Material Design and Technology Statement of Intent

General Metal Write a clear statement identifying the product, function, aesthetics, safety, cost considerations, limitations
and the purpose of the product.

I am building a BBQ from 3mm flat bar and 3mm sheet metals. The BBQ must be barrel
Design Portfolio shape with 4 legs, a lid and a small chimney and a breathing hole. The dimensions of
600x300 for the barrel and the legs must be 200 mm long. The BBQ will have a removable
grill and will be held to get by welds. I will design and build this project by end of semester
1.
I will research different types of BBQ’s to ascertain the style and concepts that I wish to add
to my design. From there I will draw design concepts and an octagonal picture to scale with
dimensions. I will design the BBQ in sketch up too to offer an exploded view to help with
the process of design to building.
The BBQ must be balanced and level and able to allow wood to burn and cook the food. The
lid must be able to close securely and have a small handle attached to it. The chimney and
small breathing hole must allow a free flow of fresh air to keep the fire ignited and the
smoke to extract out of the chimney.
I intended to cut the metal to size, 4 semi circles to make up the sides and two pices of
sheet metal which I will bend into a half barrel for both lid and base. I will shape a chimney
and cut a hole for the chimney into the lid. A breather hole will be cut and covered with a
small rotating cover made of galvanised sheet metal to control the flow of air. The legs will
be cut from round bar and secured to the base by welds. The grill will be created and
welded together from 6mm rod.
Using a MIG welder I will tack weld the pieces together allowing me to check the accuracy.
Once I am confident the pieces slot together well, I will complete the welding.
I will finish the BBQ with a black heat proof paint and primer

This Photo by Unknown Author is licensed under CC BY-NC

Student’s Name: Year 11

Teacher Tips – Who is designing, What is the project you are making, When are you making the project
(timeframe 1 term), where is the project being made and where will it go, Why are you making this project,
Teacher: Mr Basham How will you make this.
Analysis of Design Factors
To be able to grill food Portable
such as sausages and
steaks.

Tack welding, fusion

welding for joins
Contemporary look

Gloss black

Function
Guillotine used to cut
sheet metal, bench shears
to shape.
Manufacture Aesthetics
Traditional style,
matt black or
unfinished look
Approximately $50

3mm thick sheet metal

Place Picture
here of
Cost project before
Material
printing

6mm thick steel rod

Handles to carry
Safety Ergonomics

Welder requires
helmet, gloves and
Environment
apron.
Must sit at a height for the
average person when seated
on the ground

Flat sheet metal is sharp. Gloves needed.

Make sure no sharp edges on final Reuse scraps Use recycled steel
product. where you can

Your Task - Develop the initial idea against the Design Factors Teacher Tips – Think about how the idea could improve functionally, aesthetically, ergonomically, cost, environment
etc. Think about all the factors that need to be considered in order for you to produce a successful table.

