MT lecture 1

PRODUCT DESIGN | 1ST YEAR
| GIORGIA CAVARRETTA
LECTURE 1
GIORGIA CAVARRETTA
Industrial Design
Product Engineering
Material Research
giorgiacavarretta@gmail.com
LECTURE 1
DESIGN is often used as an adjective to
describe the aesthetics of objects and forms.
– That is a well-designed lamp.
DESIGN is often used as an adjective to
describe the aesthetics of objects and forms.
– That is a well-designed lamp.
DESIGN is also frequently used as a noun
when referring to certain commodities,
objects or shapes.
– I like that design.
DESIGN is often used as an adjective to
describe the aesthetics of objects and forms.
– That is a well-designed lamp.
DESIGN is also frequently used as a noun
when referring to certain commodities,
objects or shapes.
– I like that design.
As designers, we are most interested
(and involved) in DESIGN as a verb.
PLAN
PURPOSE
Industrial design is a process of design applied to products that are
to be manufactured through techniques of industrial production.
Its key characteristic is that design
is separated from manufacture:
the creative act of determining and
defining a product's form and
features takes place in advance
of the physical act of making a
product.
Its key characteristic is that design
is separated from manufacture:
the creative act of determining
and defining a product's form and
features takes place in advance of
the physical act of making a
product.
This distinguishes industrial
design from craft-based design,
where the form of the product is
determined by the product's
creator at the time of its creation.
All manufactured products are
the result of a design process,
but the nature of this process
can take many forms:
All manufactured products are
the result of a design process,
but the nature of this process
can take many forms:
- it can be conducted by an
individual or a team
All manufactured products are
the result of a design process,
but the nature of this process
can take many forms:
- it can emphasize intuitive
creativity or calculated
scientific decision-making,
and often emphasizes both
at the same time
All manufactured products are
the result of a design process,
but the nature of this process
can take many forms:
- it can be influenced by
factors as varied as
materials, production
processes, business
strategy, and prevailing
social, commercial, or
aesthetic attitudes.
Designers use the design
process to solve a problem
or develop a new or better
product.
Common steps of the
process are:
The first step in design is to
define the problem.
When writing a problem
statement, you will need to
know the Who? What? and
Why? of the proposed
project.
For example, ''Jaimie needs a
device for cooking eggs using
solar energy because the
electricity is out.''
Once the problem has been
defined, the designer will
research existing solutions
either to create something
similar or identify problems
that need to be avoided.
For example, when researching
cooking with solar energy,
Jaimie may find that others
have tried cooking on the
sidewalk and failed because
concrete does not conduct heat
as well as other surfaces.
The designer will determine
which elements will be
required in order for the
solution to be successful.
For example, the solar cooker
needs to be able to focus the
sun's rays in the direction of
the eggs, the cooking surface
needs to conduct heat, and the
cooking area needs to be
insulated to prevent heat from
escaping.
The next step is to brainstorm
as many solutions as possible.
This is a time for creativity.
To generate lots of ideas, you
may want to consider the best
parts of existing solutions or
create analogies between this
problem and other problems.
Write, draw, and give yourself
ample time to come up with
ideas. The best approach may
be days away.
Compare your solutions to the
requirements to determine which
one best meets your needs.
Some things that should be
considered include cost, time,
safety, skill, resources, and
aesthetics.
Sometimes a simple pros and cons
list can be used to compare ideas.
Sometimes, you will need a more
complex analysis of how well
each solution meets your needs.
Next, the designer will create
drawings, models, blueprints, or
storyboards to design a solution
for optimal results.
Sometimes, this involves
determining which materials are
the most practical choice to use
given available resources.
Sometimes a designer will build
several prototypes from various
materials to determine
adjustments that need to be made
before building the final product.
Prototypes are generally less
expensive versions of the final
product that are made from
available resources to test the
design.
There is a great deal of trial and
error in the design process.
Typically, there will be multiple
redesigns based on the results
of testing. Often, even after the
final design is used, a designer
will continue to enhance the
product.
