A Grade

Task 1: Bird House for a domestic garden

contentsContext and Design Brief

  Analysis of Context  Research into Existing Products  Product Analysis of PRIMARY Research  Materials and their properties  Materials and Finishes Testing  Other relevant research  User Profile  Analysis of Research  Final Specification  Initial Designs  Development  Final Design Proposal  Modeling and Testing  Evidence of CAD/CAM  Cutting List  Plan of Making – flow chart  Manufacturing Diary and Quality Control  Evaluation

Life Cycle of Product

Context & Design Brief

Context 1A Garden centre wishes to sell products to encourage wildlife into domestic gardens. Design and make a small product that could be sold in a garden centre.

Design BriefI will be designing a small wildlife attraction which could be sold in a garden centre. It will contain a small hole for the birds to go in and out and also it will contain a small water bath. I will need to add protective paint to cope with all weather conditions. And insure the product is durable. It must also be suitable for commercial manufacture – I will use CAD/CAM when designing & making it.

Analysis Of ContextWhat will the product need to store/ how will it function?I will be making a wildlife attraction to attract more birds into the garden. It will need to include a birdfeeder for the birds to eat from and also it will include a box where the birds can nest, I will also include a water bath wear birds can clean themselves and drink.

What environment will the product be designed for and how will this effect the overall design?The product I am making will be designed so it can hang on a tree in the garden, because I am making a outdoor product I will be Applying a protective paint to cope with all possible weather conditions.

What materials will the product be made out of and how will this effect the overall design? The product will be entirely made from MDF, nut it will also have a vacuum formed plastic bird bath attached. Withy my product I am going to try not to waste as much wood as possible but still get a good end product, I will be doing this so less trees need to be cut down to provide materials.

How will you assemble the materials ? Will you use joints, adhesives, components?My product will be made from MDF because even thought its not a strong material if finished right it will be durable so it can cope wi9th the weather conditions.

How will you ensure your product is suitable for commercial production ? I will designing my product so that it could be batched produced I will do this by using CAD/CAM, CAD is computer aided design this means I will design parts of my product on pro desktop, also I will use CAM this means computer aided manufacture this means a computer controls the machine to make the product a example of this is a router.

Are there any cost restrictions that will influence your design and why? When designing my product I will need to consider the cost restrictions, I will need to think about what it will hang of the tree with but also I will need to consider the cost of the MDF and also paint and finishes.

What sort of shop / retail outlet could you see your product being sold in?My product will be sold in a garden centre so it will need to match the health & safety regulations so that it can be sold to the public.

Existing Products (Primary Photo’s)This bird box is only got a nesting area so it inset as good as others on the market because others have a nesting area, a bird feeder and a water bath .This product will be made from wood, metal and slate there is a mix between materials on this product so it has a better overall look.A good point about this product is because it is made up from a variety of materials it has a attractive look, a bad point is that it is only a nesting box and doesn't include a bird feeder or a bird bath.

This bird box is only got a bird feeder so this is at a disadvantage to others because some others include a bird feeder and also a nesting area and a water bath.This bird box would be made from wood and slate, there is wood because the material is strong and slate because it is very water resistant so no water goes into where the feeder is.A good point about this product is the slate roof this is good because this stops water getting into the bird feeder, a bad point about this is that it doesn't include a water bath or a nesting area.

This bird box is different than the rest because this bird box doesn't have a nesting area or even a water bath it is only a bird feeder.This product will have been made entirely out of wood and it would have been made using machines and parts of it would be made by hand.A good part about this product would be there would be lots of food for the birds to eat.A bad point would be there is only a bird feeder attached.

This bird box is also at a disadvantage to other because it only has a bird feeder but this product also has a little area where birds can get shelter. This product also has wood and slate, it has wood because it is a strong material and it includes slate because its very waterproof so the birds wont get wet.A good point about this is it has a area where birds can get shelter, a bad point is that it doesn't include a nesting area or a water bath.

This bird box has a different design to the other because this bird box doesn't include a bird feeder or a small whole for birds to go through, but this box does include a shelter for the birds. This product is made entirely of wood because this is a very strong material which can cope with all possible weather conditions. A advantage to this box would be there is a large shelter area for the birds, a disadvantage to this box is because there isn't a whole for the birds any type of bird or some animals could come in it.

