Design Brief
What is a design brief….
‘It is a short, precise, clear statement that
summarises what is required of the design
task.’
For example: I intend to design and manufacture a toy
for a five year old.
The brief should be written based on a problem or need.
I intend to design and manufacture….
SPECIFICATION
When designing a product, a designer has to make sure that it meets the design
specification.
A specification is a statement that tells the designer exactly what the product has to
do and what the design requirements are. A specification will always:
• Describe what the product has to do
• Describe what the product will look like
• Include details of any other requirements
In detail, a specification should include the following information about the product:
Do not forget you
• The main function of the product
can use the
• The main overall dimensions of the product
acronym ACCESS
• The main materials which are likely to be used
FM to outline the
• An outline of the appearance of the product
majority of points.
• User requirements
• How anthropometrics and ergonomics effect the design
• The cost of the product
• Possible production levels - one-off, batch, mass production
• Legal requirements which may have to be met
• Environmental considerations and requirements
• Moral, social and cultural issues
Aesthetics
Cost
Customer
Environment
Size
Safety
Function
Material
Aesthetics Cost -
Does the Product look good? Does it make use of its shape, colour, finish,
texture etc? What has inspired it’s appearance?
What do you expect the product to cost to produce? How much is the retail price?
How are the answers related? Is it value for money?
is it designed for? How is your product promoted to attract the customers
Customer - Who
attention? Will it have a positive impact on the customers way of life? How?
Environment - What is the products impact on the environment? What happens when it is no
longer needed? Think about the three R rule, reduce, reuse, recycle.
Size -
Is the product/packaging suitable for the product and its use? Would it look or
function better if it were changed?
you considered safety issues needed? Will there need to be warnings
Safety - Have
stated? Will the way it is going to be used change the safety?
Function Material -
Does the product or packaging do what it is intended to do?
What material will it be made from? Would a different material work better?
Will the choice of material have a direct impact on the environment?
ERGONOMICS
Whatever you are designing, it must fit the person it is
design for (usually called the customer / client). Adults
and children come in all shapes and sizes. We all like or
dislike colours, texture, sounds, tastes, flavours, forms
and shapes.
Consequently, when we design products, factors such as
these should be kept in mind. When designing a toy there
are a number of points to consider. Children learn from
sound, sight, colour, movement and other aspects. These
all contribute to the ergonomics or anthropometrics of a
design.
ERGONOMICS is mainly concerned
with working out measurements, in
order to improve the design of
products.
ANTHROPOMETRICS
Anthropometrics is the name given to the study of the physical sizes and shapes of people
in relation to the design of products. For example, chairs used in schools need to be suitable
for most of the sizes of pupils in the schools.
It enables designers to design and manufacture products that ‘fit’ the user.
Accurate data on height, weight, limb, and body segment sizes are needed to design items
ranging from clothing, furniture, automobiles, buses, and subway cars to space shuttles and
space stations.
The three main areas (parameters) that need to be taken into consideration are:
Gender
height, size, weight, strength,
and body segment proportion
Age
height, size, weight, strength,
and body segment proportion
Ethnicity
height, size, weight, and
body segment proportion
EVALUATIONS
Designers evaluate their finished products or prototypes in order to test whether they work well and if the
design can be corrected or improved. Whatever you have designed it is important to evaluate your work
constantly during the project.
Evaluation can take a variety of forms:
General discussion with other pupils, staff and others.
Questionnaires / surveys carried out at any time during the project.
Your personal views, what you think of existing designs.
Most important of all - what do you think of your designs, prototypes and finished products ?
Can you think of any other ways of evaluating your work ?
CONSIDER THE FOLLOWING POINTS WHEN WRITING YOUR FINAL EVALUATION
1. What do you think of the overall design ? What changes would you make ?
2. Are you happy with the materials you chose ? Would you make adjustments next time ?
3. Is the colour scheme exactly what you expected ? What alterations would you make ?
4. Did the project take too long to make ? Would this alter the cost of manufacture ?
5. Would it be easy to set up a production line for the manufacture of your solution ?
6. Is your solution safe ? Could it be made safer ?
7. Are the techniques you used to make your solution adequate or would you use a different range of
manufacturing techniques ?
