B4.1.4 Production and design constraints Notes

Deconstructing Multi-Component Products

1. Break it into parts (e.g. handle, body, fasteners).
2. Identify the material and likely manufacturing method used (e.g. injection moulding, casting, laser cutting).
3. Consider why that method was used:
   1. Cost-effective?
   2. Stronger part?
   3. Faster to produce?

How Manufacturing Influences Design

Example

• In a smartphone, the casing might be made using injection molding, while the circuit board is produced through PCB fabrication.
• Understanding these techniques helps designers optimize production.

The Role of Components in Assembly and Function

1. Structural Components: Provide support and shape to the product (e.g., the frame of a bicycle).
2. Functional Components: Perform specific tasks (e.g., the gears in a watch).
3. Aesthetic Components: Enhance the product's appearance (e.g., the finish on a car).

Case study

Deconstructing a Laptop

• Components:
  • Chassis: Provides structural support and houses internal components.
  • Motherboard: Contains the CPU, RAM, and other critical electronics.
  • Battery: Powers the device.
  • Display: Provides visual output.
• Manufacturing Techniques:
  • Chassis: CNC machining or injection molding.
  • Motherboard: PCB fabrication and surface-mount technology.
  • Battery: Assembly of lithium-ion cells.
  • Display: LCD or OLED manufacturing.
• Assembly:
  • Screws and Clips: Secure components within the chassis.
  • Connectors: Link the motherboard to the display and other parts.

Production Limitations

Types of Production Limitations

1. Material Constraints
   1. Availability: Some materials may be scarce or expensive.
   2. Properties: Materials have specific characteristics, such as strength, flexibility, or weight, that influence design choices.
2. Manufacturing Techniques
   1. Precision: Some techniques offer high precision, while others may result in variability.
   2. Scalability: Certain methods are suitable for mass production, while others are better for small batches.
3. Cost and Time
   1. Budget: Financial constraints can limit the choice of materials and processes.
   2. Time: Tight deadlines may require faster, less complex manufacturing methods.
4. Technological Capabilities
   1. Equipment: The availability and sophistication of machinery can dictate what is feasible.
   2. Skill Level: The expertise of the workforce can influence the complexity of designs.

Case study

The iPhone

• Material Selection
  • Aluminum and Glass: Chosen for their durability and premium feel.
  • Limitations: Aluminum is lightweight but can dent easily, influencing the need for protective cases.
• Manufacturing Techniques
  • CNC Machining: Allows for precise cuts and a seamless design.
  • Limitations: High cost and time-intensive, impacting production scalability.
• Aesthetic Considerations
  • Polished Finish: Achieved through anodizing, but this process limits color options.
  • Sleek Design: The unibody structure enhances aesthetics but complicates repairs.

Balancing Function and Aesthetics

1. Prioritizing Function
   1. Example: A medical device may prioritize precision and reliability over aesthetic appeal.
2. Emphasizing Aesthetics
   1. Example: A luxury watch may focus on intricate design and high-quality materials, even if it increases production costs.
3. Finding a Balance
   1. Example: A car manufacturer might use advanced manufacturing techniques to create a visually appealing design without compromising safety or performance.