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Industrial Design Materials and Manufacturing Guide
2nd Edition Jim Lesko Digital Instant Download
Author(s): Jim Lesko
ISBN(s): 9780470055380, 0470055383
Edition: 2
File Details: PDF, 39.75 MB
Year: 2008
Language: english
 Table of Contents
Title Page

Copyright

Acknowledgments

Chapter 1: Introduction

Chapter 2: Overview

Chapter 3: Metals
3.1 Properties of Metals
3.2 Ferrous Metals
3.3 Powdered Metallurgy
3.4 Nonferrous Metals

Chapter 4: Metal Forming

4.1 Liquid State Forming
4.2 Plastic State Forming
4.3 Solid State Forming

Chapter 5: Metal Cutting

5.1 Sheet Punching and Shearing
5.2 Chip Forming Cutting
5.3 Nonchip Forming Cutting
5.4 Flame/Thermal Cutting
Chapter 6: Metal Joining
6.1 Soldering
6.2 Brazing/Welding
6.3 Adhesives
6.4 Mechanical Fasteners

Chapter 7: Appearance Finishing and Coatings

7.1 Formed Textures/Molded In
7.2 Cut Patterns and Abrasive Finishing
7.3 Coatings

Chapter 8: Plastics
8.1 Properties of Molded Plastics
8.2 Thermosets
8.3 Thermoplastics

Chapter 9: Plastic Forming Processes

9.1 Liquid State Forming
9.2 Plastic State Forming
9.3 Solid State Forming

Chapter 10: Machining Plastics

Chapter 11: Joining Plastics

11.1 Chemical Bonds
11.2 Welding Plastics
11.3 Mechanical Fastening
Chapter 12: Finishing Plastics
12.1 Formed
12.2 Paintings/Coatings

Chapter 13: Rubbers and Elastomers

13.1 Thermoset Rubbers
13.2 Thermoplastic Elastomers

Chapter 14: Natural Engineering Materials

14.1 Engineering Ceramics
14.2 Glass
14.3 Manufactured Carbon
14.4 Refractory Hard Metals

Chapter 15: Composites

15.1 Metal-Matrix Composites
15.2 Plastic Matrix Composites
15.3 Advanced Composite Materials

Chapter 16: Rapid Prototyping

Index
 This book is printed on acid-free paper.
Copyright © 2008 by John Wiley & Sons, Inc. All rights reserved Published
by John Wiley & Sons, Inc., Hoboken, New Jersey Published
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 Library of Congress Cataloging-in-Publication Data: Lesko, Jim.
Industrial design : materials and manufacturing guide / Jim Lesko. -- 2nd
ed.
p. cm.
ISBN 978-0-470-05538-0 (cloth)
1. Design, Industrial. 2. Manufacturing processes. 3. Materials. I. Title.
TS171.4.L47 2007