The testing and redesign portion
will often require many cycles to
develop the best solutions.
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Make ideas tangible
Give specific mechanical and
chemico-physical properties to objects
Enable determined functions
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Interface between us and the world
Communicate to our senses
Trigger an emotional response
Carry underlying meaning
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Visualize a design
Communicate a desired experience
Embody intangible values
Establish an emotional connection
All materials have particular
characteristics or properties
that influence their use.
The knowledge of these
properties allows to choose
the most suitable material
to achieve the desired
purpose and use.
Successful products begin with
appropriate materials.
You wouldn’t build an airplane out
of lead, or an automobile out of
concrete—you need to start with
the right stuff.
Material selection is a crucial step
in the process of designing any
physical object.
In the context of product design, the
main goal of material selection is to
minimize cost while meeting
product performance goals.
Systematic selection of the best
material for a given application
begins with properties and costs
of candidate materials.
The choice of a material largely depends on its properties,
which are mainly distinguished in:
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> chemical composition
> internal structure
(atomic distribution,
molecular structure, etc)
> behavior in contact
with external agents
(acids, air, water, etc.)
general characteristics and
behaviour in relation to
external agents
> mass
> thermic properties
> electrical properties
> optical properties
> ...
ability to withstand and
react to external forces and
stresses
> pressure
> shocks
> vibrations
> wearing
> ...
ability to be transformed through specific
technologies and machining
With each materials, the ultimate goal
is to convert it into some form of
useful product.
Manufacturing can be described as the
various activities that are performed to
convert materials into ‘‘things.’’
But materials rarely comes in the
right shape, size, and quantity
for the desired use.
But materials rarely comes in the
right shape, size, and quantity for
the desired use.
Parts and components must be
produced by subjecting materials
to one or more processes (often a
series of operations) that alter their
shape, their properties, or both.
Good manufacturing relies on
understanding materials’:
as well as the interrelations
between these four factors.
Good manufacturing relies on
understanding materials’:
as well as the interrelations
between these four factors.
Good manufacturing relies on
understanding materials’:
as well as the interrelations
between these four factors.
Good manufacturing relies on
understanding materials’:
as well as the interrelations
between these four factors.
Good manufacturing relies on
understanding materials’:
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STRUCTURE
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PROPERTIES
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PROCESSING
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PERFORMANCE
as well as the interrelations
between these four factors.
> understand the properties of materials, both
intrinsic and contextual
> understand the technical possibilities and designs
enabled by these characteristics
> analyze and break down industrial objects from
a manufacturing point of view
> select materials and processing technologies
to achieve specific designs
> experiment hands-on with materials
17/10 > 19/12
09/01 > 09/04
23/04/2020
17.10
24.10
31.10
07.11
14.11
21.11
28.11
05.12
12.12
19.12
Course Intro|Materials in Design
Materials classification and main definitions
Physical, Chemical and Technological properties
Metals and alloys
Wood and derivatives
Ceramics and glass
Plastics pt1
Plastics pt2
Composite Materials (overview)
Material selection best practices | Midterm test
Ulrich K. T., Eppinger S. D.,“Product Design and Development”
McGraw-Hill, 2000
Bralla, J. G., “Design for Manufacturability Handbook”
McGraw-Hill, 1999
Manzini E., “The Material of Invention”, Hyperion, 1989
Ashby M., Johnson K., “Materials and Design”, Elsevier Ltd, 2002
Lefteri C.,“Making it, Manufacturing Techniques for Product Design”
Laurence King, 2007
Thompson R., “Manufacturing Processes for Design Professionals”
Thames & Hudson, 2007
(single or group projects)
to bring at the final exam for evaluation
> Practical exercises in the classroom
> Presentation of alternative designs and weekly revisions
> Creation of models and prototypes
> Experimentation on assigned materials and technologies
> Project reports
> Intermediate deliveries and presentations
LAB PROJECTS REPORT
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THEORY ORAL EXAM
All the products that surround you in
your home, school, or workplace are
made of one material or another.
