Design

Principles and
Fundamentals
MODULE 2
HSSM301
PRODUCT DESIGN

PRODUCT DESIGN 1
Syllabus
• Understanding design principles (e.g., balance, hierarchy, contrast),
• Human factors in design (ergonomics, anthropometrics),
• Material selection and properties,
• Basics of aesthetics and styling,
• Hands-on exercises in sketching and prototyping

PRODUCT DESIGN 2
Material Selection in Product Design
• Material selection is a crucial aspect of product design, often determining the
success or failure of a product in the market.
• It involves the process of choosing the right materials for a specific product,
taking into account various factors such as functionality, aesthetics, cost, and
sustainability.
• In the context of product design, material selection isn’t just about finding a
substance that fits the purpose; it’s about aligning the material properties
with the product’s intended use, target audience, and overall design ethos.

PRODUCT DESIGN 3
Topics
• Types of Materials
• Classification of Materials
• Metals
• Ceramics
• Polymers
• Composites
• Properties of Materials

MATERIALS AND METALLURGY 4

Types of Materials
Materials can be divided into the following categories
• Crystalline
• Amorphous

MATERIALS AND METALLURGY 5

Crystalline Materials
• These are materials containing one or many crystals. In each crystal, atoms or ions
show a long range periodic arrangement.
• All metals and alloys are crystalline materials.
• These include iron, steel, copper, brass, bronze, aluminium, duralumin, uranium, thorium
etc.

MATERIALS AND METALLURGY 6

Amorphous Material
• The term amorphous refers to materials that do not have regular, periodic
arrangement of atoms.
• Glass is an amorphous material

(a) Crystalline SiO2

(Quartz)
(b) Amorphous SiO2
(Glass)

MATERIALS AND METALLURGY 7

Engineering Materials

MATERIALS AND METALLURGY 8

Classification of Materials

Metals Ceramics

Polymers Composites

MATERIALS AND METALLURGY 9

Major Classes of Materials
Metals
•Ferrous (Iron and Steel)
•Non-ferrous metals and alloys
Ceramics
•Structural Ceramics (high-temperature load bearing)
•Refractories (corrosion-resistant, insulating)
•White wares (e.g. porcelains)
•Glass
•Electrical Ceramics (capacitors, insulators, transducers, etc.)
•Chemically Bonded Ceramics (e.g. cement and concrete)

MATERIALS AND METALLURGY 10

Major Classes of Materials
Polymers
•Plastics (can be a thermoplastic or thermoset)
•Elastomers (commonly known as rubber, differ from plastics in the fact they have a great
capacity for large elastic deformation under an applied stress. In other words, they can be
stretched over 100% of their original length with no permanent deformation.)
Composites
•Particulate composites (small particles embedded in a different material)
•Laminate composites (golf club shafts, tennis rackets, Damascus swords)
•Fibre reinforced composites (e.g. fibreglass)

MATERIALS AND METALLURGY 11

Metals
•High thermal and electrical conductivity.
•Strong yet deformable under applied mechanical loads; opaque to light (shiny if polished).
These characteristics are due to valence electrons that are detached from atoms, and spread in
an electron sea that glues the ions together, i.e. atoms are bound together by metallic bonds
and weaker van der Waal s forces.
•Pure metals are not good enough for many applications, especially structural applications. Thus
metals are used in alloy form i.e. a metal mixed with another metal to improve the desired
qualities.
•E.g.: aluminium, steel, etc.

MATERIALS AND METALLURGY 12

Metals
•Steel is an alloy of iron and carbon, containing less than 2% carbon and 1% manganese and
small amounts of silicon, phosphorus, sulphur and oxygen. Steel is the world's most important
engineering and construction material.

MATERIALS AND METALLURGY 13

Ceramics
•These are crystalline compounds between metallic and non-metallic elements. They are most
frequently oxides, nitrides and carbides, including ceramics that are composed of clay minerals,
cement and glass.
•Ceramics are characterized by high hardness, abrasion resistance, brittleness and chemical
inertness.
•Ceramics are typically insulative to the passage of electricity and heat, and are more resistant
to high temperatures and harsh environments than metals and polymers.
•With regard to mechanical behaviour, these materials are hard but very brittle.

