Choosing the Right Material: Balancing Performance, Aesthetics and Context
- In product design, choosing a material is rarely about one property.
- Instead, designers must balance functional needs, aesthetic qualities, and contextual factors, all backed by research and real-world considerations.
- Think of material selection like choosing the right ingredients for a recipe.
- Each ingredient (material) has specific properties (flavors, textures) that contribute to the final dish (product).
- Balancing these properties ensures the desired outcome.
1 - Functional Performance: Selecting for Properties
- A material must perform effectively in its intended use.
- Designers evaluate three main categories of properties:
- Physical properties: e.g. density, conductivity, thermal expansion
- Mechanical properties: e.g. strength, hardness, ductility
- Chemical properties: e.g. corrosion resistance, flammability, reactivity
- In the aerospace industry, carbon fiber composites are often chosen for aircraft components due to their high strength-to-weight ratio and resistance to corrosion.
- This selection is critical for improving fuel efficiency and reducing maintenance costs.
2 - Aesthetic Appeal: Selecting for Look and Feel
- A product’s appearance and tactile experience shape user perception.
- Designers consider:
- Colour, texture, and form
- Light reflectivity (matte vs gloss)
- Finishing techniques (e.g. anodising, painting, polishing)
- These choices impact brand identity and user experience, especially in consumer goods.
3 - Real-World Considerations: Cost, Availability & Sustainability
- Even the best-performing, most beautiful material may not be practical.
- Designers must weigh:
- Cost-effectiveness at the required scale
- Availability (local supply chains reduce carbon footprint)
- Sustainability (renewable or recyclable materials, ethical sourcing)
Cost
- Initial Cost: The price of raw materials and processing.
- Lifecycle Cost: Includes maintenance, repair, and disposal costs.
Material: Mild Steel for a Bridge
- Initial Cost: cheap and easy to fabricate
- Lifecycle Cost: prone to rust and must be:
- Regularly inspected
- Frequently repainted (often every 15–20 years, or even more frequently in harsh environments)
- Maintained with specialised coatings, which are labor-intensive and costly
Availability
- Local Availability: Reduces transportation costs and environmental impact.
- Global Availability: May offer a wider range of materials but can be affected by geopolitical factors and supply chain disruptions.
The Ukraine War and Global Grain Supply
In 2022, the war in Ukraine disrupted one of the world’s largest exporters of wheat, corn, and sunflower oil. These materials are not only essential for food production but also used in biodegradable packaging, biofuels, and bioplastics, materials increasingly favored for sustainable product design.
As exports halted, global prices surged, and countries dependent on Ukrainian grain faced shortages. Designers and manufacturers had to rethink material choices, often turning to local alternatives or synthetic substitutes. This highlighted the importance of supply chain resilience, ethical sourcing, and material adaptability in design decisions.
Availability is not just about physical access to materials, it also involves ensuring a reliable and sustainable supply chain.
Sustainability
- Environmental Impact: Consideration of the material's carbon footprint and recyclability.
- Carbon Footprint: The total greenhouse gas emissions associated with a material's production, use, and disposal.
- Recyclability: The ability to recover and reuse materials at the end of their lifecycle.
- Ethical Sourcing: Ensuring materials are obtained without exploiting workers or ecosystems.
Justifying Material Choice with Research
Primary Research
Research carried out directly by the user through testing, observation, or data collection to gather original insights.
Secondary Research
Research undertaken by someone other than the user.
- Good design decisions are evidence-based.
- Designers use:
- Primary Research
- Prototype testing
- User feedback
- Performance trials
- Secondary Research
- Supplier datasheets
- LCA (Life Cycle Assessment) reports
- Industry benchmarks or case studies
- Primary Research
Steps in Material Selection Based on Research
- Define Requirements
- Identify the functional, aesthetic, and environmental criteria
- Consider factors such as strength, weight, cost, and sustainability
- Conduct Secondary Research
- Review material databases and literature
- Analyse case studies to learn from similar projects
- Perform Primary Research
- Test materials through prototyping or experiments to evaluate performance
- Gather feedback from stakeholders or end-users
- Analyse and Compare
- Use tools like decision matrices to compare materials against criteria
- Consider trade-offs between cost, performance, and sustainability.
- Justify the Selection
- Present a clear rationale for the chosen material, supported by research findings.
- Address potential risks and mitigation strategies.
Use a decision matrix as its more powerful than a simple numbered table because it lets you weigh criteria by importance, making the outcome more balanced and relevant to the design priorities.
How do cultural and economic factors influence material selection in different regions?
Checklist: Selecting Materials for a Specific Application
- Identify the requirements: What does the product need to do? (e.g. support weight, resist heat, flex under pressure)
- Prioritise key properties: Which physical, mechanical or chemical properties matter most?
- Evaluate trade-offs: Is it better Cheaper or more sustainable?
- Consider cost and availability: Is the material affordable and easy to source?
- Check environmental impact: Is it recyclable, biodegradable, or responsibly sourced?
Reflection and Application
- Selecting a material is like choosing the right fabric for a garment.
- It must be comfortable (functional), look good (aesthetic), and fit within the budget (cost).
A glass table top might look sleek and modern (aesthetic), but if it’s too reflective or prone to smudges (functionality), it might frustrate users.
Apple’s MacBook uses an aluminium unibody chassis that strikes a careful balance between:
- Physical properties: Lightweight for portability.
- Mechanical properties: Strong and rigid to protect internal components.
- Chemical properties: Corrosion-resistant to extend product lifespan.
- Aesthetic appeal: Sleek, matte metallic finish conveys precision and premium design.
This combination contributes to the MacBook’s reputation for both durability and style.
In the table below, you have been presented with the functional and aesthetic requirements for a reusable cup. Can you identify a suitable material based of these requirements?
| Category | Key Requirement |
|---|---|
| Physical | Lightweight |
| Mechanical | Impact resistance |
| Chemical | Resistant to corrosion |
| Aesthetic | Glossy finish |
- Did you identify a material that satisfies all the key requirements for the product?
- Were any compromises necessary, and if so, which properties were prioritised?
