Methods of Manufacture

Methods of Manufacture

You are expected to demonstrate an understanding of the working characteristics of a range of materials and components that are appropriate to the manufacture of your product. Your chosen materials should achieve the performance requirements specified in your production plan (they should do what you want them to do / why you picked that material – it’s properties).

To a certain extent you have already demonstrated understanding of the materials, components and processes needed to manufacture your product. You modelled, prototyped and tested materials, components and processes. You annotated your design ideas and developments. In your planning you should have specified the materials, components and processes required to make your product. 

Although most of your practical work will involve making a ‘one-off’ product, there may be times when two or more identical components will have to be made. Your product will either be a one-off for a client, or a prototype product that could then be manufactured in higher volume i.e. injection moulded. This prototype product will still be a one-off, but it will require a different approach, shown in your Development, since its target market is wider and its manufacture may require different materials or processes to those of a one-off product for a single client.

While making your prototype you will encounter complications such as constraints related to the materials (what you can do with that type of material, the size of the bed of the machine, cost of materials), tools and equipment available to you i.e. only 1 Centre Lathe in Department – limited access. If problems occur with the availability of resources, for example, you may have to change your original choice of materials or adapt the processes you use. If this happens, do not forget to record any changes in your diary / production plan and justify any new choices of materials, components or processes. You should investigate Vacuum Casting for batch production of your prototype as this is the method used by industry to produce a small batch (about 50 – 100) for product testing / consumer testing / consumer reaction. This is done before injection moulding the final product to fully test the design before committing to the cost of tooling for injection moulding (potentially hundreds of thousands of pounds).

Other planning decisions may involve:

·       Reflecting on how easy the product was to manufacture in the time available, if it is necessary to simplify anything or if any special materials or tools are required

·       How were the components manufactured – CADCAM, Hand tools / workshop 

·       Estimating costs of materials, production costs and a possible selling price