VCE Product Design and Technologies (Year 11) · Unit 1 — Design Practices · 12m read

Materials, Tools, Processes and Workshop Safety

Choosing the right material and process — and using it safely — is central to producing a quality product in Units 1–2.

Learning objective: Select materials by their properties and use tools and processes safely, including completing a risk assessment.

By the end of this lesson you can:

• I can describe properties of common materials.
• I can match materials and processes to a design.
• I can complete a simple risk assessment.

Choosing the right fabric for the weather. You would not wear a woollen jumper to the beach. Materials must suit the job a product needs to do.

Materials and safety

MATERIAL PROPERTIES: strength, hardness, toughness, flexibility, durability, weight, workability, appearance, cost, recyclability.

COMMON MATERIALS
• Timbers — solid (pine, Tasmanian oak) and manufactured boards (plywood, MDF).
• Metals — aluminium (light, corrosion resistant), mild steel (strong, rusts).
• Polymers — acrylic (laser-cuttable), PLA (3D printing), HDPE.
• Textiles — natural (cotton, wool) and synthetic (polyester, nylon).

PROCESSES: cutting, shaping, joining (mechanical fasteners, adhesives, joints, welding, stitching), finishing (sanding, oiling, painting).

RISK ASSESSMENT: identify the HAZARD → judge the RISK → set a CONTROL (guarding, PPE, training, safe procedure).

Worked example (Medium)

Complete a risk assessment line for using a pedestal drill.

1. Hazard. Loose clothing or hair caught in the rotating chuck; flying swarf.
2. Risk. Serious injury — high.
3. Controls. Tie back hair, no loose clothing, wear safety glasses, clamp work, use the guard, teacher induction.

Answer: Hazard: entanglement and swarf; risk: high; controls: clamp work, guard, eye protection, no loose clothing or hair.

Common mistakes

• Choosing MDF for an outdoor product MDF swells and breaks down when wet. Fix: Use treated or durable timber, aluminium or suitable polymers outdoors.
• Listing PPE as the only control PPE is the last line of defence. Fix: Start with guarding, clamping and safe procedures.

Practice questions

1. Which material is best for a lightweight, corrosion-resistant outdoor frame?

   1. MDF
   2. Aluminium
   3. Untreated pine
   4. Cardboard

   (1 marks)

2. Identify a hazard for a process you have used, the risk, and two controls.

   (3 marks)

Summary

• Choose materials by properties linked to function.
• Know timbers, metals, polymers and textiles.
• Hazard → risk → control.
• PPE is the last line of defence.