8. Is the solution the right size/shape ?
9. What are the views of other people regarding your design ?
10. Does it work ? What changes are required ?
The final evaluation is often neglected because it is the last part to any design and make project. Do not
make the mistake of completing it quickly or not doing it all as it counts for a lot of marks.
PACKAGING SYMBOLS
Packaging symbols are widely used to clearly and easily show a certain way in which that
product should be handled or cared for. Below are just a few common examples:
This symbol reminds those handling the package
to keep out of the rain and not to store it in damp
conditions. it is normally found on card based
packages which would be damaged if wet.
The symbol seen opposite tells those handling
the package that it must be stored the right
way up. The arrows point towards the top of
the package
Created in 1988, when the Lion mark is
displayed on a product it means that the
manufacturer/retailer has agreed to the ‘British
Toy and Hobby Associations’ Code of practice.
A symbol that is occasionally seen on
packaging is the Fair Trade symbol. It means
the farmer has received a fair price for the
contents.
The two hands holding or protecting the
package is another reminder that the contents
should be handled with care
POLYTHENE TEREPHTHALATE (PET) is
a material widely used for packaging,
especially drinks containers. It is 90%
recyclable.
These are internationally recognisable symbols for
recycling. They are seen on many packages.
Again, it is to remind the consumer of the potential
recycling properties of the package he/she is about
to throw away. It is aimed at encouraging the
consumer to recycling packaging rather than
throwing it into a general rubbish bin.
The symbols here, represent that the product inside
has been tested to British and European safety
standards. These symbols that are normally
applied to non-food products such as electronic
products or toys.
This symbol is often found on the packaging for
batteries. The crossed lines means that the
batteries should not be disposed of in a dust bin
after they have been used.
Keep Britain tidy sign to remind people to not
drop litter on the floor.
The broken wine glass suggests that the product
inside the packaging could be easily damaged if
dropped or handled without care and attention. The
contents are fragile !
MORAL SOCIAL AND CULTURAL ISSUES
Moral issues are key points that the designer has to make to decide if
something could be dangerous or controversial. They are not covered
by any law or design regulation, and are usually related to a specific
target market. For example, a poster designed to help discourage
teenagers to stop taking dangerous drugs would be morally correct.
Social issues relate to the type of advertisement or promotion of
products for use or consumption that may not be in the interest of the
general consumer. These are related to the wider public in general.
For example, the promotion of fast food, high sugar sweets and
drinks.
Cultural issues are quite specific to the product and its advertising or
packaging. They are quite dependant on the actual target market. For
example, most packaging for vegetarian products will have a large
green ‘V’ in a prominent place to show that it has no animal
products.
KEY DESIGNERS
There are literally millions of designers around the globe yet some are a lot more
influential than others. Most people have their own influential designers due to taste,
likes and dislikes but all designers are influenced by the past present and what they
think the future should or could look like.
You need to be able to recognise some key designers and their work so that you know
and understand the impact they have had on current designers and work. Below are a
few key designers that you will need to research and know and understand a little bit
about for your final exam:
• Harry Beck – Was an English Engineering Draftsman. He crated the iconic and very
distinctive London underground map whilst working at the London Underground signals
office in 1933.
Although it was a very radical design, looking like an electrical wiring circuit diagram,
rather than a map, it proved to be a huge success and although changes have been
made since the original version, the current map is still very close to the original.
Many other companies around the world use his Designer of the famous London
underground map making it simple and easy to read.
KEY DESIGNERS
•Alberto Alessi - The Italian design manager joined the family company of making metal
kitchenware as design manager after training to be a lawyer. His vision was to combine mass
production with good design creativity and craftsmanship, so that well designed and stylish
products could be made available for everyone.
Alessi’s main contribution to design is not based on products he designed, yet his whole
philosophy about products that inspired the likes of Philippe Starck and Alessandro Mendini to
come up with stylish, creative and interesting products that could appeal to everyone. Alessi
wanted his company to be an ideas factory.