This is a attractive bird box so that it will attract birds into the garden because of the colours used on this product.To make this product it would need a protective paint so that the product can cope with all weather conditions but also It has to be bright so that birds will easily recognise it and bring more birds into the garden.This product will of been made of wood so that it is strong and durable also this product will have been made entirely using machines.A good point about this product would be because of the way the top is going over the sides there wont be any water getting into the nesting area,A bad point to this would be it would be very hard to hand in the garden because of the shape of the product.

Existing Products (Secondary)

This bird boxes main function is for birds to nest, this product has less to offer because it doesn't include anywhere for the birds to eat from and doesn't include a bath for the birds. This product will also have to have a protective coating so that it Can cope with the weather conditions.This product would be made out of wood so it is very durable.A good point is the design is very attractive and looks like a real house, a bad point is that this product will be very heavy.

This bird box is only for nesting, it doesn't have a bird feeder or a bird bath for the birds to use. This product will need to have a protective paint so that it can cope with all weather conditions.This product will be entirely made from wood and will have been made using machines but also parts would be done by hand.A good part about this product is it is light but also very strong, a bad point would be because it is only quite small it might not attract as many birds into the garden.

This bird box also has a disadvantage because its only a nesting box, it also has a very unique design as a minurcture garden shed this would appeal to more of a humorous person. This product would be made from wood it would be made using machines but also parts of it could be hand made.A good point about this product is it’s a very unique design a bad point about this is it is only a nesting box and doesn't include a bird feeder and a water bath.

This bird box has a very unique design because it includes a large area of shelter for birds, but also it also includes a bird feeder for the birds to eat, because of these features this is my favourite design. this box would be made from wood because of its strength and slate because it is a very good material to use for a shelter because water doesn't soak into it and go damp. A advantage to this box is it has a very large shelter, a disadvantage to this box it doesn't include a water bath which others have.

Materials ResearchMDFMDF is a relatively cheap board to make, but it is also a quality board, This board is composed of fine wood dust and resin pressed into a board. I think this could be a key part of my design as I will be making a mould out of MDF which I will then use the vacuum former to make the bird bath I will be adding to my design.

PlywoodThis is made from veneers of timber with each grain layer being at right angles to each other and bonded together by resin and pressure. This will be a key part of my design because I will be making my product almost entirely using plywood and flexi-plywood because it is a very good material to work with..

HIPS plasticThis material is Strong and resists weathering, flexible, Can withstand sunlight for long durations and also acrylic is a very good material to work with because it can be cut easy and moulded into any shape you may what. This would be useful for my design as I will be including a bird bath so that has to be very water resistant an I will be able to mould it into any shape required.

Metal BracketThis material is very strong and can hold a lot of weight which is essential for my product, it is also very easy to attach to my product and also you can buy it ready made so this saves time, and it will be to a high quality. This material will be essential to my product because this will be what I attach my bird feature to a tree in a domestic garden, I have choose this material because of the strength, durability and ease of attaching.

Finishes and Components Research

Cuprinol shades Cuprinol shades is a wood stain, this will be the finish I will apply to my product this is because it is very weather resistant so it will cope with harsh weather conditions, but also it is a very bird friendly finish, this means that if the bids are inside the box they wont be inhaling the fumes of the finish.

Danish oilDanish oil is also a finish that could be applied to my product to give the whole product a nicer finish and appearance, a good point about this finish is that it gives a shinny finish so it looks better overall, also this finish is bird friendly so the birds will not be inhaling any fumes.

Eco varnishEco varnish is a varnish that could be applied to my product because it can be used outside it will be able to protect my bird feature but also because this product is eco friendly I will be able to use this on my bird feature because it won’t harm the birds in any way.

Ergonomics And AnthropometricsErgonomics needs to be taken into consideration so that the wildlife attraction is made to the correct size and is comfortable for the birds to nest inside and possibly eat from.

Anthropometrics also needs to be taken into consideration because I will need to collect all the relevant measurements of a wildlife attraction, so I will have a idea on what size my wildlife attraction will be, Anthropometrics means the study of humans and animals and its movements.

I gathered lots of information from the RSPB about different sizes needed for different birds. The bird feature that I will be making will need to be an appropriate size; such as the entrance hole should be big enough, but not too small to attract certain birds. I have found this list below of a wide range of birds with their required entrance size, this is very helpful to me because now I am able to see the wide range of birds with the entrance whole size they require to enter the nesting box. Also below I have included the measurements for a wildlife attraction all these measurements have been collected my myself so I am positive that these results are correct. I will make sure I use these when designing and making my birdhouse so that it is safe and accessible for the right birds and not their predators.