Unless the thing you're looking at
happens to be natural, like a tree or a
flower, someone had to decide what
material to make it from.
Those people probably use some
aspect of materials science to make
that choice.
Materials science is a part of
engineering that involves
discovering and designing new
materials and analyzing their
properties and structure.
That information can then be used
to make design choices.
We can also use our knowledge to
break materials apart and
recombine them in creative ways.
Materials science is important
for the development of
technology and has been for
thousands of years.
Different materials have
different strengths and
weaknesses and are better
for different purposes.
Since technology is the process of
using our scientific knowledge to
create devices and objects that
benefit humans, understanding
materials is an important step in
this process.
The more you understand the
materials that you have choose
from, the better choices you
will make.
Part of materials science involves
classifying materials: putting
them into groups.
Materials are generally split into
four main groups: metals,
polymers, ceramics, and
composites.
Metals are materials like iron,
steel, nickel, and copper.
They're found on the left of the
periodic table of chemistry.
They tend to be shiny, strong,
and usually require high
temperatures to melt.
They can be further split into
ferrous metals and alloys and
nonferrous metals and alloys.
Ferrous metals are anything
that has some iron content.
So this includes iron itself, carbon
steels, stainless steels, and other
iron alloys (mixtures).
Nonferrous metals include
aluminum, copper, and nickel,
among others.
Metals are generally used when
strength is particularly important
and when the material also needs
to be fairly thin.
Polymers are substances
containing long repeating
chains of atoms.
Most polymers we use in our
daily lives (such as plastics,
for example) are man-made,
but natural polymers like
wool, silk, and natural rubber
do exist.
The use of polymers depends on
the exact material, because they
each have different
properties.
Plastics are found all over the
place because they're cheap
and easy to make, and they're
strong and durable.
Ceramics are materials
traditionally made from clay that
has been hardened using heat.
But in material science, ceramics
also include glasses, graphite,
diamond, and other crystalline
structures.
Ceramics are most commonly
used for pottery like plates and
bowls, for translucent services
like windows, and for
decoration.
They vary a lot, but tend to have
a high melting point, be
particularly hard, nonelastic,
and can't be broken apart
without shattering.
Composites are materials made
up of two or more of the above
materials that are combined or
otherwise mixed together.
This might be done by layering
two materials on top of each other
or by melting materials and
literally mixing them together.
Composites can be mixes of
ceramic and metal materials,
reinforced plastics, and materials
that are inherently mixes like
concrete.
These materials are directly derived from animals and plants, often produced
by craft working (they are the materials typically used by artisans).
They could be classified as "zoo-materials" and "plant materials“, depending
on where they are derived from.
From the point of view of manufacturing, it is preferable to classify wood and
plastics in their own respective categories, even if they could be classified
as biological materials.
From the ethical point of view, while the materials derived from plants are
socially well-accepted by the consumers, the animal-derived ones are
sometimes rejected because of the life sacrifice their use involves.
These are the materials derived from rocks: in the antiquity they were
sometimes used as they were found in the environment to construct rural
buildings, civil works or tools (stones), or cut into geometrical shapes (cut
stone) to use for the prestigious architectural buildings, or even finely worked
for creating various objects.
In the past very specific uses were defined for some of these materials (for
example, the “soapstone” to construct fire cooker objects like pots); today
instead, they are usually known and used for the generic and civil
constructions (from fine marble, granite, porphyry to the most functional
gravel and sand which are also used with the binders to produce concrete and
mortar; sand is also important to produce glass).
These materials are the result of woodworking process which is made from
almost all the “dicot(yledon) essences” (trees) except the ones made from
“monocot(yledon)s” (palms and reeds) which are not used in the production of
woodwork.
From wood, as well as the first level processed wooden materials (wood primary
processed products, also known as solid wood), are produced the wood
secondary processed materials, the most important ones for industrial
products, like plywood panels, MDF, glue-laminated timber. Also cellulose pulp,
paper (paperboard) and cardboard can be considered derivatives of wood.