• Jock Kinnear and Margaret Calvert - The road signs in the 1950’s were very hit and miss and
finding your way became dangerous. Jock and Margaret first developed the ‘typeface’ they
would use called sans serif before adopting the idea of using pictograms (a 2D block coloured
picture that explains a meaning or warning) to help “everyone” understand the possible
warnings. The colours used were also there idea as they thought they are a simple yet bold
enough colour to easily read and see.
KEY DESIGNERS
•Wally Olins - Branding is a logo or image that is associated by the public with a product.
Companies use graphic design to promote their products through a branding or corporate
image. Wally is a brand consultant that has helped companies like P&O and BT develop a
very successful corporate identity.
Great examples of these are Nike’s tick and Cadbury’s glass and a half of milk.
• Robert Sabuda - Used to love pop-up books as a child and as a result taught himself paper
engineering; precise accurate mechanisms made from paper, and specially designed to
enable the desired actions to take place.
After working for several publishers, Robert published his own books himself. He has won
many awards and prizes for his unique, fun and style of pop-up books, cards etc. that are
enjoyed the world over.
EQUIPMENT
A drawing compass is a drawing
tool that can draw circles and
arcs (incomplete circles) on
sketches and diagrams
A circle template is used as
a guide or template for
drawing circles with different
diameters without the use of
a compass.
A circle cutter is used
to cut the circle out
directly rather than
Locking drawing it first. You
nut
set the diameter just
like a compass and
use the blade to draw
Compass
and cut the circle out.
point
Handle
Scale
Blade
A rotary cutter looks very
similar to a pizza cutter and is
used in the same way,
however, as the blade is very
sharp it is used to cut through
fabric, card and paper. You
can change the blade to suit
your desired edge, for
example wavy or dotted.
A scalpel or hobby knife
is a sharp knife used for
cutting through card or
paper giving it a clean
and neat edge. Most
allow you to change the
blade when it becomes
blunt.
These are just a few of the different
equipment pieces that could be
used whilst making your products.
Be sure to look for and revise them
all though.
SKETCHING/DRAWING TECHNIQUES
Isometric is the best method of showing three
dimensional (or pictorial) views of an object and can be
done using freehand or drawing equipment.
When drawing in isometric, ensure that:
• All upright lines remain upright
• All horizontal lines are at 30°
• All measurements remain the same (full size as given)
30°
The thick and thin line technique is easy to
remember - If you can see both of the faces (or
sides) which make up the edge of the shape
then draw a thin line to represent it. If you can
only see one side, draw a thick line.
30°
SKETCHING/DRAWING TECHNIQUES
Orthographic drawings contain all the information needed to make an item. Therefore this information must
be accurate.
Orthographic drawings usually show three views of the object:
• The plan (from above)
• The front elevation (front view)
• The side elevation (side/end view)
The way orthographic drawings are laid out is defined by a British drawing Standard. This standard is
BS8888. You need to ensure that your dimensioning is done to BS8888 in order to gain full marks.
Third angle projection is the standard layout you will be expected to use in the exam. Always make sure
that the view you see from the right of the original object (front view) is drawn on the right. The view
from the left is drawn on the left and what you see from above is drawn above (the front view).
Hidden detail is shown as
dotted lines.
A simple example
of a 3rd angle
orthographic
projection
3rd angle
projection symbol
SKETCHING/DRAWING TECHNIQUES
One and two point perspective is based on the fact
that all lines will meet at either one or two vanishing
points.
One point perspective is made using one vanishing
point. All horizontal lines meet together at one
vanishing point. A good example of this is when you
look down the railway line or straight road and the
lines all seem to meet at one point as the image
opposite suggests.
Two point perspective is a little more complicated
as there are no horizontal lines. Instead, all nonvertical lines should be drawn going to either one of
the two vanishing points on the horizon as shown in
the diagram to the right.
TYPES OF LINE / DIMENSIONING
There are lots of different line types that are needed when drawing in graphics. The
main ones you will need to know are:
Outlines - Thick and continuous
Section / Projection lines - Thinner than outlines
Center lines - Chain, long then short dash
Hidden detail - Short continuous dashes
Dimension Lines - Lighter than outlines with
arrow heads that touch the line it meets.
