Myton School Design and Technology Department. Year 7 Resistant Materials. Pewter Casting. Teacher: Personal Target: Target Review:

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1 Myton School Design and Technology Department Year 7 Resistant Materials Pewter Casting Name: Group: Teacher: Personal Target: Target Review: 0

2 Criteria Design Ideas Manufacture Level Designing the mould using CAD Presentation of final design Assembly of mould Finish of completed product 6 All instructions are followed independently. The mould has been well thought out and designed using an existing image from Google. The design includes a piece of acrylic for added detail. All work is laid out to the correct size. Sprues have been correctly included to allow the pewter to be poured successfully. The final design is presented in 3D with neat line work. The final design is fully rendered to give a realistic appearance. Comprehensive annotation explains the details of the design. Tools and equipment are used with precision and resilience to complete the product to a very high standard. It is smooth and shiny all over with no scratches. The product is identical to the original intention. 5 Most instructions are followed independently. The mould has been designed using an existing image from Google. The design includes a piece of acrylic for added detail. All work is laid out to the correct size. Sprues have been included to allow the pewter to be poured. The final design is neatly presented with clean line work. Colour is used to give an impression of the materials used. Annotation explains the details of the design. All parts of the mould are securely sandwiched and glued in the correct place, exactly as laid out in the CAD work. All work is completed independently. Tools and equipment are used with accuracy and resilience to complete the product to a high standard. It is mostly smooth and shiny. The product is very like the original intention. 4 The mould is rather simplistic however an existing image from Google has been used as the basis of the design. Some instructions are followed independently; support is required at times. The final design is clearly presented. Labelling is used to communicate the details of the design. Colour is used to enhance the presentation. The mould is securely sandwiched and glued together. Most parts of the mould have been glued in the correct place as laid out in the CAD work. Most work is completed independently. Tools and equipment are used safely and correctly to complete the product. It is fairly shiny though a little rough in places. The product is similar to the original intention. 3 The mould is simplistic and makes use of shapes available on Techsoft 2D Design. The design does not include an acrylic part. Support is required throughout. A labelled sketch is presented to communicate the design. Sketch work is rather rough and little colour is used to enhance the presentation. The mould is securely sandwiched and glued together. Most parts of the mould have been glued in the correct place as laid out in the CAD work. Support is required. Tools and equipment are used safely to complete the product, which is shiny in places. The product is similar in some aspects to the original intention. Support is required at times. 0

3 Assessment Self Assessment: Layout of mould using CAD (Task 10) Star 1:... Star 2:... Star 3:... Wish 1: Please tick this box if you have acted upon Wish 1, to improve your work Peer Assessment: Final Product Star 1:... Star 2:... Star 3:... Wish 1: Please tick this box if you have acted upon Wish 1, to improve your work Teacher s feedback: Working at Level 1

4 Pewter During your Year 7 Resistant Materials module, you will design and manufacture a small pewter product. Pew-ter (noun) 1. An alloy, which means it is composed of more than one metal (typically 96% tin and 4% copper). 2. It is a soft metal and can be shaped easily by hand tools and machine tools. 3. Due to its low melting point (approximately 230 C) it is suitable for casting. You might choose to make a necklace pendant, a key ring, a fridge magnet, a badge... or anything else that you can think of! Task 1 Complete the mind map below, exploring the different products that you could make. Badge Key ring Pewter Product Task 2 Complete the mind map below, exploring themes on which you could base your product. Animals Themes 2

5 Design Brief a general description of the problem. Task 3 In the space below, complete your individual design brief for your project. I intend to design and make a, which will be based on the theme of. The product will appeal to. Research Images Task 4 Using Google Images, search for a variety of simple black and white images based on your chosen theme. Print out these images and stick them in to the space below. Top tip: Use the word silhouette within your search 3

6 Research Materials Wood Wood is a very versatile material, which has been used throughout history for many purposes. There are two main types of wood: Natural wood Manufactured boards Natural Woods Natural woods can be divided into two categories: Softwoods (from coniferous/evergreen trees) Hardwoods (from deciduous trees... trees with leaves) Manufactured Boards Manufactured board is processed by cutting up solid timber and putting it back together in different ways. The main reason for doing this is to end up with large flat sheets of timber, which are stronger and don t expand or shrink. Examples: MDF, chipboard, plywood hard board and blockboard. Task 5 Read the information above and then, using the words in bold below, complete the following paragraphs. hardwoods fast coniferous thirty needles colder Softwood Softwoods come from trees, which have rather than leaves. They don t lose their needles and grow mostly in climates. Softwood trees are growing, with most reaching maturity within years. This makes them easy to replace with new trees and therefore cheaper than. Examples: Pine, Spruce and Cedar. one hundred slow deciduous softwoods warm Hardwood Hardwoods come from trees. They grow in climates and are usually growing, hence the rings closer together and therefore making them physically harder. They can take around years to reach full maturity, which makes them more expensive than. Examples: Oak, Mahogany, Beech, Elm and Birch. 4