195mm

160mm

28mm

150mm

User ProfileName: Pauline OwenAge: 72Occupation: retiredInterests: gardening, shopping and bird watching.

I am a 72 year old woman who enjoys being out in the garden watching the wildlife. I live in a very natural house in a small town. Because of this I enjoy watching the birds in there habitat which is why I try to keep my garden as tidy and suitable to there needs as possible. I could use a bird feature where the birds can come and nest in the winter and also feed, drink and clean. I would be willing to pay up to £30 for a feature which includes all of these features. I would like this product to include all the features named all in one simple product, I would like it to have something to do with great Britain as it is where I was born and have always lived.

Analysis of ResearchExisting productsFor my research I have collected primary research where I have gone on collected them myself and also secondary research where I have collected images from the internet. They are all light and cheap to make, they are all made from wood and include some slate for shelters. All these boxes are suitable for the birds to nest, eat or drink. Most of these bird boxes don’t need a large base because they are designed to hang off tree’s etc, but two of these bird features have a large base because they will have a stand which will support the feature, this is a option that I will have to consider when I am designing my bird feature. Also a lot of the bird features don’t include nesting areas, bird baths or bird feeders this will also be a option which I will consider when designing my bird feature.

Materials researchI have collected some research about all different materials that I will be including in my bird feature. All of these materials are appropriate to add to my design, all of these materials are very light and cheap, also point is that all of them are very easy to work with and will get a good end finish. There are a different range of materials on this page such as wood, metal and plastic, I will be including all of these materials in my bird feature to show that I have shown a wide range of materials.

Ergonomics and AnthrometricsI have collected all the measurements and dimensions of a bird feature which is relative to mine I have done this so I will have a idea of what size my bird feature, also I have included a table of a wide range of birds with there required entrance whole. This is helpful to me because when I will design my bird feature I will be able to tell what size entrance whole I will need for certain birds.

Finishes and componentsOn this page I can done some research on finishes and components, all of the research that I have done are all appropriate for my outdoor product, this is because I have only researched eco products so they will be able to cope with the possible weather conditions and also so they wont cause any harm to the birds. All of the products are cheap and wont effect the environment this was a key feature that the finish that I will use will need to have. This will help my because I now know what finishes there are that are ideal for the product I will be making.

SpecificationMy design must; my design must be targeted at the right audience, this will be to both men and women from the ages 30 upwards

my design must not be able to offend anyone in any way, such as if there could be any offending messages on it

my design must be able to attract birds into the garden and nest, feed, drink and bath in my bird feature

my design must be designed to fit into any garden and it will have to be able to hang from a tree for the birds to access easily

my design must be able to fit certain types of birds in such as blue tit’s, but at the same time keep certain types of birds out such as crows. So my design must have the required entrance hole size to do this = no larger than 28mm in diameter

my design must be a certain size it will have to be light so that the feature will be able to be free hanging off a tree but it will also have to be slightly heavy so that it will not break or fall off in very windy conditions

my product must be able to last at a minimum of 6years and would be expected to last for around 15 years so will have a protective finish and be well made / assembled with strong joints and glue

my product must be able to look nice in the garden to attract the birds, but also it must attract the customer in the garden centre

my product must be waterproof so that it can keep the birds dry when they are using the feature. I plan on using some flexible ply wood this is so I can mold it into any shape I need and it is very strong and easy too use and is waterproof with a finish

my design must be cheap but even though the materials will be cheap they will still have to be very strong and durable

my design must be environmental friendly because I will be making a bird feature so it must not harm the birds in anyway, because of this I will be only using environmentally friendly materials

my design must be able to be mass produced, this is so it will be able to be sold in a garden centre, so that the product will be able to be bought by customers all around the world

My design must have a good water tight finish such as cuprinol shades to keep all water out and the birds dry

Initial IdeasThis is a very simple design, it will be made out of MDF because MDF is a cheap material and is easy to work with. This design will include a entrance whole for the birds to go in and out of. It will also include a perch and fat ball this is so the birds can stand on the perch and eat from the fat ball, this would be cut by hand and the roof would be cut out using the router.