Cutting line - Long line followed by two short dashes
Dimensions are always in
millimetres.
205
205
Dimensioning correctly means you need to keep to the British Standard 8888. This states
that your dimension needs to written be above the line but not touching it or the drawing. If
it is from the side then it needs to be able to be read from the right.
From the right
INFORMATION DRAWING
Data is probably best represented through the use of
charts or graphs as it is simple to understand and easy to
conclude from. It can be represented in a number of ways:
• Bar charts - great for showing comparisons
• Pie charts - great for showing proportions
• Line graphs - used to show the changes in data
• Pictographs - using symbols that the information refers
to, to represent data.
Corporate identity is the primary method of making an
organisation identifiable using only visual images that can
be easily remembered.
Most companies use a logo to help the general public
recognise them. This is usually a combination of type and
symbols however, there are several different types of
logo:
• Logograms - use the initial letters of an organisation.
• Symbols - use a simplified image.
• Logotypes - use a different typeface.
• Background - an image used to communicate
information to the customer.
Information can be described in a
number of different ways but it is
sometimes easiest to see and
read in a graphical form.
Signs and labels are around or attached to
everything we interact with on a day to day basis.
The majority of signs are there to give us
instructions or warnings about certain things. These
need to be eye-catching and clear. Good examples
are road work signs.
Labels tend to explain a lot about the things we buy
or use giving us clear information. Great examples
of these are barcodes, nutritional information,
washing instructions on clothes and ingredients on
food packaging.
Symbols are visual images used to communicate
information to help people. There are three
different types of symbols:
• Enactive or action - Showing something
happening.
• Iconic or pictorial - Wordless simplified images
(often called pictograms)
• Symbolic or abstract - To represent something we
can recognise from the concept the image is
portraying.
Ideograms are simplified images or pictures which
relate to other people or things. For example, you
would relate a picture of a plate, knife and fork to
somewhere you can eat.
This is only a selection. You need to revise more.
MATERIALS
Corrugated card is used widely
for packaging as it is strong
and gives rigid support for the
products inside. The internal
structure differs depending on
the situation it is needed for.
Styrofoam is used a lot for
model making as it is very
dense and easily
manipulated making it very
versatile for lots of designs.
Corriflute (polypropylene
corrugated board), is similar
to corrugated carboard in its
structure but made from
plastic and used a square
structure instead of a wavy
form. It is used mainly for
packaging or POS displays.
Foam board is rigid foam
sandwiched between two
pieces of heavy paper. It
comes in a variety of
colours and finishes. It is
usually used for POS and
model making.
Card is also available in a
large variety of colours,
finishes and sizes,
depending on the
situation. They can also
come textured if required.
Paper is used very widely
for most items and
graphic products. It
comes in a wide range of
finishes and sizes
depending on the
situation needed. For
example, A0 is sixteen
times the size of A4.
PAPER AND BOARD
The main factors that are taken
into account when choosing a
paper or board are:
• Cost
Corriflute or Correx is a fluted plastic board
(similar to corrugated board) and used mainly
for exterior purposes as it is light and strong but
also weather resistant. A common use for this
material is estate agent for sale boards.
• Finish
• Strength
• Brightness (whiteness)
• Thickness
Paper is sold by weight in grams per square metre
(gsm). When it gets to 220 gsm it is considered
board.
Board (card) is measured in microns (µm). There are
1000 microns in 1 mm. A typical birthday card is
about 300 microns thick.
Foam board is generally between 4000-7000
microns thick and is made from two outer layers of
high-quality card and a central layer of foam. It has
quite a high cost ratio in comparison to other
materials and is generally used for presentation
boards.
Corrugated card is a very common type of
boards used mainly for packaging protection
and point of sale stands. This is due to the card
being quite thick, between 3000-5000 microns,
giving it a strong yet fairly lightweight
construction.
Virgin paper makes up 90% of all paper and the remaining 10%
has some recycled content. Virgin paper tends to be stronger and
generally used for food containers, helping to reduce contamination
risk.
