Materials and Design. The Art and Science of Material Selection in Product Design. Second Edition

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1 Materials and Design The Art and Science of Material Selection in Product Design Second Edition

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3 Materials and Design The Art and Science of Material Selection in Product Design Second Edition Mike Ashby and Kara Johnson AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Butterworth-Heinemann is an imprint of Elsevier

4 Butterworth-Heinemann is an imprint of Elsevier Linacre House, Jordan Hill, Oxford ox2 8dp, 30 Corporate Drive, Suite 400, Burlington, ma 01803, 2002, 2010, Mike Ashby and Kara Johnson. Published by Elsevier Ltd. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress. isbn: For information on all Butterworth Heinemann publications visit our website: Designed by Swayspace, New York. Illustrations by Marco de Luca and Mario Petriccione, Torino. Typeset in Mrs. Eaves designed by Zuzana Licko and Knockout from The Hoefler Type Foundry. Printed in Canada

5 Preface Preface Books on material selection and there are many focus on finding a match between material properties, the technical requirements of a design, and the science of materials. There are now well-developed methods for doing this, supported by sophisticated software tools. Together they form the basis for the teaching of materials selection in engineering programs around the world. But these programs frequently ignore or at best devote little attention to what might be called the art of materials the role they play in industrial design. This may be because the more technical aspects of engineering form a structured, analytical field that can be recorded and taught as a set of formal procedures. Design cannot so easily be formulated as a method; it relies instead on visual thinking, sketching and modeling, an exploration of aesthetics and perception, and storytelling. This book is about the role of materials and processes in product design. It complements an earlier text that develops methods for choosing materials and processes to match the technical requirements of a product. Here, by contrast, the emphasis is on a wider range of the information about materials that designers need, the way they use it and the reasons they do so. The reviews received and conversations we had with students, professors and working designers about the first edition of this book have encouraged us (and the publishers) to capture new experiences, new ideas and recent developments in industry in a second edition. With help from Willy and Patrick at Swayspace, we also spent time rethinking the design, layout, color and content of the book in order to enhance the message and its presentation. We have included new case studies, derived from the experiences that one of us (KJ) had working with ideo. And these case studies illustrate the idea of materials and design in a way that is more complete and more inspiring. Based on Mike s recent work, there is an increased emphasis on sustainability and issues related to eco- and green design. The material and process profiles, too, have expanded slightly and have improved photography to make them more accessible and more inspirational. The book has two audiences: students and working designers. For students, the purpose is to introduce the role of materials in and manufacturing in design, using language and concepts with which they are already familiar. For working designers, the purpose is to present a concise reference source for materials and manufacturing, profiling their characteristics. To this end, the book is divided into two parts. The first presents ideas about design and methods of material selection; the second is devoted to the profiles. Many colleagues have been generous with their time and ideas. In particular, we are grateful for discussions, criticisms, contributions and construc-