This design has a clear theme, which is it will be designed after a royal mail box, this will be made from plywood this is because with plywood I will be able to steam bend the material so that the whole box is circular. This box will include a entrance whole for the birds to go into and nest it will also have a fat ball, a perch and a place where you can insert a apple for the birds to eat from. This design will be made by hand for cutting the base and also the laser cutter for the water bath and also the router for cutting the bottom and top.

This design is a very unique design because will be designed as a CCTV camera, this design would be made from plywood and MDF, it will be made from plywood for the actual camera head this is because it is a cheap material and I will be able to steam bend it into the required shape I need. I will be using MDF for the other parts on the design this is because MDF is durable and strong which is a key factor because this will be what is keeping the camera head up. This design would be mainly made by hand but the bracket and the camera head would be cut using the router.

This design has a very unique design because I have never seen anything like this before, this design would be entirely from plywood this is because the two main parts of this design this would be the two eye pieces, these would be made from plywood because I would be able to steam bend the material into the two shapes, this design would be made using the router but the connecter in between the two eye pieces would be cut by hand.

This design is a very simple design which would be made from MDF this is because MDF is a cheap material to buy and is very easy to work with so I would be able to get the finish that I need. This design would be mostly cut by hand the only parts that would be cut on the router would be the roof, and I would also need to use the laser cutter to cut out the windows to give it a better look and overall appearance.

Initial IdeasThis is a very quirky design because it is designed after a pumpkin, this design would be entirely made with plywood this is because plywood is very flexible so I would be able to steam bend it into the circular shape. this design would be entirely cut using the router, but some of the details on the face of the design would be cut on the laser cutter.

This design is also very quirky because by looking at it you wouldn't know what it was but this is in the design to look different to others. This would be made out of plywood and MDF because the main part of the design would be made out of MDF because it is a strong material and also is very easy to work with, also the food stick would be made out of plywood because it will be circular and by using plywood I would be able to get this shape, this design would be mainly made on the router but the food stick would be made cut by hand.

This design is different to all my others because of one main reason this is because this design wont be hung off a tree, this will have a stand and would be placed on the floor. This design would be made entirely out of MDF this is because it will need to be strong because it will have to hold the various layers on the stand, also this will be made from MDF because it is a easy material to work with and is a cheap material to buy. This would be cut by hand for the most of it, the only parts which would be cut on the router would be the stand.

This design is inspired by the company ALLESI this is because all of ALLESI’S designs are all very quirky and different, so this is designed as a old phone and is also very quirky and different to other products iv seen. This would be made using plywood and plastic, the whole design would be made from plywood as that it is a very shapely design plywood would be able to be shaped to that shape, the only part which would be made from plastic would be the feet and this is because plastic is a strong material and would support the box. This would be entirely made on the router and laser cutter.

This design is very different to other designs because you wouldn't except this to be a bird box, this would be made entirely from MDF because it will need to be very strong and would need to be easy to work with because of the range of different joints which would be needed to join all the different parts of this design. this design would be made up of all different methods such as the main part of the box would be cut all by hand but the smaller parts such as where the speakers would be including the entrance wholes for the birds to do in would be cut using the router.

My Initial Strategy

Development This is my first design of my bird box product, for this design I have followed the style of a classic post box, this includes a nesting area, a fat ball hook, a standing perch and it also includes a bird bath. This design is a basic box shape which can look slightly like other boxes on the market. This design has a lot of certain parts which I like and will want to include in my final product.

This is my second developed design this shows some of the same features which my first design has but I have taken out some of the features which are included on my first design, on this design I have changed the shape to a semi-circle this is because it makes the design unique. I believe this design doesn't have enough features to be features on my final product.

This is my third developed design, this shows features from both the above designs and I have developed it further, in this I have taken all the features from the first design and included them into this design also I have used the shape from the second design but I have slightly modified it by making it fully spherical, I believe that by doing this I have made my design unique and I haven't seen another product like it on the market.

The top of the bird box will be a circular shape with a whole in the middle for the bird bath to sit, this will be made from flexible plywood and cut on the jigsaw this will be made like this because it is strong and durable, The bird bath will be made from HIPS and I will make a MDF mould and I will vacuum form the HIPS over, this will then slot into the top part of the bird box and fit in nicely and will be able to slot out when I will be cleaning the bird box.

Development The sides will be made using flexible plywood and will be cut using the jigsaw and tacked into place, it will all be put together using a butt joint because this is a strong and durable joint and will be able to cope with the weight of the whole structure.