PLASTICS
95 percent of all plastics are made from the nonrenewable and environmental unfriendly material - oil.
The other 5 percent is made from animal and vegetable
matter which is biodegradable and therefore
environmentally friendly.
Plastics are widely used in packaging due to their large
list of benefits. These include:
• Tough - so that the product is protected.
• Lightweight - So that the product is not made to be
heavy.
• Clear - So that the consumer can see the product
inside.
• Economical - Easily available and easy to make
packaging from.
There are many different types of plastics
used for packaging, each with their own
advantages and disadvantages. Most of
them come with their own distinct recycling
sign stating what type of plastic it is, as
shown below.
There are however, 8 main different types of
thermoplastic used in packaging. These are
stated below and highlighted in Yellow.
It is now your job now to find out a little more
information about each one.
• Aesthetically useful - It is easy to be made to look good
and can be printed on.
PETE - Polyethylene Terephthalate
HDPE - High Density Polyethylene
V - Expanded Polystyrene / Styrofoam
PVC - Polyvinyl Chloride
LDPE - Low Density Polyethylene
PP - Polypropylene
PS - Polystyrene
Other - All other recyclable plastics
Acrylic
Cellulose Acetate
Bioplastic
SHAPING AND FORMING
PLASTICS
Vacuum forming is used to create fairly simple
hollow shapes using a heated plastic such as
polystyrene or PVC.
An accurate former or mould is made first of all with
the same detail that you want the finished plastic
form to have. This former is then placed at the
bottom of the vacuum former.
The plastic is then clamped in place above the
mould and heated up until it softens. The plastic
must not touch the former at this stage.
Injection moulding is the most common process
used to shape many different ‘thermoplastics’ into
the many different shapes of products and
packaging you see around you everyday.
Injection moulding involves heating up plastic
granules of a thermoplastic into a liquid and forcing
it into a metal mould before allowing it to cool and
then solidify. This is then taken from the machine
ready for it to be done again and again right after
each other.
The former or mould is then raised into the heated
plastic sheet before the air is sucked or vacuumed
out from underneath the former so that the plastic
takes the same shape as the former. The plastic is
then allowed to cool before the mould is taken out
leaving a hollow plastic shape the same as the
former.
Blow moulding is the process in which plastic is
heated up and forced into a mould.
Compressed air is then forced into the mould
making the plastic expand into the same shape
before cooling down and being released e.g. a
plastic drinks bottle.
PACKAGING
Stacking and storage is fairly critical to
ensure that a product is able to be stored
and stacked on each other both in the
warehouse or on the shop floor creating
less wasted space yet keeping the product
safe inside. Some products however, have
over packaging - where too much
packaging is used to help advertising; under
packaging - where too little packaging is
used and therefore doesn’t protect the
product; and deceptive packaging - where
the package gives the customer a false
impression of the product inside.
Information is now a legal requirement on
most products, ensuring that the customer
knows exactly what the product is inside the
packaging and what it contains.
There are 5 main reasons for packaging:
• Stacking and storage
• Information
• Protect
• Preserve
• Promote
Protection is key in order for the product to
make it to the customers house in perfect
condition. Materials such as corrugated
card, bubblewrap and expanded
polystyrene are good examples.
Preserving is mainly used within food
packaging to keep the contents fresh and
edible. The packaging often acts as a
barrier against air, therefore an airtight seal
is needed.
Promotion is a large part of ensuring that
the product is bought by the customer.
Large graphics and good use of bright
colours are often incorporated into the
design of the packaging to help catch the
eye of the customer.
SMART MATERIALS
"Smart" materials respond to environmental stimuli with particular changes in some variables. For that
reason they are often also called responsive materials.
Depending on changes in some external conditions, "smart" materials change either their properties
(mechanical, electrical, appearance), their structure or composition, or their functions.
Photochromic materials change
colour in response to light.
They are colourless in a dark
place, and when sunlight or
ultraviolet radiation is applied
molecular structure of the
material changes and it exhibits
colour. E.g. light sensitive
sunglasses.
Hydrochromic materials
change colour depending
on the amount of water
applied. For example,
moisture testers for
watering plants.
