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Year 10 Resistant Materials - The Car Scraper and Jig

The Task

To design and make a hand held polystyrene windscreen scraper. The scraper will be shaped and drilled accurately using a jig, which the pupils will also make from m.d.f.

Setting The Task

As part of the course students need to examine methods of manufacturing. We will use this project as a vehicle to examine Batch Production.

· For pupils to understand the importance of using a jig and how and why it is used in industry.
· For pupils to use materials other than metals ( polystyrene)
· For pupils to make an accurately made product.
· For pupils to understand the properties of different materials.
· For pupils to make a jig and the scraper.
· For pupils to learn of anthropometrics.
· For pupils to create a quality finish (edge treatment).

· To understand what batch production is as opposed to mass production.
· To use a variety of materials and to understand the properties of materials (polystyrene as opposed to acrylic).
· To understand the importance of a quality finish in relation to jigs.
· To further they're designing skills.
· To understand industrial processes.


The Nature Of The Product

· Each pupil will design and make a suitable hand held car scraper.
· Each pupil will develop a jig to accurately drill and shape the scraper.
· Each pupil will test their scraper to establish if it meets the specifications and original design brief.
· Each pupil will evaluate the scraper and jig
· Each pupil will (using a c.a.d package) design The scraper and jig in orthographic projection.
· Each pupil will produce a spreadsheet to cost out the project and decide upon a suitable price for his or her scraper.

Technical Knowledge and Understanding

· Importance of accuracy and consistency in batch production.
· Edge treatment of acrylic and polystyrene.
· Properties of materials and the suitability of materials for a job.
· Costing a product.
· Quality of finish.

Tools and Equipment Needed

· A Hegner. Marking out equipment.
· Coping saws. Plastic polish.
· Belt sander. U.H.U glue and P.V.A. glue.
· Pillar -drill and drill bits. Panel pins.
· M.D.F Pin hammers.
· Polystyrene.
· Glass paper
· Buffing Machine and polishes
· Scraping


Using Mathematics

· Marking out and measuring.

Using I.T
· Spreadsheets.
· C.A.D packages.
· D.T.P.

Using Science
· Properties of materials ( hardness, malleability,
brittleness, protection against natural elements.)

Using Other Subjects
Using Economic And Industrial Understanding

· Batch production and Industrial processes.

Programmes Of Study References

1a Assignments in which they design and make products. Taken together these assignments should require activity related to industrial practices and the application of systems and control;
3a To develop and use design briefs and detailed specifications;
3c To design for manufacturing in quantity;
3f To determine the degree of accuracy required for the product to function as planned, taking account of critical dimensions and tolerances in determining methods of manufacture;
3g To generate design proposals against stated design criteria, and to modify their proposals in the light of on-going analysis and product development;
3h How graphic techniques, I.T equipment and software can be used in a variety of ways to model aspects of design proposals and assist in making decisions;
3k To apply and apply test procedures to check the quality of their work at critical points during development, and to indicate ways of improving it;
3l To ensure that the quality of their products is suitable for intended users.
4b To use tools and equipment accurately and efficiently to achieve an appropriate fit and finish and reliable functioning in products that match the specification;
4c A range of industrial applications for a variety of familiar materials and
4e How products are manufactured in quantity, including the application of quality control and assurance techniques;
4k To apply and devise test procedures to check the quality of their work at critical points during development, and to indicate ways of improving it;
4l To ensure through testing, modification and evaluation, that the quality of their products is suitable for intended users.
7e The application of scientific principles;
8d Its impact beyond the purpose for which it was intended, e.g. the impact on the environment;
8e How far it meets manufacturability and maintenance requirements
5a How materials are cut, shaped and formed to designated tolerances;
5b How materials can be combined and processed to create more useful properties, and how these properties are utilised in industrial contexts;
5c How materials are prepared for manufacturing, allowing for waste and fine line finishing;
5d About a variety of self-finishing and applied finishing processes, and to appreciate their importance
For aesthetics and functional reasons;
5e That to achieve the optimum use of materials and components, account needs to be taken of the complex interrelations between material, form and intended manufacturing processes;