745.2--dc22
2007017878
 Acknowledgments

The idea for Industrial Design: Materials and Manufacturing began about
1975 when Professor Born asked me to teach the subject at the University
of Cincinnati. I had the good fortune of having an exceptional group of
students, including John Bucholtz, Mike Gallagher, and Sam Lucente,
whose enthusiastic response to my organizational structure of the subject
convinced me that a simple visual text was necessary to get the interest of
students trained in art. Many of the existing texts and journals on the
subject do a great job for those students whose interest is in the amount of
detail presented, with an emphasis on quantifiable arguments and
explanations. I learned from these texts and journals, and they remain a
necessary part of the learning process for design students. But impatient
industrial design students who want to understand concepts, need an
overview: read a summary, see examples, and go on to the next topic in
some logical manner. Design students seem to sense that they will not have
the prime responsibility in selecting materials or in specifying the
manufacturing process in the design of products, but intuitively they
understand that they must be conversant on the subject and that materials
and manufacturing methods will be a determinant in the design process.
There is a growing excitement and exploration in materials and
manufacturing in the design community because of the recent explosion of
ideas engendered by the advances in aerospace research. Mutant Materials
in Contemporary Design, organized by Paola Antonelli, Associate Curator
at the Museum of Modern Art, and the Material Connextion conceived by
George Beylerian, are outstanding examples of this renewed energy focused
on this essential aspect of design. Within the Industrial Designers Society of
America (ISDA), Dave Kusuma was instrumental in organizing the
Materials and Processes Group and in bringing the Society of Plastics
Engineers and IDSA together for meetings and conferences.
For years I hoped that someone else would produce such a text. After
teaching the subject for more than 15 years, I realized that no designers
were presumptuous enough to try to develop a text for industrial design
students, so I began to collect my notes. While at Pratt Institute, I received a
Mellon grant to produce a structure for the information. During this first
phase, several students assisted me, including Deborah Zweiker and Eileen
Lee. Without the advantage of a computer, we labored most of the summer
laying out the organizational charts and making the many lists of
information by hand. While I was at Carnegie Mellon University, Professor
Alex Bally, head of the Industrial Design Department, and Professors
Greenberg and Paxton of the Materials Science Department, reviewed my
preliminary concepts and provided many suggestions and encouragement.
While I am responsible for the use I made of the information that I
received, it was impossible to complete this undertaking on my own. In
fact, this book is the work of many people: the many students who sat
through the lectures and provided feedback, and the manufacturers and
suppliers who graciously spent valuable time and had endless patience with
me trying to ensure that I received the information I needed. There are
many who stand out, who went way beyond that call of duty.
This book would not have been completed without Ed Eslami, who on a
number of occasions, rescued me from panic, and whose calm assurance,
clever drawings, and graphic layout brought the book out of the morass that
it was in at times. I am grateful for his help and his exceptional talent. Many
students helped with research and drawings, including Kyang Haub Kang,
Tong Jin Kim, and Minghsiu Yang.
Don Blair of Talbot Associates was with me almost from the beginning,
and later Jeff Talbot joined him to provide hours of discussion, stacks of
brochures, and many sources of information on casting. Christine Lagosz
and her associates at Trumpf, Inc., Bill Guftner of US Amada Ltd., Steven
Friedman of Peterson, Walter Ackerman of Risdon, John Matthews of
ESAB Welding & Cutting Products, and Bob Cook of Bridgeport Machines
were just some of the great individuals who provided all the information I
requested on metal forming and cutting.
Dave Kusuma and Michael A. D'Onofrio, Jr. and their associates of at the
Bayer Corporation; Jack Avery, George Whitney, and their associates at GE
Plastics; Steve Ham; Dave Beck of Pappago; Victor Gerdes and his
associates at the Stevens Institute; Bill Fallon of Sikorsky; and George
Cekis of Solvay provided important parts in building the plastics section. I
am thankful that the publishers of Injecting Molding Handbook by Rosato
& Rosato and Plastics Engineering Handbook by the Society of the Plastics
Industry allowed me to reproduce many drawings.
For this second edition, I am extremely fortunate that Edward Eslami
again was my guiding light and helped make new ideas happen. Mike
Gallagher, a former student and now a colleague, provided inspiration and
enthusiasm once again by inviting me to Crown Equipment Corp. for a tour
of its design and manufacturing facilities. Jim Kraimer, Jeff ery Mauch, and
Doug Rinderle and their many associates led this tour and ably answered
my many questions. Manuel Saez and Lachezar Tsvslotinv, also former
students, described their work at HumanScale and provided images of their
current projects. Peter Bressler and his associates and Dave Kaiser and his
associates kindly responded to my call for images. David Stricker of
Production Resources and Robert Hagemeister of Parametric Design
Associates provided important current information.
Many of the casting descriptions were taken from the 2006 Casting
Source Directory, published by Engineered Casting Solutions, with the kind
permission of Publisher and Editor Alfred T. Spada. John Chion of Talbot
Associates reviewed my draft of the casting section and provided guidance
and suggestions. Obviously, many others plowed through my drafts and
patiently corrected my errors and contributed their expertise; their thoughts
are somewhere inside these pages.
I am grateful that an endless number of students are always ready to help.
Zackary Smith helped with the graphic layout, and Soo Hwan Cho and
Wooyeon Cho provided many illustrations. When I arrived at Dongseo
University in Korea Sang-Hwan An, Sang-Wook Eom, Ji Young Kang,
Hyo-Jin Kim, and Joon-Goo Lee helped with illustrations and drawings. I
would also like to thank the many companies at the INTERMOLD KOREA
2007 Exhibition for the stacks of brochures and endless pictures. The
enthusiasm and willingness to help on the part of nearly everyone whom I
contacted kept me going. I am grateful to all.
I would also like to thank the many engineers and designers who helped
and encouraged me. This book is dedicated to them; to the memory of
Donald R. Dohner, the father of American industrial design education; and
Other documents randomly have
different content
 Art - Term Paper
Third 2025 - College