Thermochromic materials
change colour depending
on their temperature.
‘Thermo’ means heat
and ‘chromic’ means
colour. E.g. temperature
gauges.
Electrochromic materials
change colour depending
on the amount of
electricity applied, for
example, liquid crystal
displays (LCD) in clocks
or watches.
Phosphorescent
materials absorb light
energy during the day
and give this energy off at
night. For example watch
hands that glow in the
dark or glow in the dark
stickers.
MODERN MATERIALS
The greatest modern technology is within the
alternatives to the use of thermoplastics being
used within packaging and modeling.
Cornstarch Polymers are derived made from
crops such as potatoes, corn and maize
which are high in starch. They are used to
replace some of the oil based thermoplastics
that are more commonly used in some food
packaging as they are biodegradable
although not as versatile.
Polymorph is a unique plastic that is hard at
room temperature yet can be softened at 60
degrees to be easily molded into any shape
needed. It can be machined when hard and
returns to its hardened form when the heat
is taken away.
Lyocell is a high strength paper fibre
produced from wood pulp and is completely
biodegradable within eight days if placed
within damp conditions. It is used to make
tea bags, envelopes and coffee filters.
A modern material is not ‘smart’ as it does not
react to its surroundings but it is a new
material that has been created within the last
50 years.
Paperfoam is made from a combination of
starch based polymers and simple paper
fibres. This produces a material that is
scratch resistant and can be molded to
form inserts to different packaging. It is
fully biodegradable, weighs less than oil
based plastic and can be dyed to any
colour.
Nano technology is a method of changing
the atomic structure of materials to make
them better. For example, nano technology
can make materials lighter, stronger, less
expensive. For example, manipulating
carbon to create a diamond.
PMC (precious metal clays) are made of
99.9% metal and 0.01% clay. This gives the
metal an amazing ability to be shaped at
room temperature. They are expensive
however and used mainly by jewelers.
SUSTAINABILITY
Sustainability looks at the ways in which an item tackles the situation of making as
smaller an impact on the environment as possible.
Examples of this are:
• Can the packaging be made from a more sustainable material? Does it have an
impact on the environment?
• Can technology be used to develop alternative energy sources to manufacture the
item?
• Will the final product be priced to high for people to purchase it?
The six R’s are used to help designers and manufacturers reduce the environmental impact
that a product may have. These are:
• Rethink - Is there other solutions to make the product more environmentally friendly?
• Refuse - Will the consumer accept the item or refuse it due to it’s sustainability issues?
• Reduce - Can the product use less energy or material to manufacture? Should the
consumer buy a product that is not being sustainable?
• Re-use - Can the product or packaging be re-used after its initial purchase?
• Repair - Is the product repairable or is it designed to fail?
• Recycle - The last resort to all items really, but can the packaging or product be recycled to
become more efficient and sustainable?
FLOWCHARTS
There are three main flowchart shapes that would be used within a process or
flowchart for the manufacture of your product or any prototype you may need to
suggest in your exam.
There are a lot more shapes used in large scale production runs, however these
are the three main ones that you will need to know about.
Terminator – This is
used to start and
stop flowcharts.
Process – This is
used for every
process throughout a
flowchart.
Decision – This is
used for each
decision option within
a flowchart.
PRINTING PROCESSES
There are many different processes for printing many different types of media.
• Offset Lithography
• Letterpress
• Gravure
• Screen Printing
• Flexography
• Digital printing
Physical products are still being printed on for all different purposes even though the
modern world is dominated by the world of the internet. We still need magazines,
books, stationary, newspapers, plastic bags etc. for everyday use.
All printing is the process of transferring text or images onto a substrate.
PARTS OF THE PRINTING PROCESSES
There are 3 main parts to any printing process. These
are :
• Ink – These are generally a runny fluid that comes in
many different colours. They tend to have many different
chemicals in them to help them set, dry quickly etc.
therefore they need good ventilation for health and
safety. The main colours are Cyan, Magenta, Yellow and
Black. These are more commonly known as CMYK
(K meaning black - a key colour)
• Image Carriers – This is a physical component on
which the image to be printed, is either cut, burnt or
machined.