Function
(What are the requirements or what must the product do?)
The BBQ must be portable, able to cook enough meat for 2 people, woodfired with a removable grill.
It should have a lid with an opening at the base of the bbq and a chimney
Material Type Properties Products and Uses
ferrous metal • Ferrous metals are mainly composed of iron Ferrous metals include mild
and have magnetic properties. Steel, an iron steel, carbon steel, stainless
alloy containing carbon, steel, cast iron, and wrought
iron. These metals are
primarily used for their
tensile strength and
durability, especially mild
steel which helps hold up the
tallest skyscrapers and the
longest bridges in the world.
The most commonly used non-ferrous metals are Generally, more expensive
non-ferrous metals aluminium, copper, lead, zinc, nickel, titanium, cobalt, than ferrous metals, non-
chromium and precious metals. ferrous metals are used
because of desirable
properties such as low weight
(e.g. aluminium), higher
conductivity (e.g. copper),
non-magnetic property or
resistance to corrosion (e.g.
zinc).
Material Type Properties Products and Uses
Stainless steel Stainless steel is the generic name for Kitchen benches
a number of different steels used Exhaust system on cars motorbikes
primarily because of their corrosion
resistance. All stainless steels share a
minimum percentage of 10.5%
chromium. Chromium is always the
deciding factor, although other
elements, particularly nickel and
molybdenum, are added to improve
corrosion resistance.
Aluminium The properties of aluminium include: Aluminum (aluminium) is used in a
low density and therefore low weight, variety of industrial, structural, and
high strength, superior malleability, consumer applications. Aluminum is
easy machining, excellent corrosion used in dyeing cloth, in making paper,
resistance and good thermal and and in tanning leather. As a
electrical conductivity are amongst lightweight and durable metal, it is
aluminium’s most important widely used in aircraft and other
properties. vehicles.
Wrought iron Wrought iron is an iron alloy with a Decorative items such as railings,
very low carbon content in contrast outdoor stairs, fences and gates
to cast iron. It is a semi-fused mass of Nuts and bolts
iron with fibrous slag inclusions, Handrails.
which gives it a "grain" resembling
wood that is visible when it is etched
or bent to the point of failure.
en.wikipedia.org/wiki/Non-ferrous_metal
www.stainless-steel-world.net/basicfacts/stainless-steel-and-its-
families.html
en.wikipedia.org/wiki/ferrous_metal
www.answers.com/Q/What_is_aluminium_used_for
www.aluminiumdesign.net/why-aluminium/properties-of-aluminium/
Research Research
Collect examples (photos or pictures) of the type of models you wish to make. Collect examples (photos or pictures) of the type of models you wish to make.

PMI Chart – Write in full sentences PMI Chart – Write in full sentences
Example Picture Plus Minus Interesting Example Picture Plus Minus Interesting
What are some of the What are some What do you find What are some of the What are some What do you find
positives? negatives? interesting? positives? negatives? interesting?

Lid can be used as a wind Plain shape, functional but Fold up legs Large grill May be difficult to move as That it doesn’t have some
break boring. Handles it looks heavy type of lid.
Lid holds cooking utensils. Tripod concept
Fold up legs and latch for lid No lid

Source:
Source:
Contemporary design Legs could be different to The handle on the grill Contemporary shape No handles to carry I find the design interesting
Flat grill and char grill with a match the rest of the style Large grill
handle. Legs match the design

Source:

Source:
Nice shape Too shiny and hard to keep The simple leg design I like the shape and the It would be difficult to make Looks like a UFO
Shiny clean safety mesh over the top. Not easily portable
Simple design

Source:
Source:
Source: Place the URL from where you have copied the photo or picture from

Summary of Research Concept Ideas

You must put in written explanations on all diagrams
What is available on the market? Thumbnail Sketch of Ideas Positive Aspects Negative Aspects
What makes them attractive?
Nice shape Difficult to bend
What are they made of and what colour are they?
Chimney to allow metal in a semi-circle
smoking and faster shape evenly.
There are many different looking BBQ’s, some traditional but many are
cooking of food.
contemporary. They are generally black or Stainless steel, as black hides the stains
and stainless steel is easy to clean.

I nice looking BBQ has clean defined lines, with a sturdy frame and a good sized
cooking area. 600mmX300mm lid, Chimney 200mm with
a 40mm radius. Handle is 6mm rod, 300mm
long.
What are some of the design features you wish to incorporate into your own design? Legs look good, Maybe hard to attach
different from other BBQ to legs. Legs will
I will make the BBQ similar to the one researched which was in the shape of an X. I like the
styles. need to be wider than
different look with the triangular BBQ with an opposing Triangle leg/frame that gives it the ’X’
look. BBQ to prevent
toppling over
I like the idea of using the lid as a utensil holder and wind break.