The base of the bird box will be made from MDF and will slot into the bottom of the sides an I will glue into place with PVA , I will be making the bottom from MDF because it is a sturdy material to use and It will be cut using the router so that I can get the exact shape required. I will be using PVA to glue the bottom in place because it is the best way to glue wood to wood which will be the strongest and be able to stay in place permanently.

I will be using MDF to make the entrance whole to the nesting area I will be using this because it will be strong and wont morph into a different shape in the various conditions, I will be cutting this out by hand using a coping say I will be using this method because I can get the exact shape required band will be able to make the cut very precise.

I will be making the apple holder and the fat ball holder out of MDF this will be cut out by hand using a coping saw this is because I can get the exact cut I need and very precise.

Also the standing perch will be made from a MDF dowel an I will be cutting this down to the exact size required by hand using a coping saw and I will be using the drill to make two small indented whole into the side of the sides and gluing it in with PVA glue so that it can stick into place easily and will be very strong and will be able to with stand any weight that could be on it.

Final DesignThe function of this design is to be a bird feeder, a water bath and be a nesting box. In this design I have included all of these aspects and so that it is appropriate for the birds. This design will have strong string attached the main body compartment which will then hang off a tree in a stable position. My design wont need a large base because it will hang of but on my design I have included a larger base because of the theme which I am using. In this design I will be including a fat ball holder this is to provide the birds with food, also I will be including a standing perch for the birds to stand on and I will also be including a holder which you can insert a apple or fruit into for the birds to feed off.

The finish on the product that I will be making will be cuprinol shades this is required because as I am making a product which will be outside I will need it to be suitable for all weather conditions, also I will need it to be environmentally friendly because as I am making a bird box the birds are part of the environment so I need to make sure the birds cannot be harmed in any way.

The product will be made in three separate pars these would be the top, the base and the main side panel, I will construct the three parts and then tack them together this is because this will be very strong and stable. For my design the only joint which I will be using is a tack joint this is because it will be very durable and will be stable when and when not in use.

The materials I will be using for my product is plywood and flexi-plywood this is because I am making a product which will be used outside so I will need a material which can handle the conditions which may be outside. For part of my design I will need to bend the flexi-plywood and this will be done by soaking the wood in water overnight so that I can bend it into the correct shape I will need.

Materials cutting listPart Material Thickness Size (mm) quantity Finish to be appliedSide Flexi-plywood 6mm 250 x 700mm 1 Cuprinol shadesbottom plywood 12mm 270 x 270mm 1 Cuprinol shadesSmaller bottom plywood 12mm 210 x 210mm 1 Cuprinol shadesperch dowel 12mm 65mm 1 Cuprinol shadesSmaller top plywood 12mm 210 x 210mm 1 Cuprinol shadestop plywood 12mm 270 x 270mm 1 Cuprinol shadesCircle top outer Flexi- plywood 6mm 20 x 820mm 1 Cuprinol shadesCircle top inner Flexi- plywood 6mm 20 x 645mm 1 Cuprinol shadesCircle top plywood 12mm 270 x 270mm 1 Cuprinol shadesFood holder Bright Drawn mild

steel4mm 140mm 1 Cuprinol shades

Modelling and TestingAt this part of designing my product I have created a card model of my design so I can get a feel of how the product will look and work and I will also be able to see everything that will work and everything that won’t to then go on further and change anything that needs to be improved on or fixed to give the product a better overall standard. It meets all points given on the specification apart from having a hole which will be added.I have modelled my card model using card and I have stuck it together using masking tape, I have used this method because my using card I will be able to get a very clear view of that my product will look like when finished and I have used masking tape because it is strong and will be able to keep the model together.

I believe that the prototype was very successful because I can see where everything will be placed and how it will look so I know if I need to make any alterations or improvements. I believe that from seeing my card model that I do not need to make any alterations to my design because everything works as it should and everything fits where it is supposed to no I don not think I need to make any changes to the design or the measurements.

Overall I think that the style of the product is very unique and I have never seen any other product like it so this is why I would purchase this in a store for around the price £25-30. I think that the main advantages to this product are that it is different and quirky which appeals to the public and would convince them to prefer my product.

My card prototype shows that my product will be very easy to use as I have included string which you will be able to easily hang it from a tree, so by doing so it shows that my end product will be able to hang from a tree easily and effectively.Because I have made my card model to scale I am able to see if everything will work as it should , and by doing this I am able to see that there will be no changes to my design before manufacture.