• Substrates – These are the products that are printed
upon.
Offset lithography
• Flat aluminium plates
(specially treated)
• Photographically exposed
then wrapped around roller
• Exposed parts attract water
• Non exposed parts allow ink
to stick
• Print onto plain roller to
reverse image
• Transfers to card or other
materials
Printing card
• Typically offset lithographic or gravure
process used
• 4 process colours – yellow, magenta, cyan,
black
• Varnishing, foil blocking, embossing are
common
GRAVURE PRINTING
• Used for very large print
runs
• Uses engraved plates
Impression cylinder
• Ink is held in recesses
Paper
known as cells
• Paper is pressed onto
Ink cells cut
plate and ink is lifted
in cylinder
Doctor blade
from cells
scrapes excess
ink from cylinder
Ink Trough
PRINTING TERMS
•Process colours – yellow, magenta and cyan
make full range of colours, black adds definition
(and text)
•Spot colours – mixed to exact colour
•Web offset – printed onto a roll (e.g.
newspapers)
•Plate – has the image on, wraps around a
cylinder
•Offset cylinder (or blanket cylinder) – reverses
image
•Impression cylinder – presses paper onto plate
•Varnish – adds shine (or could apply a matt
finish) to print, sometimes in isolated areas
•Substrate – material to be printed e.g. paper
OTHER RELATED PROCESSES
• Die-cutting is the method most paper/card shapes are cut
out (very similar to a pastry cutter). In the packaging industry
the cutter is known as a cutting forme.
• Foil blocking is a method of applying a very thin layer of
metal foil onto the surface to add a special effect
• Embossing is the method where the surface of the card is
pressed upwards to create a special effect
• Varnishing gives a smooth and shiny finish to the image
making it look better and adding some protection.
• Laminating provides a greater protection than simple
varnish. It involves heat sealing a thin layer of a clear plastic
to the printed surface.
• A surface development is a 2D, or flat, version of an item
that will be eventually assembled into a 3D object.
A FEW EXAM TIPS
• Offset lithography is the best answer
for any questions relating to the
printing of card packaging.
• Flexography is the best answer for
any question relating to the printing of
plastic film (such as carrier bags).
• Printing is a finishing technique
suitable for card and some other
materials.
MANUFACTURING METHODS
There are quite a few different types of production methods although only a few
would normally be used for graphic products. The main ones that you will need to
understand are:
Batch production – This technique is used when an
item is produced over a series of different
workstations stage by stage. For example, seasonal
items as the company does not yet know the
demand for the product.
Mass production – This is used to
produce standardised items on a very large
scale yet is not a continuous run. For
example, this is used for chemical product
on an assembly line.
One-off production – This is where a single
item is made for a certain or specific purpose.
For example, a car with specific requirements
such as colour, interior, heated seats etc.
Continuous production – This is, as the
name suggests, a continuous production
run that does not stop. It works 24/7, 365
days a year and is used to produce items
such as coca-cola cans.
DESIGN ANALYSIS
Tips for successful product design analysis
• Make sure you understand what the product actually does
and how it works.
• Learn carefully how products are made in industry - especially
look at what materials are used and how they are cut, shaped,
formed, joined and finished.
• Apply this knowledge to the product you are asked to analyse.
• Think carefully about possible markets for different products:
Who would buy the product? Why would they buy it? Where
would it be used? Who would use the product?
CAD/CAM
Computer Aided Design (CAD) - This is using the computers to assist the designer during
the design process itself. Computers can be used very effectively when designing and making
graphic products. An example of the tasks that can be done are:
• Import images
• Continually edit and revise work
• Create animated sequences
• Create accurate models with real render
• Communicate designs
These all help to save time and money, encourage experimentation and enable more
information to be stored amongst other things.
Computer Aided Manufacture (CAM) - is the manufacturing process of the item through a
computer system. There are also lots of benefits of using IT in manufacturing processes.
Some examples of these are:
• Simulate and test products
• Monitor accurate costs
• Control machinery
• Control the flow of material used in manufacturing
• Communicate information
• Improve health and safety.