Making It: Manufacturing Techniques for Product Design

by Chris Lefteri

• ISBN13: 9781856697491
• ISBN10: 1856697495
• Edition: 2nd
• Format: Paperback
• Copyright: 2012-03-26
• Publisher: HACHETTE

Summary

There are many ways in which a product can be manufactured but most designers know only a handful of techniques. Both informative and incredibly easy to use, this bestselling book explains over 100 production methods in detail. With specially commissioned diagrams, case studies and step-by-step photographs of the manufacturing process, Making It uses contemporary design as a vehicle to describe production processes. It lists their pros and cons, suitable production volumes, costs involved, speed of production, relevant materials and typical applications. The new edition of this inspirational book also evaluates each process in terms of sustainability and its effects upon the environment. Making It appeals not only to product designers but also to interior designers, furniture and graphic designers who need access to a range of production methods, as well as to all students of design. The expanded edition includes 10 new processes and an all-new section of over 30 finishing techniques.

Author Biography

Chris Lefteri is Senior Lecturer in Product Design at Central Saint Martins College of Design, London. He also runs his own product-design, packaging and furniture business in London. His previous books include five titles in the Materials for Inspirational Design series covering plastic, wood, glass, metals, and ceramics.

Table of Contents

Introduction	p. 6
Comparing Processes	p. 10
Cut from Solid
Machining	p. 18
Computer Numerical Control (CNC) Cutting	p. 21
Electron-Beam Machining (EBM)	p. 24
Turning	p. 26
Jiggering and Jollying	p. 29
Plasma-Arc Cutting	p. 33
Sheet
Chemical Milling	p. 38
Die Cutting	p. 40
Water-Jet Cutting	p. 42
Wire EDM (Electrical Discharge Machining) and Cutting	p. 44
Laser Cutting	p. 46
Oxyacetylene Cutting	p. 48
Sheet-Metal Forming	p. 50
Slumping Glass	p. 52
Electromagnetic Steel Forming	p. 54
Metal Spinning	p. 56
Metal Cutting	p. 59
Industrial Origami®	p. 61
Thermoforming	p. 64
Explosive Forming	p. 67
Superforming Aluminum	p. 70
Free Internal Pressure-Formed Steel	p. 73
Inflating Metal	p. 76
Pulp Paper	p. 78
Bending Plywood	p. 80
Deep Three-Dimensional Forming in Plywood	p. 83
Pressing Plywood	p. 86
Continuous
Calendering	p. 90
Blown Film	p. 92
Exjection	p. 94
Extrusion®	p. 96
Pultrusion	p. 99
Pulshaping™	p. 102
Roll Forming	p. 104
Rotary Swaging	p. 106
Pre-Crimp Weaving	p. 108
Veneer Cutting	p. 112
Thin & Hollow
Glass Blowing by Hand	p. 116
lampworking Glass Tube	p. 118
Glass Blow and Blow Molding	p. 120
Glass Press and Blow Molding	p. 124
Plastic Blow Molding	p. 127
Injection Blow Molding	p. 129
Extrusion Blow Molding	p. 132
Dip Molding	p. 134
Rotational Molding	p. 137
Slip Casting	p. 140
Hydroforming Metal	p. 143
Backward Impact Extrusion	p. 146
Molding Paper Pulp	p. 149
Contact Molding	p. 152
Vacuum Infusion Process (VIP)	p. 154
Autoclave Molding	p. 156
Filament Winding	p. 158
Centrifugal Casting	p. 161
Electroforming	p. 164
Into Solid
Sintering	p. 168
Hot Isostatic Pressing (HIP)	p. 170
Cold Isostatic Pressing (CIP)	p. 172
Compression Molding	p. 174
Transfer Molding	p. 176
Foam Molding	p. 178
Foam Molding into Plywood Shell	p. 181
Inflating Wood	p. 184
Forging	p. 187
Powder Forging	p. 190
Precise-Cast Prototyping (pcPRO®)	p. 192
Complex
Injection Molding	p. 196
Reaction Injection Molding (RIM)	p. 199
Gas-Assisted Injection Molding	p. 201
Mucell Injection Molding	p. 203
Insert Molding	p. 206
Multishot Injection Molding	p. 209
In-Mold Decoration	p. 212
Over-Mold Decoration	p. 214
Metal Injection Molding (MIM)	p. 216
High-Pressure Die-Casting	p. 219
Ceramic Injection Molding	p. 222
Investment Casting	p. 224
Sand Casting	p. 228
Pressing Glass	p. 231
Pressure-Assisted Slip Casting	p. 234
Viscous Plastic Processing (VPP)	p. 236
Advanced
Inkjet Printing	p. 240
Paper-Based Rapid Prototyping	p. 242
Contour Crafting	p. 244
Stereolithography (SLA)	p. 246
Electroforming for Micro-Molds	p. 250
Selective Laser Sintering (SLS)	p. 252
Smart Mandrels™ for Filament Winding	p. 255
Incremental Sheet-Metal Forming	p. 257
Finishing Techniques
Sublimation Dye Printing Vacuum Metalizing	p. 262
Flocking Acid Etching	p. 263
Laser Engraving Screen Printing	p. 264
Electropolishing Tampo Printing	p. 265
Suede Coating Hot Foil Blocking	p. 266
Over-Molding Sandblasting	p. 267
i-SD System In-Mold Decoration	p. 268
Self-Healing Coating Liquid-Repellent Coatings	p. 269
Ceramic Coating Powder Coating	p. 270
Phosphate Coatings Thermal Spray	p. 271
Case Hardening High-Temperature Coatings	p. 272
Thick-Film Metalizing Protective Coatings	p. 273
Shot Peening Plasma-Arc Sptaying	p. 274
Galvanizing Deburring	p. 275
Chemical Polishing Vapor Metalizing	p. 276
Decalization Pickling	p. 277
Nonstick Coating (organic) Nonstick Coating (inorganic)	p. 278
Chrome Plating Anadizing	p. 279
Shrink-Wrap Sleeve Dip Coating	p. 280
Ceramic Glazing Vitreous Enameling	p. 281
Glossary	p. 282
Index	p. 284
Acknowledgments	p. 287
Picture Credits	p. 288
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