MATERIALS AND METALLURGY 14

MATERIALS AND METALLURGY 15
Glass
• Glass is an amorphous (non-crystalline) solid.
• Because it is often transparent and chemically inert, glass has found widespread
practical, technological, and decorative use in window panes, tableware, and optics.
• Due to its ease of formability into any shape, glass has been traditionally used for
vessels, such as bowls, vases, bottles, jars and drinking glasses.
• Soda–lime glass, containing around 70% silica, accounts for around 90% of modern
manufactured glass.
• Glass can be coloured by adding metal salts or painted and printed with vitreous
enamels, leading to its use in stained glass windows and other glass art objects.

PRODUCT DESIGN 16
Polymers
•Many of these are organic substances and derivatives of carbon and hydrogen.
•Polymers have very large molecular structures. Most plastic polymers are light in weight and
are soft in comparison to metals. Have typically low densities and may be extremely flexible and
widely used as insulators, both thermal and electrical.
•Few examples of polymers are nylon and rubber.
•The overriding consideration of the selection of a given polymer is whether or not the material
can be processed into the required article easily and economically.

MATERIALS AND METALLURGY 17

Polymers

MATERIALS AND METALLURGY 18

Composites
•A composition of two or more materials in the first three categories, e.g. metals, ceramics and
polymers, that has properties from its constituents., fibre glass, reinforced plastics, etc.
•Fibre glass is a most familiar composite material, in which glass fibres are embedded within a
polymeric material.
•A composite is designed to display a combination of the best characteristics of each of the
component materials. Fibre glass acquires strength from the glass and the flexibility from them
polymer.
•A true composite structure should show matrix material completely surrounding its reinforcing
material in which the two phases act together to exhibit desired characteristics.

MATERIALS AND METALLURGY 19

Composites
•These materials as a class of engineering material provide almost an unlimited potential for
higher strength, stiffness, and corrosion resistance over the ‘pure’ material systems of metals,
ceramics and polymers.
•Many of the recent developments of materials have involved composite materials.

MATERIALS AND METALLURGY 20

Amorphous or Glassy Metals
•Amorphous metals are made from alloys whose constituents may include Fe, Ni, and Co and a
metalloid or glass former such as silicon, boron, or carbon.
•A typical amorphous metal, offered for sale by Allied Signal Inc., USA, is METGLAS 2826, which
has the composition Fe40Ni38Mo4B18.

MATERIALS AND METALLURGY 21

Amorphous or Glassy Metals
•An amorphous metal (also known as metallic glass or glassy metal) is a solid metallic material,
usually an alloy, with disordered atomic-scale structure.
•Most metals are crystalline in their solid state, which means they have a highly ordered
arrangement of atoms. Amorphous metals are non-crystalline, and have a glass-like structure.
•But unlike common glasses, such as window glass, which are typically electrical insulators,
amorphous metals have good electrical conductivity and they also display superconductivity at
low temperatures.
•Zr-Al-Ni-Cu based metallic glass can be shaped into 2.2–5 mm by 4 mm pressure sensors for
automobile and other industries, and these sensors are smaller, more sensitive, and possess
greater pressure endurance compared to conventional stainless steel made from cold working.

MATERIALS AND METALLURGY 22

Topics
• Types of Materials
• Classification of Materials
• Metals
• Ceramics
• Polymers
• Composites
• Properties of Materials

MATERIALS AND METALLURGY 23

Properties of Materials
•An alternative to major classes, we may also divide materials into classification
according to important properties.
•One goal of materials engineering is to select materials with suitable properties
for a given application, so it’s a sensible approach.
•Just as for classes of materials, there is some overlap among the properties, so
the divisions are not always clearly defined.

MATERIALS AND METALLURGY 24

Important Properties of Materials
•Mechanical properties
•Electrical properties
•Dielectric properties
•Magnetic properties
•Optical properties
•Corrosion properties
•Biological properties
Shape Memory Alloy

MATERIALS AND METALLURGY 25

Properties of Materials
Mechanical Properties F. Toughness
A. Elasticity and stiffness (recoverable G. Resilience
stress vs. strain)
H. Fatigue
B. Ductility (non-recoverable stress vs.
strain) I. Creep

