS

The following project outcomes indicate competencies and measur-able skills that students develop as a result of completing this project:

• Introduction to emerging material properties and associated manufactur-ing processes.

• Familiarity with innovative material applications for a consumer product.

• Demonstration of the ability to understand a range of diverse materi-als and appropriate applications.

• Develop truly innovative solutions for emerging materials

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PorcelainProduct 1 (Material)

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Ideation

WOOD

CERAMIC

PLASTIC METAL

GLASS

PORCELAIN

Porcelain is a ceramic material made by heating raw materials, generally including clay in the form of kaolin, in a kiln to temperatures between 1,200 °C (2,192 °F) and 1,400 °C (2,552 °F). The toughness, strength, and translucence of porcelain arise mainly from the formation of glass and the mineral mullite within the fired body at these high temperatures.

Porcelain can informally be referred to as "china" or "fine china" in some English-speaking countries, as China was the birthplace of porcelain making.

The most common uses of porcelain are for utilitarian wares and artistic objects. It can be difficult to distin-guish between stoneware and porce-lain because this depends upon how the terms are defined. A useful working definition of porcelain might include a broad range of ceramic wares, including some that could be classified as a stoneware. Porcelain is used to make household wares, decorative items and objects of fine art amongst other things.

Kaolin is the primary material from which porcelain is made, even though clay minerals might account for only a small proportion of the whole. The word "paste" is an old term for both the unfired and fired material. A more common terminology these days for the unfired material is "body", for example, when buying materials a potter might order an amount of porcelain body from a vendor.

The composition of porcelain is highly variable, but the clay mineral kaolinite is often a raw material. Other raw materials can include feldspar, ball clay, glass, bone ash, steatite, quartz, petuntse and alabas-ter.

The clays used are often described as being long or short, depending on their plasticity. Long clays are cohe-sive (sticky) and have high plasticity; short clays are less cohesive and have lower plasticity. In soil mechanics, plasticity is determined by measuring the increase in content of water required to change a clay from a solid state bordering on the plastic, to a plastic state bordering on the liquid, though the term is also used less formally to describe the facility with which a clay may be worked. Clays used for porcelain are generally of lower plasticity and are shorter than many other pottery clays. They wet very quickly, meaning that small

MaterialDescription:

Composition:

Material prices: $ 500 - 1,000 /ton

changes in the content of water can produce large changes in workability. Thus, the range of water content within which these clays can be worked is very narrow and the loss or gain of water during storage and throwing or forming must be carefully controlled to keep the clay from becoming too wet or too dry to manipulate.

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CHOPSTICKS

Ceramic finger chopsticks with overmolded rubber

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ORTHOGRAPHIC VIEW

EXPLODED VIEWChopsticks Porcelain Injection molding 2

Description Material Man-Process Quantity

1

Finger covers Silicone Over molding 22

Process

Silicone rubber is an elastomer composed of silicone—itself a polymer— containing silicon together with carbon, hydrogen, and oxygen.

Silicone rubbers are widely used in industry, and there are multiple formulations. Silicone rubbers are often one- or two-part polymers. Silicone rubber is generally non-reac-tive, stable, and resistant to extreme environments and temperatures from −55 °C to +300 °C while still main-taining its useful properties. Due to these properties and its ease of manufacturing and shaping, silicone rubber can be found in a wide variety of products, including: automotive applications; cooking, baking, and food storage products; apparel such as undergarments, sportswear, and footwear; electronics; medical devices and implants; and in home repair and hardware with products such as silicone sealants.

During manufacture, heat may be required to cure the silicone into its

Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic or other materials including metals, glasses, elastomers and confections. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the cavity. After a product is designed, usually by an industrial designer or an engineer, molds are made by a moldmaker (or toolmaker) from metal, usually either steel or alumi-num, and precision-machined to form the features of the desired part. Injection molding is widely used for manufacturing a variety of parts, from the smallest component to entire body panels of cars.

Over molding (injection molding)is a term used to describe injection molding over any preformed material.