After questioning my Nan (The User Profiled) she thinks that the shape is a little too short and needs to be taller to give it the post box feel. Additionally there would be no need for the perch on the left as there is nothing to access where the perch is. So this will be removed.

start

Gather all ply-wood for base

and top of product

Mark out where will be cut on

base and top of product.

Next mark out holes to show where you will

drill out

Using the pillar drill, drill out the

holes marked out

Cut out the shape marked

out on ply-wood using the

jigsaw

Mark out centre of each circle on top and bottom

Glue a piece of dowel into the two pieces of plywood for base of product to keep in place.

Repeat last step for top of product

Gather the side piece of flexi- ply

On 2D design, design the holes which will be cut

into the side piece of flexi-ply which

will be cut using the router

Send design to router to cut

holes out the side piece of flexi-ply

Soak the side made from flexi-

ply in water overnight

Bend the flexi-plywood into the

correct shape

Tack the sides into the base and

top

Now gather the top piece of flexi- ply and soak it over

night in water

Now bend the top piece of flexi-ply into

the correct shape

Using 2D design mark out the top

piece of ply

Now send the design to router to

cut out the top piece of plywood

Tack the top piece into the side piece

of flexi-ply

Gather MDF to create a mould for

bird bath

Now cut the MDF which has been gathered to

the correct shape which the bird bath will be

Use the wood mould and using the vacuum former To melt the piece of HIPS over the mould to create the bird

bath

Slot the bird bath into place and glue

into place.

Finish

Do you have enough

materials

Has it been marker out correctly

Is there enough MDF

to use

Is it the correct shape

Has the HIPS been heated to the right

temperature

Make sure enough tacks

are used

Has it sent the right shape

Are all the sizes correct

Make sure it’s the correct

shape

Has it been soaked for long

enough

Make sure its bent into the

correct shape

Make sure it has been soaked for long enough time

Has it sent properly

Has it been cut correctly

Have the sizes been added up

correctly

Is the size of plywood the

right side

Is there enough glue

Have they been drilled in the right

place

Has it been marked out

proper

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Manufacturing Diary & Quality ControlHere showing is me making each part of my product, this shows how I use tools to make my product at each stage and show what my product looks like at each stage and how I will then continue to make my product.

This is showing my two pieces of plywood which I had cut out into the correct shape using the jigsaw. I had marked out the exact shapes so I knew where to cut..

This is showing me drilling holes into my pieces of plywood using the pillar drill which I had marked out the holes where I would drill.

This is showing the plywood after I had drilled the holes which I had marked out in a earlier stage.

This is showing how I will fit the two pieces of plywood together using dowel for the top and the bottom of the product. I had accurately marked out how long each piece of dowel would need to be.

This is showing my two pieces of plywood stuck together using a combination of dowel so they don’t slide and PVA glue to keep together.

This is showing me designing my top circle which had the bath glued into it. I designed this on 2D design..

This is showing me setting up the software for the Boxford router. I needed to do this correctly so my designs was not cut out wrong.

This is showing the software for the Boxford router recognising the designs for the top circle which had earlier designed on 2D design

This is showing the router preparing the design to be cut using the designs I had checked over that they are all the correct sizes.

This is showing the router cutting my design into the piece of 12mm plywood for the top circle of my product..

This is showing my piece of plywood after it had been cut by the router after this I measured all the sides which had been cut to make sure it would fit on my product.

This is showing the two circles which I used the router to cut out which I had measured and they was all the correct sizes.

This is showing me putting PVA glue onto my top circle to stick it to the lid of my product which I lined up perfects so that it didn't fit together out of centre.

This is showing me sticking the top circle to the lid of the product which I had lined up perfectly so it was all centred so that it didn't ruin my overall product.

This is showing my clamping the lid of my product together so that it sticks together properly without moving.

This is showing me clamping the base together so that is doesant move and sticks together correctly.

This is showing me setting up the vacuum former to make the plastic bath which I needed to make sure that temperature was correct to get the required shape.

This is showing me putting the HIPS onto the vacuum former which I had checked that the temperature of the HIPS was correct so that it would mould it properly and fit into my product..

This is showing the vacuum former moulding the HIPS over the wood after I had checked the temperature because if I didn't it may of not moulded over my template of wood to make the bath.

