How do new and emerging technologies have an impact on production techniques and systems?

Welcome to the Future of Making!

In this chapter, we are going to explore how fancy new gadgets and clever computer systems are changing the way products are made in factories. We call these new and emerging technologies.

Why does this matter? Well, as a designer, you need to know not just what to make, but how the latest tech can make it faster, cheaper, and better. Don't worry if some of the terms sound a bit "sci-fi" at first—we will break them down into simple pieces together!

1. What are Disruptive Technologies?

The word "disruptive" usually sounds like a bad thing (like someone talking during a movie!), but in Design and Technology, disruptive technologies are exciting! They are new inventions that completely change—or "disrupt"—the traditional way of doing things.

The two biggest "disruptors" in manufacturing right now are 3D Printing and Robotics.

A. 3D Printing (Additive Manufacturing)

Traditional manufacturing often uses "wastage" (cutting bits away). 3D printing is the opposite. It is called additive manufacturing because it builds an object by adding material layer by layer.

Analogy: Think of making a tower out of LEGO bricks. You add one layer at a time until the tower is finished. This is much less wasteful than starting with a giant block of plastic and carving the tower out of it!

The Impact of 3D Printing:

• Rapid Prototyping: Designers can make a "test version" of a product in hours rather than weeks.
• Customisation: It is easy to change a digital file to make a product fit a specific person (like a prosthetic limb or a custom phone case).
• Less Waste: Since you only use the material you need, there is very little "scrap" left over.

B. Robotics

Robotics involves using programmable machines to do tasks that humans used to do. In modern production, these aren't usually walking, talking robots; they are often high-speed mechanical arms.

The Impact of Robotics:

• Efficiency: Robots don't need to sleep, take lunch breaks, or get tired. They can work 24/7.
• Accuracy and Repeatability: A robot can do the exact same weld or cut 1,000 times perfectly. Humans eventually make mistakes when they get bored or tired.
• Safety: Robots can do "the three Ds": jobs that are Dull, Dirty, or Dangerous (like working with high heat or toxic chemicals).

Quick Review: Disruptive tech like 3D printing and robots change the "rules" of making by reducing waste and increasing speed.

2. Economies of Scale

This is a fancy term for a very simple idea: The more you make of something, the cheaper each individual item becomes to produce.

New technologies help companies reach these "savings" much faster. When a company uses robots to mass-produce 10,000 toothbrushes, the "cost per unit" (the price to make just one) drops significantly because the expensive machines are being used to their full potential.

The Formula for Unit Cost:

\( \text{Unit Cost} = \frac{\text{Total Production Cost}}{\text{Number of Items Made}} \)

Example: If it costs £1,000 to set up a machine and you only make 10 items, each item "carries" £100 of that setup cost. If you use that same machine to make 1,000 items, each item only "carries" £1 of the setup cost! That is Economies of Scale in action.

Key Takeaway: New technology allows for mass production, which lowers the price for customers and increases profit for businesses.

3. Evaluating the Impact: Benefits vs. Implications

In your exam, you might be asked to "critically evaluate" these technologies. This just means looking at the good points (benefits) and the tricky points (implications).

The Benefits (The Good Stuff):

• Product Enhancement: Products can be more complex and higher quality than if they were made by hand.
• Sustainability: Modern machines are often more energy-efficient and produce less waste (like 3D printing).
• Lower Prices: Because of economies of scale, products become more affordable for everyone.

The Implications (The Challenges):

• Ethics and Jobs: If a robot takes over a job, what happens to the human worker? This is a major social concern.
• Initial Cost: Buying a fleet of robots or industrial 3D printers is incredibly expensive. Small companies might struggle to compete.
• Maintenance: If a complex robot breaks down, the whole factory might stop until a specialist can fix it.

Did you know? Some factories are now "Lights Out" factories. They are so fully automated with robots that they don't even need the lights on because there are no humans working inside!

4. Summary and Memory Aids

To help you remember the impact of robotics, try the "Three Rs":

1. Repeatability: Doing the same thing perfectly every time.
2. Reliability: Working 24 hours a day without a break.
3. Reduction of Risk: Keeping humans away from dangerous tasks.

Common Mistake to Avoid:

Don't assume 3D printing is always better than traditional making. While it is great for one-off items or prototypes, it is currently much slower than traditional "injection moulding" for making millions of items at once!

Key Takeaway: New technologies make production faster, more accurate, and less wasteful, but they require high investment and can lead to job losses in traditional roles.

Keep going! You are doing a great job mastering these concepts. Understanding how things are made is the first step to becoming a great designer!