Ceramic injection molding is ideal for high-volume production of complex, tight-tolerance components, ceramic injection molding offers significant advantages over conventional forming methods:• Cost-effective technique for complex designs• Ability to produce net or near-net shape parts• Very tight tolerance control• Low-cost, high-volume manufactur-ing runs

Overmolded material:

Over-molding:Injection Molding:

Ceramic IM:

(Phillips Plastics Corporation)

rubber-like form. This is normally carried out in a two stage process at the point of manufacture into the desired shape, and then in a prolonged post-cure process. It can also be injection molded.

High toolingLow units costs

Cost

Very high surface finishHighly repeatable process

Quality

Injection cycle time is generally between 30 and 60 seconds

Speed

Environmental IMPACTAlthough many of the environmental effects of pottery production have existed for millennia, some of these have been amplified with modern technology and scales of production. The principal factors for consider-ation fall into two categories: effects on workers, and effects on the general environment. Within the effects on workers, chief impacts are indoor air quality, sound levels and possible over-illumination. Regarding the general environment, factors of interest are fuel consumption, off-site water pollution, air pollution and disposal of hazardous materials.

Historically, "plumbism" (lead poisoning) was a significant health concern to those glazing pottery. While the risk to those working in ceramics is now much reduced, it can still not be ignored. With respect to indoor air quality, workers can be exposed to fine particulate matter, carbon monoxide and certain heavy metals. The greatest health risk is the potential to develop silicosis from the long-term exposure to crystalline silica. Proper ventilation can reduce the risks. Another, more recent, study at Laney College, Oakland, Califor-nia suggests that all these factors can be controlled in a well-designed workshop environment.

The use of energy and pollutants in the production of ceramics is a growing concern. Electric firing is arguably more environmentally friendly than combustion firing although the source of the electricity varies in environmental impact

Ceramic is not recyclable, and a broken plate will contaminate a whole crate of recycled glass.

But it is repurposed, ceramics are now being crushed to produce Recycled Porcelain Aggregate. This green building material is extremely hard, durable, and has zero absorp-tion making it ideal for a wide variety of applications including Terrazzo flooring, high friction road surfacing, permeable paver infill, and many more.

LampworkingProduct 2 (Process)

Ideation

LAMPWORKING

ProcessGlass is formed I to hollow shapes and vessels by lamp working, also known as flame working, by a combi-nation of intense heat and manipula-tion by a skilled lamp worker. Prod-ucts range from jewelry to complex scientific laboratory equipment.

Lampworking is a type of glasswork where a torch or lamp is primarily used to melt the glass. Once in a molten state, the glass is formed by blowing and shaping with tools and hand movements. It is also known as flameworking or torchworking, as the modern practice no longer uses oil-fueled lamps.

Lampworking differs from glassblow-ing in that glassblowing uses a furnace and glory hole as the primary heat source, although torches are also used.

Early lampworking was done in the flame of an oil lamp, with the artist blowing air into the flame through a pipe. Most artists today use torches that burn either propane or natural gas, or in some countries butane, for the fuel gas, mixed with either air or pure oxygen as the oxidizer. Many hobbyists use MAPP gas in portable canisters for fuel.

Beadmakers sometimes make hollow vessels by forming a steel wool shape around the end of a mandrel. Glass is wound around the shape, then gaps are coaxed shut to make a solid surface. The artist continues to add glass to build the vessel and create the envisioned shape.The steel wool is not removed until after the vessel is kiln annealed. Some lampwork artists use rubber plugs at the top of the vessel and some make tiny glass plugs to close them so that they can safely hold essential oils or other liquids..

Lampworking

Typically no tooling cost Moderate to high unit

Cost

Very high but depends on hand work (lamp worker)

Quality

Moderate to long cycle time depending on the size and complexity of the piece

Speed

Lampworking is used to create artwork, including figurines, trinkets, curios, Christmas tree ornaments, beads and much more. It is also used to create scientific instruments as well as glass models of animal and botani-cal subjects.

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TEA CUP

Triple walled lamp-worked cup, has a barrier forthe tea leaves and prevents your hands to get burned with the boiling water.

