Implementation and

realisation
PROCEDURES AND MAKING PREPARATION
At this stage of the designing process a solution to the problem has
been found and the client and users are happy with the design. The
next stage is to prepare for production.
The drawings and research that have already taken place will be the
foundation for this stage.
MARKING OUT
Marking out is where the raw materials are drawn on to mark out the
sizes from the drawing in preparation for cutting.
When a piece of material has been prepared from a cutting list, it is
always advisable to check that the sizes are correct (quality control).
The material is then ready to mark out in preparation for machining,
shaping, cutting, and so on.
A datum needs to be prepared. Datum is an accurate line where all
measurements will be taken from.
Tools for marking out
When marking out, it is important to take your time, do it very
accurately and check against your orthographic drawings.
Making mistakes here could mean materials are wasted, which can cost
valuable time and money. Always ensure:
• that sharp marking out tools are available
• that marking out guides are placed accurately on materials
• that you check for accuracy against the drawings.
On the next slide is a table of common marking out tools in a basic
workshop situation.
 Tool Paper/card Wood Metal Plastic

✓ ✓
Pencil

✓ ✓ ✓
Marking Knife

✓ ✓
Scriber

✓
Marking gauge

✓
Odd leg calipers

✓ ✓
Crayon

✓ ✓ ✓
Tri-square

✓ ✓
Engineer’s square

✓ ✓ ✓
Compass

Templates ✓ ✓ ✓ ✓
SELECTING APPROPRIATE PROCESSES FOR MAKING
The products all around us are made from a huge variety of materials.
These materials are cut, shaped, formed, joined, fitted together,
finished and tested, once again, by a large variety of machines and
equipment.
Many of the processes available in industry will not be available in your
school.
However, having an awareness of industrial practices is important so
that you appreciate commercial techniques.
Here is a table that loosely categorises materials with industrial
processes.
 Paper Electronics Wood Plastics Metals
and card
Shaping Laser cutting ✓ × ✓ ✓ ✓
Cutting Planing × × ✓ × ×
Laser cutting ✓ ✓ ✓ ✓ ✓
Shearing ✓ ✓ × × ✓
Die cutting ✓ × × × ×
Sawing × × ✓ ✓ ✓
Wasting Abrading × × ✓ ✓ ✓
Turning × × ✓ ✓ ✓
Milling × × ✓ ✓ ✓
Routing × × ✓ ✓ ✓
Drilling ✓ ✓ ✓
Finishing Laminating ✓ ✓ ✓ ✓ ✓
Painting:
- oil based ✓ × ✓ × ✓
- solvent based ✓ ✓
- water × × ✓ × ✓
 Paper Electronics Wood Plastics Metals
and card
Moulding Injection moulding × × × ✓
Blow moulding × × × ✓ ×
Rotational moulding × × × ✓ ×
Extrusion × × × ✓ ✓
Compression moulding × × × ✓ ×
Joining Adhesives: - solvent × × × ✓ ×
- superglue ✓ ✓ ✓ ✓ ✓
- PVA × × ✓ × ×
- hot melt glue ✓ ✓ × × ×
- epoxy ✓ ✓ ✓ ✓ ✓
- contact ✓ × × ✓ ×
Welding × × × × ✓
Ultrasonic welding × × × ✓ ×
MIG welding × × × × ✓
 Paper Electronics Wood Plastics Metals
and card
Fitting Rivets ✓ ✓ ✓ ✓
Nuts and bolts ✓ ✓ ✓ ✓ ✓
Screws × × ✓ ✓ ✓
Nails × × ✓ × ×
Knock down fitting (KD) × × ✓ × ×
Staples ✓ × ✓ × ×
Casting Sand casting × × × × ✓
Pressure die casting × × × × ✓
Lost wax casting × × × × ✓
Printing Gravure ✓ ✓ ✓ ✓ ✓
Sublimation ✓ ✓ ✓ ✓ ✓
Lithographic ✓ × × × ×
Laser ✓ × × × ×
Screen ✓ × × ✓ ×
Etching ✓ ✓ ✓ ✓ ✓
FIXING AND JOINING TECHNIQUES
When making a product, the different sub-assemblies (parts) need to
be joined together.
There are two main ways of joining parts:
permanently or non-permanently.
The type of fixing/joining methods used will depend on many variables,
such as:
• Are the materials the same/different?
• Does the product need to be taken apart for maintenance/recycling?
• How strong does the join need to be?
• Should the join be visible/hidden?
For example, you wish to join a piece of acrylic to some sheet metal.
Will it need to be permanent? If so you may choose an adhesive such as
epoxy resin. If non-permanent, then you may possibly use a nut and
bolt made from steel/nylon.
Standard components
A pre-prepared part that is used in the production of many products.
Are common components used in manufacturing and consumer items.
Example,
- a battery operated torch comes with standard batteries. The
manufacturer of the torch does not make the batteries.
-Standard components used in manufacture are nuts and bolts.
- In the electronics industry, most components are standard and the
combination of components create a range of circuits to perform
different tasks.
Knock-down fittings
Are standard components that are used to temporarily/permanently fix
materials together, normally using only a screwdriver, drill, hammer or
other basic tools.
They are common in modern flat-pack furniture that consumers can
build at home.
Both manufacturers and consumers benefit from knock-down fittings
as costs are reduced by putting the assembly element of the product
construction in the hands of the consumer, therefore reducing
manufacturing costs and the costs of the product.
Example of knock-down fitting, plastic corner block, use as kitchen
cabinet carcasses.
Tolerances
When preparing materials and components for manufacture, each part
usually has a size tolerance.
This is the acceptable error of the dimension.
For example, a piece of steel rod for a lamp needs to be 1000mm long.
If it has an acceptable tolerance of 1% then the material could be in the
range of 990 mm to 1010 mm to be acceptable in a quality control
check. If parts are outside their tolerance range they may not fit
together.
Question
1. what are the benefits to the user of standard components and KD
fittings?
2. why are KD fittings and standard components beneficial to
manufacturers?
3. what is a material tolerance?
4. why is marking out so important?
5. what tools and equipment would you use to mark out a sheet of
aluminium?
FURTHER WORK (SKILLS ACTIVITY) ON PAGE 46 TO 47 QUESTION 1 TO
4.