Design and Technology – Resistant materials | e-Consult

When selecting materials for manufacturing, a designer must consider several key factors. These factors are closely linked to the chosen manufacturing processes and the desired product performance:

• Strength and Stiffness: The material must be able to withstand the stresses and strains of use. Examples: High-strength steel for structural components (often used with processes like stamping or casting), Aluminium for lightweight components (suitable for extrusion or casting), and Composites (for high strength-to-weight ratio, often using injection moulding or lay-up processes).
• Corrosion Resistance: The material should be resistant to degradation from environmental factors like moisture, chemicals, or UV radiation. Examples: Stainless steel, plastics like HDPE or PP, and coated metals. This will influence the choice of processes as some processes may compromise corrosion resistance.
• Temperature Resistance: The material must be able to maintain its properties over a range of operating temperatures. Examples: High-temperature alloys for engine parts (requiring processes like casting or forging), and Thermoplastics for products used in hot environments (suitable for injection moulding).
• Cost: The material cost must be considered in relation to the overall product cost. Examples: Steel is generally cheaper than titanium, and plastic is often cheaper than metal. This will influence the choice of manufacturing process as some are more expensive than others.
• Workability: The material must be suitable for the chosen manufacturing process. Examples: Materials that are easily machinable are suitable for processes like machining and turning. Materials that can be easily formed are suitable for processes like stamping, deep drawing, or extrusion.

Here's a table showing examples of materials and suitable manufacturing processes:

The selection process is often iterative, involving prototyping and testing to ensure the chosen material meets all performance requirements and is compatible with the chosen manufacturing methods.