From the environmental point of view, it is important to underline the fact that
the production of wood and its derivatives can be extremely impactive.
These are the materials produced from inorganic non- metallic substances,
formed at natural temperature and consolidate in hot temperatures.
From this definition, some materials like glass, stones and binders, in the past
sometimes generically included, do not belong to this class.
From the archaeological point of view, because of its characteristics in time
resistance and customization (decoration), the ceramic pottery had a great
importance in the cultural development documentation.
The typical characteristics of these materials were extremely important in
buildings and construction of the past (brick). Nowadays they are not
replaceable in some applications like “bathroom furnitures” and they are
continuously studied and developed in order to obtain new special materials
known as “advanced ceramic”.
Scientifically they are inorganic liquids with “glass state” behaviour; this
glass state can be intuitively assimilated like as if a “sub-cooled” liquid.
This class is entirely perceived as the material that is commonly named “glass”
and historically known for its characteristics amongst these is transparency;
however even the glass has its own structured classification which range from
glass sodium-calcium (the common glass) to the special type of glasses like
photo-reactive glasses.
Depending on the transformed component shape, we can also speak about
“flat glass” and “hollow glass”. It is also important in composite materials
production, in which it is used reduced in fibers.
These materials are not real physical ones and could be called “pre-materials”
because they are the substances that harden in the air or water or both cases.
They form the “matrix” of a particular category of composite materials which
are used especially in construction and civil architecture, such as mortar and
concrete, where the binders is the cement; the clay is also considered a binder
(once the huts were made from clay and vegetable fibers), even if, by means of
firing, it can be transformed into a ceramic material.
Even though they are often used as composite matrix, is preferable to attribute
this adjective to the class of materials with the polymer matrix.
Metals are chemically very simple “elements” even if sometimes are extracted
from very complex ones, and in the past this represented a great problem, like
in the aluminium case.
Metallic materials are rarely used as raw structure materials because it almost
always need to be transformed into “alloys” in order to be able to
improve the mechanical characteristics.
Metallic materials are accepted as structural materials for their excellence,
although – in recent decades – increasingly they become to be used together
with the polymer matrix composites.
It would be better to call them “plastic polymer materials” as their
fundamental characteristic is to be polymeric substances, usually
organic origin (except silicone polymer, for example), normally produced
by molecular synthesis, starting from hydrocarbons (petrolium and gas),
even if still different polymers derive from “natural substances” (rubber,
castor oil and so on).
They are “the modern materials” of our era and often led to the decline of
the usage of the traditional materials but, as being “modern”, they become
constantly the subject of ecological debates even if some of them can be
considered ecological.
These are the materials that consist of two different phases; the first phase is
the continuous one which is called the “matrix” and the second is the
discontinuous phase called “reinforcement” made either of particles or fibers.
They were always existing but had a great impulse with the advent of polymers
since these materials nearly always perform the function of matrix; in this case
they are called “polymer composite materials”.
If plastics are considered modern materials, the composites – especially the
structural ones (almost always reinforced by means of fibers) – are the materials
of the future: their resistance is sometimes greater than that of the metals
and especially their resistance/weight ratio is extremely high and make this
materials fundamental for high performance applications (kinematics, sports
equipment, cars, trains, ships, planes, spacecraft etc.).
Advanced materials can be defined in many ways. The broadest definition is to
refer to all materials that represent advances over the traditional materials
that have been used for hundreds or even thousands of years.
From this perspective, advanced materials refer to all new materials and
modifications to existing materials to obtain superior performance in one or
more characteristics that are critical for the application under consideration.
They can also exhibit completely novel properties. The development of
advanced materials can even lead to the design of completely new products.
This is a category of special materials, often composites, in which can converge
the use of materials of various kinds, and different science research, in order to
use them in very special functional and/or structural applications.
Different examples can be given for this class: electroluminescent materials;
thermochromic polymeric materials; the last generation molecular materials
produced with nanotechnology, graphene and so on.
PRODUCT DESIGN | 1ST YEAR
GIORGIA CAVARRETTA