This is showing my work after I had used the vacuum former to for the bird bath which I had placed centre on the vacuum form bed so that it would be the best possible quality that it could be.

This is showing my soaking my flexi plywood in the sink so that it would be able to bend into the correct shape.

This is showing me spraying my product with a second coat of lacquer to make sure the paint is ceiled into the product...

This is showing how my lid bath will fit into the lid of my product.

This is showing is also showing how the bird bath will fit into the lid of my product.

This is showing the product with the chain which will be hooked onto my product to hang it from a tree..

This is showing that there is no hook yet on the product and where I will be hooking the chain onto..

This is showing the setting of the laser cutter which I set up to cut out and engrave the pieces of plastic to give my product

the full effect of the design.

This is showing my pieces of plastic when the laser cutter had finished making them.

This is showing where I have tacked a piece of flexi plywood I have done this because it gives the product a better overall look.

This is showing my top after I have painted my product, this is because it looks better overall and more professional.

This is showing my fully finished product with all my features added onto it.

This is showing me drilling the entrance hole for the birds to go into and out of this was done using the pillar drill and was marked out in the exact place needed.

This is showing my flexi ply and the base and top which I would then go onto tack them together .

This is showing when I was bending my flexi ply around the base of my product I had to do this fast because the wood was starting to dry out and the flexi ply would not of bent round my base for the correct shape.

This is showing my product after it had been tacked to the base and I had tacked the top inside circle to get the lip in the correct place.

This is showing Me filling the gap where the flexi ply meets with wood filler to give it a better overall finish I needed to be carful doing this because if I had got any of the wood filler onto the main side then the finish on the whole product wouldn't look as good.

This is showing how the lid will fit into the hole at the top of the product I needed to test this because if it didn't fit correctly I would of needed to sand the inside of the lid down to make it fit together.

This is showing my product with the lip into the product I had got to this stage after I had to sand down the inside of my lid to they would fit together.

This is showing how my product will look with the bird bath in place I needed to do this because I needed to make sure that they both fitted together.

This is showing me painting my product to the colour which i designee it as and also I used this so that you could still see the grain of the wood to make the appearance look better.

This is showing me adding Danish oil onto the side pieces for my product which I have made using layers of plywood I did this because it would bring out the grain out of the wood.

This is showing me using the hand drill to drill two holes where I will screw my side features onto my product I had marked out where these holes would be cut so that all the features would fit on correctly

This is showing me gluing one of the side pieces to my product and lining it up so that I had screw it in to make it stronger..

This is showing me screwing my side feature to the main part of the product this needed to be screwed and glued to keep the pieces from not moving.

This is showing me spraying lacquer onto my product to keep the paint from wearing off over time.

Manufacturing Diary & Quality Control

CAD/ CAM EvidenceThis is showing how I have used CAD/ CAM in the development of my product, this part is showing where I have used CAD which means computer aided design for this part I have used 2D design and his was to design the top circle where the bah will sit, this part of my design needed to be designed using CAD because otherwise the bath would no of fitted in correctly because it needed to be a perfect circle.

This is also showing how I have used CAM this is computer aided manufacture and this means where you send your CAD design to the Boxford Router which can cut the materials to the exact same shape I have used his method using the router, I have chosen to do this because the shape I need would have to be cut into the ext shape required to fit the bath in so I used CAM for this stage of production.

There are advantages to this and disadvantages, one advantage to this would be that because it is all cut precisely you get a very accurate cut and its cut exactly how you may require it, plus it’s faster.

One disadvantage to this would be is that if you do not get all the measurements correctly then you could not only break the wood and the machine but you could also hurt yourself if you haven't taken all the safety precautions

I also used the laser cutter to cut out the post box decoration using 3mm thick acrylic. Again, the designs were easy to cut getting a high quality finish.

AcrylicCut – Speed 1.7%, Power 100%Engrave – Speed 90%, Power 10% HIPS (High Impact Polystyrene)Cut – Speed 2.2%, Power 100%Engrave – Speed 2.0% Power 100% 

Thin cardCut – speed 65%, power 100%Engrave – Speed 100%, Power 20%

flexible plywoodSpeed 0.8%Power 85%

Evaluating against SpecificationI have now finished making my product completely and at this stage I will be evaluating my finished product. Here is the original Specification that I set out to achieve. I think that my product has met all of these points of my specification.

