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Unit 3 : How Stuff Works

- Experience looking into the inside of a consumer product. Seeing how it works and find out the design intent of the engineers - Understand what are the manufacturing processes that goes into the making of a consumer product. - To know the various types of materials that are used in a consumer product.

Schematic diagram of a steam iron
Steam rate dial Water tank Temperature dial

Thermostat Dosing point

Electric current


Steam chamber

Heating element

How does a steam iron works ?
4. Dosing pin controls the steam rate generation 3. Thermostat maintains desired temperature

1. Electric current

2. Heat transfer from heating element to soleplate 5. Steam generated in chamber gushing out from steam hole on soleplate

Lets Tear it Apart!
Work in groups of 4 and with a phillips screw driver, dismantle the electric iron. (approx 7 parts)

Over moulding/Insert moulding

Injection moulding


Pump mechanism, Injection moulding

Injection moulding

Back cover

casting, sheet metal stamping

Manufacturing Processes
2) 3) 4) 5) 6) 7) 8) 9) Plastic injection Moulding Sheet metal stamping Compression Moulding Sintering Turning Casting Anodizing Spot Welding

Types of Materials
2) 3) 4) 5) 6) 7) Engineering plastics ( PP, PP+PPS , PC,PBT) Elastomers Spring steel Brass Ceramic - alumina Phosphate steel

Please Re-assemble the irons Thank You

a. By turning the temperature dial, a ceramic pin in turn pushes leaf spring downwards to set temperature Q: How to achieve rotary action to linear action?

e. Spring becomes unstable and flip open the silver contacts f. Contact opens to prevent temperature from rising. Q: What is this ?

d. Ceramic pin moving up. Q: Why use ceramics ?

c. Bi-metallic strip bends upwards

b. Boss on soleplate heated up

Turning the steam dial to lift the dosing pin……..

Q: How to convert rotary action of steam dial to linear action?

Gap increasing Q: So can you lift the dosing pin while the soleplate is cold?