Made out of 20mm square tubing, Leg lengths

approximately 212mm

What environment issues are there to consider? Nice and sturdy design The design doesn’t
for a BBQ base. Made suit all BBQ shapes
I will look at using recycled wrought iron out of 25mm square e.g. the triangular
I will design a lid that can be used as a wind break since it is a woodfire BBQ and tubing. Easy to BBQ
wind could blow embers away and start fires. measure, cut and
assemble.
 Concept Ideas
You must put in written explanations, labelling, dimensions etc on all diagrams
Thumbnail Sketch of Ideas Positive Aspects
Triangular lid will allow food to
600x100
be cooked quicker giving an
300x600 oven effect. Handle will help
opening lid safely when hot.
600x30
0
Square lid allows for less weight
than other lids. Easy to
measure, cut and assemble.
100x600
Door on side of BBQ will
help to clean and
remove ash from BBQ.
Easy to measure and cut.
100x20
0 with a strong latch and
Contemporary design
that looks good. Metal
tubing used for legs that
wrap around and join to
make one piece giving it
a sturdy base for BBQ
Conclusion
What conclusion can you now write about that explains the suitability of the design
Negative Aspects ideas you have drawn in your concepts, in relation to your statement of intent?
Adds weight and size to BBQ
making it less portable. Could
use a chimney to allow air I conclude that the designs I have chosen originally in the statement of intent may not be the best ideas for
flow and keep fire burning.
the BBQ. I have had to think about weight, portability and the construction process. I therefore, feel that the
original idea and concept needed to be changed.
Not an aesthetically pleasing
lid.
BBQ is portable and Which design or aspects of the design will you use for the final idea? Why?
this may be redundant
if it is easily turned over
to clean. Could be a
problem if not secured I have changed the BBQ concepts to allow for an easier design and build. I have decided not to go with the
semi-circular concept with chimney for the reason of difficulty and portability. The original concept would
hinges. be heavier and less portable and therefore I have decided to go with a triangular designed BBQ with
triangular legs and a flat lid. This design allows for portability and reduced weight while still maintaining a
contemporary look.
Design is complex and
will be hard to make.
 Development Ideas
Choose aspects of your final concept and develop them further (minimum 6). Show exploded views of different options i.e. how do you plan to join pieces together,
different joining options. Include dimensions, materials, types of finishes. You must include written explanations and labelling on your diagram.
Development Sheet 1 Development Sheet 3

25mm Square tubing will be 595mm

used, with a matte black finish. It

212mm
300mm
will be cut using the cold saw
and welded together using a MIG
welder.

295mm

100mm
Frame of grill will me made out of 6mm Steel Rod and the
char grill will be made out of 6mm solid square rod. Cut on
cold saw and welded with MIG welder.

Development Sheet 2 Development Sheet 4

The BBQ lid will be 605mmx305mmx3mm The BBQ lid will be 605mmx305mmx3mm
sheet metal, with a handle on top that is sheet metal, with a handle on top that is
centred and 200mmx6mm steel rod. centred and 200mmx6mm steel rod.
On the back of the lid will be 2 hooks Sheetmetal to be cut with guillotine, edges
approximately 50mmx3mm steel rod that folded with the magna bend and fusion
will allow the lid to attach to the back of welded together in the corners.
the BBQ to give it a windbreak.
Handle to be made out of 3mm steel rod
Sheetmetal to be cut with guillotine, edges and welded onto the lid with the MiG
folded with the magna bend and fusion welder
welded together in the corners. Hooks to
be made out of 3mm steel rod and welded
onto the lid with the MiG welder
 Development Ideas
Choose aspects of your final concept and develop them further (minimum 6). Show exploded views of different options i.e. how do you plan to join pieces together,
different joining options. Include dimensions, materials, types of finishes. You must include written explanations and labelling on your diagram.
Development Sheet 5 Development Sheet 6
BBQ will be made out of 3mm Sheetmetal, cut on the guillotine and tac welded on
the inside with a MiG welder and fusion welded outside seams with Oxy/Acetylene.

Grill will have 6mm steel rod

handles. They will be 100mm long
and 50mm high, cut on a cold saw
and welded onto the grill with a MIG
welder.

Development Sheet 7 Development Sheet 8

 Presentation Drawing

Teacher Tip: This should be a neat 3D scaled drawing of your preferred design. It should be rendered (shaded & coloured) it should give a good indication of what the final product will look like.
 NAME: TITLE: DATE:
Working Drawing

Teacher Tips: Draw a scaled Orthogonal Drawing (top view, side view, end
view) of the product, including hidden details and dimensions. This will be
the drawing that you will work off when you begin construction. Any
templates you may need (i.e. for making multiple parts the same) should be
included.