6 Preface tive suggestions from Professor Yves Brechet of the University of Grenoble; Dr. David Cebon, Dr. John Clarkson, Dr. Hugh Shercliff, Dr. Luc Salvo, Dr. Didier Landru, Dr. Amal Esawi, Dr. Ulrike Wegst, Ms. Veronique Lemercier, Mr. Christophe LeBacq and Mr. Alan Heaver of Cambridge University; Dr. Pieter-Jan Stappers of the Technical University of Delft; Dr. Torben Lenau of the Technical University of Denmark; and Julie Christennsen of Surface Design, San Francisco. In the second edition, we were able to include case studies from ideo and we deeply appreciate the opportunity to continue to work with ideo to explore the role of materials in design. We owe a special thanks to Nicolas Zurcher from ideo and Jihoon Kim from idtc who were each willing to share some of their images for the material and manufacturing profiles. We particularly wish to acknowledge the contribution of Willy Schwenzfeier and Patrick Fenton of Swayspace, New York, to the design of the book itself. Many other people and organizations, listed on the following page, contributed images or gave us permission to reproduce their images and photographs of their products. Mike Ashby and Kara Johnson June 2009 Our Top Five Lists As part of the preface to this book, we would like to include out own Top 5 lists for books that serve as good reference, inspiration and learning for materials and manufacturing. These books help us remember to get inside the factory, to focus on visualization, to explore design basics and to experiment. Mike Ashby 1. The Material of Invention Intriguing descriptions of the role of material in invention. Manzini, E. (1989), isbn Experiences in Visual Thinking A very readable introduction to creative thinking and design. McKim, R.H. (1980), isbn The Visual Display of Quantitative Information The bible of graphical methods for representing and mis-representing information. Tufte, E.R. (1983), isbn x 4. Designing Pleasurable Products A discussion of the design requirements of function, bility and pleasure. Jordan, P.S. (2000), isbn Design of Everyday Things A book that provides insight into the design of familiar products. Norman, D.A. (1998), isbn Kara Johnson 1. Manufacturing Processes for Design Professionals The best reference available to get inside the factory. Thompson, R. (2007), isbn The Material of Invention An iconic and inspiring story of materials. Manzini, E. (1989), isbn Haptic A collection of objects inspired by and made from paper. Takeo Paper Show (2004), isbn Se Se, Fuwa Fuwa, Zawa Zawa A collection of extreme manipulations of beautiful fabrics. Nuno Corporation, 5. I Miss My Pencil A series of experiments in the senses, modern craft, love and fetish. Johnson, K. and Bone, M. (2009), isbn

7 Acknowledgements Acknowledgements alpa of Switzerland Capaul & Weber Neptunstrasse 96 po Box 1858 ch-8032 Zurich Switzerland Antiques Collectors Club 5 Church St Woodbridge, Suffolk Apple Press 6 Blundell St London n7 6bh Arnoldo Mondadori Editore S.p.A. Milan Italy Bang and Olufsen, 630 Wharfdale Rd Winnersh Triangle Berkshire rg41 5tp Cynthia Nicole Gordon 4108 Eastern Ave North Seattle, wa Dyson 20 Shawfield St London sw3 4bd Ergonomic Systems Inc Overpass Rd Santa Barbara, ca Gisela Stromeyer Architectural Design 165 Duane St #2b New York, ny ideo 100 Forest Avenue Palo Alto, ca idtc (International Design Trend Center) # 625, Hongmun R-dong, Hongik Univ , Sangsu-dong, Mapo-ku, Seoul, Korea mas Design Axis House, 77a Imperial Rd Windsor sl4 3ru Nokia Group Keilalahdentie 4 fin-02150, Espoo Finland Porsche Design GmbH Flugplatzstrasse 29 a-5700 Zell am See Germany Sony Corp Kitashinagawa Shinagawa-Kei Tokyo Japan Vectra 1800 S. Great Southwest Parkway Grand Prairie, tx Vitra Management ag Klünenfeldstrasse 22 ch-4127 Birsfelden Switzerland Yamaha Corporation 10-1, Nakazawa-cho Shizuoka Pref., Hamamatsu Japan Han Hansen Admirilitätstrasse 71, Hamburg Germany

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9 Ten Chapters Chapter 1 Function and Personality 2 Chapter 2 What Influences Product Design? 8 Chapter 3 Design and Designing 28 Chapter 4 The Stuff Multi-dimensional Materials 54 Chapter 5 Other Stuff Shaping, Joining and Surfaces 94 Chapter 6 Form Follows Material 104 Chapter 7 A Structure for Material Selection 122 Chapter 8 Case Studies in Materials and Design 142 Chapter 9 New Materials The Potential for Innovation 158 Chapter 10 Conclusions 172 Appendices Exercises for the Eye and Mind 176 Selected Material Maps 179 A Practical Reference for Inspiration Material Profiles 193 Shaping Profiles 250 Joining Profiles 272 Surface Profiles 298 Index 324