EvaluationI have now finished making my product completely and at this stage I will be evaluating my finished product, my product does meet all the design specifications which are noted in my specification. My product is easy to use for the user and this is because if it was difficult for the user they wouldn't want to use my product because they might not be able to use the product correctly. Each of the products functions work the way which that was intended I made sure I would make these features precisely to the way which they would work and fit onto the product this is because if I had made any changes which didn't follow the same specifications it may not fit onto the fit and maybe of not worked correctly.

USER OPINIONSI have asked other people what they think of overall product and all feedback was positive results it has been said that my finished product is very unique and will appeal to my target audience. The people who I have presented my product to they have all liked all the features on my product and they have said that each feature has a purpose and that they are all essential for the bird feature which is in the criteria for my product. My nan says “A great overall finish which meets all that you set out to complete. I would have this in my garden and I’m sure the birds would enjoy using it. Maybe add a different colour to the door step in future s o it matches the black plastic on the front”.

The intended user for this product would purchase it because it includes everything in the specification and also some added features, my intended user would pay £30 for my product which is my estimated price for my product. Consumers would buy this product from others because it includes a number of varied features which other bird features do not which I researched whilst doing my primary existing products, so because my product offers that bit more this is why consumers should buy product. The environmental impact which it has made during making the product has been kept to a minimum this is because as I have made a bird feature I have made sure that the product doesn't have any materials which could harm the birds using the product and also the environment.

Evaluation - ModificationsDuring product I encountered two main problems so from these problems I have made modifications and overall improved my product because of these, one of these modifications which I have made is in my initial design I had added a feature on the left side of the product which would clap in fruit, but whilst in production I realised that I would have been able to add this feature without the birds been harmed so because of this I modified my product and added a standing perch at the front of the product.

My second problem that occurred was whilst I was cutting out the small inside circle the plywood started pealing off due to the hard shape so to fix this I designed the shape on 2D design and cut it out using the Boxford router. This happened when peeling the MDF base off the plywood, it splintered and damaged the surface which I had to cover up when gluing to another piece of plywood. I was lucky I had something to glue it to.

If I was to make my whole product again I would try to make it so that the whole centre piece doesn’t leave a small gap which is displayed to the right, I would do this by soaking the plywood in the water for a longer period of time so that each part of the plywood was able to bend, this would improve the overall look of the product and would give it a more professional look.

If I was to make my whole product again I would try to make more features onto it by adding something onto the right side of the product, this would help more customers to buy my product because it would include more in the product but by adding this it could increase the price of the product.

If I was to make my whole product again I would also maybe change the size of the entrance whole for the birds so that a wider variety of birds would be able to use this product buy I would need to do this carefully because if one particular bird is preyed by another I would not make the whole big enough to let these certain birds come in so that all the birds are safe inside my product.

If I was to make my whole product again I would change the shape of the perch, I would do this so that maybe more birds would be able to stand on it, this might increase the amount of people who would by my product.

As well I would add a groove in the base that would sit against the tree so it doesn’t blow about in the wind as I think this will be a problem after seeing it roll against the tree when testing it.

Evaluation -3rd person viewsName Style Function Improvements

Michael Kelly Its very unique Works very well with the environment

Add multi access holes for the birds to enter the box

Anthony Stevens Its very interesting

It functions with ease

Include more features

Lee O’Neill It looks like it was designed like

It does everything that the specification says.

Make sure all tacks where covered with filler so you cannot see them from the surface.

Most people questioned think the style is interesting and unique and it functions well. They do say that they want multi access holes for the birds to go in and out but this is not what nesting boxes should have. Especially when young chicks are in the nest as they might get eaten by other birds or animals and it might be too cold with 2 holes because the wind might fly through.

I do agree with Lee though that the tacks should be covered up so they cannot be seen. When I looked at most birdhouses in the garden centre they all had screws, nuts, bolts, nails on show so I though this would be OK, but I now realise that some people don’t like them showing. So I would fill them with filler if I did this again.

Life Cycle Of The BirdhouseTrees are cut from a sustainable forest using either a chain saw or a machine.

Trees then cut down into smaller pieces to be transported easier.

Then the wood is sent to a factory to make each individual board.

Then the wood would be sent to schools or other factories and made into a product, in this case it’s for a bird box.

This is when the product is at the end of its life cycle or is broken it is sent to a recycling plant to be stripped and made into sawdust then crushed into a manmade board such as MDF.

Final Product