C. Strength
D. Hardness
E. Brittleness

MATERIALS AND METALLURGY 26

Properties of Materials
Electrical properties Magnetic properties
A. Electrical conductivity and resistivity A. Paramagnetic properties
Dielectric properties B. Diamagnetic properties
A. Polarizability C. Ferromagnetic properties
B. Capacitance
C. Ferroelectric properties
D. Piezoelectric properties
E. Pyroelectric properties

MATERIALS AND METALLURGY 27

Properties of Materials
Optical properties Biological properties
A. Refractive index A. Toxicity
B. Absorption, reflection, and B. Bio-compatibility
transmission
C. Birefringence (double refraction)
Corrosion properties
A. Corrosive
B. Non-corrosive

MATERIALS AND METALLURGY 28

Mechanical Properties
1. When a load is applied on a material, it may deform the material.
2. What do force-extension or stress-strain curves look like? Why?

MATERIALS AND METALLURGY 29

Elasticity and stiffness
•Elastic deformation is the deformation produced in a material which is fully
recovered when the stress causing it is removed.
•Stiffness is a qualitative measure of the elastic deformation produced in a
material. A stiff material has a high modulus of elasticity.
•Young’s modulus is the slope of the stress-strain curve during elastic
deformation.

MATERIALS AND METALLURGY 30

Elasticity
and
Stiffness

MATERIALS AND METALLURGY 31

Ductility
•Ductility is the ability of Fracture Very
Ductile
Moderately
Ductile Brittle
behavior:
the material to stretch or
bend permanently
without breaking.
•Ductility is a measure of
the deformation at Large Moderate Small

fracture - Defined by
percent elongation or
percent reduction in area.

MATERIALS AND METALLURGY 32

Strength
•Yield strength is the
stress that has to be
exceeded so that the
material begins to
deform plastically.
•Tensile strength is
the maximum stress
which a material can
withstand without
breaking.

MATERIALS AND METALLURGY 33

Hardness
•Hardness is the resistance to
penetration of the surface of a
material.
•It is known as indentation hardness
which is the resistance of a material
to indentation.
•The usual type of hardness test is
where a pointed or rounded indenter
is pressed into a surface of the
material under a substantially static
load.

MATERIALS AND METALLURGY 34

Brittleness and Toughness
•The material is said to be brittle if it
fails without any plastic deformation.
•Toughness is defined as the energy
absorbed before fracture.

MATERIALS AND METALLURGY 35

Toughness
Toughness = the ability to absorb
energy up to fracture.
= the total area under the strain-
stress curve up to fracture

MATERIALS AND METALLURGY 36

Resilience
• The ability of a material to absorb energy when
deformed elastically and to return it when unloaded is
called resilience.
• This is usually measured by the modulus of resilience
which is the strain energy per unit volume required to
stress the material from zero stress to the yield stress
σ.
• The ideal material for resisting energy loads in
applications where the material must not undergo
permanent distortion, such as mechanical springs,
have a high yield stress and a low modulus of
elasticity.

MATERIALS AND METALLURGY 37

Fatigue
•Fatigue failure is the failure of material under fluctuating load.
•Fatigue life is defined as the number of loading (stress) cycles of a specified
character that a specimen sustains before failure of a specified nature occurs.

MATERIALS AND METALLURGY 38

Creep
•Creep is the time dependent permanent deformation under a constant load at
high temperature.
•Plastics and low-melting-temperature metals, including many solders, can begin
to creep at room temperature.
•Glacier flow is an example of creep processes in ice.
•The effects of creep deformation generally become noticeable at approximately
35% of the melting point for metals and at 45% of melting point for ceramics.
• Creep is progressive plastic deformation under constant stress with time, and
is important in high temperature applications

MATERIALS AND METALLURGY 39

Creep in Metals
•Primary creep: creep rate decreases with
time due to strain hardening.
•Secondary creep: Creep rate is constant
due to simultaneous strain hardening
recovery process.
•Tertiary creep: Creep rate increases with
time leading to necking and fracture.

MATERIALS AND METALLURGY 40

Sketching Basics

PRODUCT DESIGN 41
PRODUCT DESIGN 42
PRODUCT DESIGN 43
PRODUCT DESIGN 44
One Point Perspective

PRODUCT DESIGN 45
One Point Perspective

PRODUCT DESIGN 46
PRODUCT DESIGN 47
PRODUCT DESIGN 48
Three Point
Perspective

PRODUCT DESIGN 49