Prepared by: Professor Brown

Date: August 12, 2025

Results 1: Fundamental concepts and principles

Learning Objective 1: Key terms and definitions
• Learning outcomes and objectives
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Learning Objective 2: Assessment criteria and rubrics
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Learning Objective 3: Key terms and definitions
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Learning Objective 4: Study tips and learning strategies
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Learning Objective 5: Interdisciplinary approaches
• Learning outcomes and objectives
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Learning outcomes and objectives
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Practice Problem 6: Comparative analysis and synthesis
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Fundamental concepts and principles
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Learning outcomes and objectives
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 9: Theoretical framework and methodology
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 10: Diagram/Chart/Graph]
Section 2: Best practices and recommendations
Example 10: Learning outcomes and objectives
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 11: Diagram/Chart/Graph]
Important: Practical applications and examples
• Learning outcomes and objectives
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Example 12: Current trends and future directions
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Key Concept: Fundamental concepts and principles
• Case studies and real-world applications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 14: Problem-solving strategies and techniques
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Example 15: Research findings and conclusions
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Learning outcomes and objectives
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Statistical analysis and interpretation
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 18: Diagram/Chart/Graph]
Important: Practical applications and examples
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Research findings and conclusions
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Test 3: Comparative analysis and synthesis
Note: Key terms and definitions
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Note: Fundamental concepts and principles
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Key Concept: Critical analysis and evaluation
• Case studies and real-world applications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 23: Diagram/Chart/Graph]
Practice Problem 23: Best practices and recommendations
• Literature review and discussion
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Theoretical framework and methodology
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Remember: Learning outcomes and objectives
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Experimental procedures and results
• Literature review and discussion
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Note: Key terms and definitions
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Definition: Interdisciplinary approaches
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Experimental procedures and results
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Module 4: Best practices and recommendations
Definition: Theoretical framework and methodology
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Example 31: Literature review and discussion
• Practical applications and examples
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
[Figure 32: Diagram/Chart/Graph]
Key Concept: Best practices and recommendations
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 33: Diagram/Chart/Graph]
Important: Practical applications and examples
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Example 34: Critical analysis and evaluation
• Assessment criteria and rubrics
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 35: Ethical considerations and implications
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Literature review and discussion
• Learning outcomes and objectives
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Important: Key terms and definitions
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Remember: Critical analysis and evaluation
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 39: Diagram/Chart/Graph]
Note: Critical analysis and evaluation
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Chapter 5: Literature review and discussion
Important: Problem-solving strategies and techniques
• Best practices and recommendations
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Definition: Critical analysis and evaluation
• Critical analysis and evaluation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Remember: Study tips and learning strategies
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 43: Practical applications and examples
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Important: Experimental procedures and results
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Research findings and conclusions
• Theoretical framework and methodology
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 46: Key terms and definitions
• Problem-solving strategies and techniques
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Definition: Experimental procedures and results
• Learning outcomes and objectives
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Note: Practical applications and examples
• Study tips and learning strategies
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Note: Experimental procedures and results
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Conclusion 6: Key terms and definitions
Remember: Case studies and real-world applications
• Current trends and future directions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 51: Study tips and learning strategies
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 52: Practical applications and examples
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Key Concept: Learning outcomes and objectives
• Historical development and evolution
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Experimental procedures and results
• Interdisciplinary approaches
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Formula: [Mathematical expression or equation]
Practice Problem 55: Critical analysis and evaluation
• Assessment criteria and rubrics
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Practice Problem 56: Learning outcomes and objectives
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
Key Concept: Practical applications and examples
• Ethical considerations and implications
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Definition: Interdisciplinary approaches
• Comparative analysis and synthesis
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
[Figure 59: Diagram/Chart/Graph]
Practice Problem 59: Problem-solving strategies and techniques
• Fundamental concepts and principles
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Topic 7: Case studies and real-world applications
Key Concept: Literature review and discussion
• Research findings and conclusions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Example 61: Comparative analysis and synthesis
• Key terms and definitions
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Formula: [Mathematical expression or equation]
Note: Experimental procedures and results
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Remember: Best practices and recommendations
• Assessment criteria and rubrics
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Important: Theoretical framework and methodology
• Assessment criteria and rubrics
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Key Concept: Learning outcomes and objectives
• Literature review and discussion
- Sub-point: Additional details and explanations
- Example: Practical application scenario
- Note: Important consideration
Practice Problem 66: Historical development and evolution
• Statistical analysis and interpretation
- Sub-point: Additional details and explanations
- Example: Practical application scenario
[Figure 67: Diagram/Chart/Graph]
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