7 Plastic Most plastics are produced by industry using water, oil, air and salt. There are two families of plastics: Thermoplastics Thermosetting plastics Thermoplastics Thermoplastics are easily formed into shapes. They don t resist heat very well, which means they can be ground down, melted and re-used/recycled. Examples: Acrylic, ABS, Polystyrene. Thermosetting Plastics Thermosetting plastics undergo a chemical change when heated to become hard and rigid. They resist heat and fire so they are often used for electrical fittings and pan handles. This type of plastic is non-recyclable. Examples: Epoxy Resin, Melamine-formaldehyde. Task 6 Using the words in bold below, complete the word search on plastics. Thermosetting Acrylic ABS Rigid Epoxy Melted Polystyrene Oil Plastic Thermoplastic Recycle V B T Q A R Y R C L U O P T E Y N M H X Z M E L T E D F S D F G E R E C Y C L E T Y C X S D E R V P R A S D R H M L O P A Q E F O J M H A J F K E Y R C R U L X K M O B V T F A D W I V I S Y G T I S I C K C P Y T J L G X V D L C E B S R J M S I H R I C S W V N T L Y N B A V F S X D J U R I O T L D F L Z D B G F E H J Y D X I N T P O L Y S T Y R E N E H C N P R T B N Y F X D S A E G B H G W Y H F S E Y K I O P Y B M S D T H E R M O P L A S T I C K 5

8 Metal Metals are usually produced by mining ore from the Earth, then extracting the metal out of the rocks in a large scale industrial process. There are three main categories of metal although some will fit into more than one type: Ferrous Metals Non-ferrous Metals Alloys Ferrous Metals Ferrous metals consist mostly of iron and small quantities of other elements and metals. Ferrous metals are prone to rusting if exposed to moisture and can be picked up by a magnet. Examples: Mild Steel, Cast Iron, and Stainless Steel. Non-ferrous Metals Non-ferrous metals do not contain any iron at all. These metals therefore do not rust when exposed to moisture and are not attracted to a magnet. Examples: Copper, Aluminium, Tin, Lead and Zinc. Alloys These are substances that contain two or more metals, and sometimes other elements, to improve their properties. The metals are carefully chosen and mixed to achieve specific properties which may include reducing the melting point. Examples: Brass, Pewter, Casting Alloy and Duralumin. Task 7 Using the information above, complete the crossword on metals. 1. These substances contain two or more metals. 2. What this crossword is all about! 3. This metal was once used in pencils. 4. This metal can be stainless or mild. 5. The type of metal that is attracted to a magnet. 6. Plumbers use this metal. 7. Your baked beans may come in a can made of this metal. 8. A ferrous metal 9. The type of metal that is not attracted to a magnet. 10. An alloy of copper and zinc. 11. This is what happens to ferrous metals when exposed to moisture

9 Pewter Casting The mould is made by creating a hardboard sandwich. Any pieces of acrylic must be glued in place. Sprue Hardboard Acrylic Molten pewter poured in to mould Air escapes from the mould Once finished, the product would look like this. 7

10 Product Specification a list of points that should provide a detailed description of what the product must have/do/be. Task 8 Complete the Product Specification below for your individual project. Function: Target Market: Appearance: The must. (Product) The will appeal to. The should be eye catching, original and based on the theme of. Materials: The will be cast in pewter and must include a small amount of acrylic to add extra decoration. Size: Quality: The must be no bigger than 40mm x 40mm. The should have a smooth polished finish with no sharp or rough edges. Task 9 Choosing the most suitable image from Task 4, and taking your Product Specification in to consideration, sketch, colour and annotate your final design. 8

11 Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) You will use both CAD to design the mould for your product and CAM to manufacture the mould for your product. The pattern will be designed using 2D CAD software called Techsoft 2D Design. Data will then be transferred from the computer to the laser cutter, which will cut your design. This is known as Computer Aided Manufacture (CAM) 9

12 Final Design using CAD Task 10 Using the CAD package Techsoft 2D Design, produce the layout for the mould for your final design, as sketched in Task 9. Stick a print out of your work in the box below. (This should look similar to the example layout on page 9) 10

13 Health & Safety in the Workshop Pewter casting is potentially very dangerous because of the high temperatures involved. Task 11 What would you consider to be the five most important safety rules to follow when carrying out an activity like this? 1)... 2)... 3)... 4)... 5)... Task 12 Complete the table below, outling the differences between a safety sign and a poster? Safety Sign Poster 11

14 Task 1 3 In the space below design a safety sign for one aspect of safety in the workshop. (THINK: What is the difference between a sign and a poster?) 12

15 Evaluation What evidence would you give to say that your final product is a success? (THINK! Design Brief and Product Specification ) What new skills have you learned/developed? What did you find most enjoyable about the project (both design and make)? You be the judge! What are you most proud about? What did you find most difficult about the project (both design and make)? How would you improve your product if you were to make it again?

16 Extension Tasks Task E1 In the space below design an educational poster to inform young children about woods, plastics and metals. Remember to layout in pencil and add colour to your poster using colouring pencils. 14

17 Extension Tasks Task E2 Using the pictures you can see around the room, draw, colour and label all of the tools and equipment you have used to make your product. (Include both CAD and CAM equipment) 15