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MaterialDescription:Class is an amorphous (non-crystal-line) solid material. Glasses are typically brittle and optically transpar-ent.

The most familiar type of glass, used for centuries in windows and drinking vessels, is soda-lime glass, composed of about 75% silica (SiO2) plus sodium oxide Na2O from soda ash, lime CaO, and several minor addi-tives. Often, the term glass is used in a restricted sense to refer to this specific use.

In science, however, the term glass is usually defined in a much wider sense, including every solid that possesses a non-crystalline (i.e., amorphous) structure and that exhibits a glass transition when heated towards the liquid state. In this wider sense, glasses can be made of quite different classes of materials: metallic alloys, ionic melts, aqueous solutions, molecular liquids, and polymers. For many applications (bottles, eyewear) polymer glasses (acrylic glass, polycarbonate, polyeth-ylene terephthalate) are a lighter alternative to traditional silica glasses.

Also called soda-lime-silica glass, is the most prevalent type of glass, used for windowpanes, and glass contain-ers (bottles and jars) for beverages, food, and some commodity items. Glass bakeware is often made of tempered soda-lime glass.

Soda-lime glass is prepared by melt-ing the raw materials, such as sodium carbonate (soda), lime, dolomite, silicon dioxide (silica), aluminium oxide (alumina), and small quantities of fining agents (e.g., sodium sulfate, sodium chloride) in a glass furnace at temperatures locally up to 1675 °C. The temperature is only limited by the quality of the furnace superstruc-ture material and by the glass compo-sition. Relatively inexpensive miner-als such as trona, sand, and feldspar are usually used instead of pure chemicals. Green and brown bottles are obtained from raw materials containing iron oxide. The mix of raw materials is termed batch.

Soda-lime glass is divided technically into glass used for windows, called flat glass, and glass for containers, called container glass. The two types differ in the application, production method (float process for windows, blowing and pressing for containers), and chemical composition. Float glass has a higher magnesium oxide and sodium oxide content than container glass, and a lower silica,

Soda Lime Glass

Material price:Soda lime tubes

$ 500 - 5,000 / Ton

calcium oxide, and aluminium oxide content. From this follows the slightly higher quality of container glass for chemical durability against water, which is required especially for storage of beverages and food.

Principal Uses:

Mirrors, microscopic slides, touch screens, filters, photomasks, glass masters, data storage disks, printed circuit substrates, photographic plates, substrates, wafers and optical windows

Environmental IMPACTThe common glass (soda-lime glass) is surprisingly friendly when it comes to the environment. It uses common, easy to extract materials, the produc-tion process does not generate much waste, and the recycling ratios of glass are one of the highest of all materials (about 50% in US, 60% in UK, up to 95% in Switzerland).Glass is composed of about 70% silica (silicon oxide, or, basically, sand), 15% soda (sodium carbonate), 15% lime (calcium oxide, usually made on site from limestone), and minor amounts of other additives. Thus the name of the common glass: soda-lime glass. Glass is used in huge variety of product, but vast majority is made into windows or into contain-ers. For many uses glass needs to be made with different additives. For example, replacing the lime with lead oxide produces "crystal" glass, replac-ing soda and lime with boron oxide produces borosilicate glasses such as Pyrex, etc. However, we do not consider these specialty glasses in this article.The production of glass is composed of three major parts:

• Preparation of raw materials (here, for example, a lot of water is used -- to wash the recycled bottles...)

• Melting (here the most energy is used - usually in form of burning of

natural gas)

• Forming and annealing (where the products assume their final shapes).

SOURCES

http://www.phillipsplastics.com/capabilities/processes/ceramic-injection-molding-cim

http://www.ceradyne.com/products/medical/ceramic-injection-molding.aspx

http://businessrecycling.com.au/recycle/ceramics

http://glassproperties.com/glasses/

http://www.alibaba.com

http://envimpact.org/glass

http://www.britannica.com/EBchecked/topic/551995/soda-lime-glass

http://jewelry.about.com/cs/glassbeads/a/glass_beads.htm

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