DES 2033
Joining
Methods and
Materials
in Design
Mete GODOLLAR
Miray HAMARAT DÜNDAR
1. Introduction to Joining Techniques: Fundamental Concepts and History
2. Comparison of Plastic and Metal Fasteners: Benefits and Limitations
3. Adhesives and Mechanical Fasteners: Applications in Product Design
4. Mechanical Durability and Performance of Joining Materials
5. Selection of Joining Materials from a Sustainability Perspective
6. Use of Joiners in the Design Process: Examples and Applications
DES 2033
1. Introduction to Joining
Techniques: Fundamental
Concepts and History
Joining techniques have been a cornerstone of design and
manufacturing from the creation of the first tools to modern
innovations. This topic explores the historical methods of joining
materials and their evolution into modern product design. It will also
highlight the transformation of these methods, the materials used,
and their significance in the design process.
Subtopics:
● From Ancient Times to Modern Era: The Evolution of Joining Techniques
● Diversity of Joining Materials and Their Early Uses
● The Industrial Revolution and the Rise of Mechanical Fasteners
● Modernization of Adhesives and the Advent of Chemical Joiners
● The Role and Future of Joining Techniques in Design
From Ancient Times to Modern
Era: The Evolution of Joining
Techniques
The historical progression of joining techniques, from natural
adhesives like resin and leather in the Stone Age to riveting
techniques in the Metal Age.
Examples:
Wooden dowels and rope bindings in ancient shipbuilding.
Early metallic riveting techniques, such as those in Bronze Age
chariots.
Diversity of Joining Materials
and Their Early Uses
The initial use of wood, metal, and natural adhesives in joining
processes and their impact on product design.
Examples:
Handmade dowel systems in wooden toys.
Metal joiners in Roman-era bridges.
The Industrial Revolution and
the Rise of Mechanical
Fasteners
The development of riveting, screws, and welding during the
Industrial Revolution and their influence on mass production and
design.
Examples:
Riveting systems in constructing iron bridges (e.g., Eiffel Tower).
The importance of screws in modern machinery assembly.
Modernization of Adhesives and
the Advent of Chemical Joiners
The advent of synthetic adhesives with advancements in chemical
engineering and their ability to revolutionize product design.
Examples:
Epoxy adhesives in today’s applications.
Adhesives replacing welding in automotive metal joining.
The Role and Future of Joining
Techniques in Design
Current technologies and the future transformation of joining
processes with innovations such as nanotechnology and 3D
printing.
Examples:
Fusion techniques in 3D printing.
Carbon fiber adhesives for lightweight product design.
DES 2033
2. Comparison of Plastic
and Metal Fasteners:
Benefits and Limitations
Plastic and metal fasteners offer solutions tailored to different needs
in product design. This section explores the advantages and
limitations of these two types of fasteners, discussing when and why
each should be preferred. Factors such as cost, durability,
aesthetics, sustainability, and manufacturing processes will be
analyzed to guide material selection.
Subtopics:
● Advantages and Applications of Plastic Fasteners
● Limitations of Plastic Fasteners and Solutions
● Advantages and Applications of Metal Fasteners
● Limitations of Metal Fasteners and Solutions
● Hybrid Solutions: Combining Plastic and Metal Fasteners
Advantages and Applications of
Plastic Fasteners
Plastic fasteners are lightweight, flexible, and often more
economical. This section discusses their ability to speed up
assembly, recyclability, and flexibility.
Examples:
Plastic clips in consumer electronics.
Snap-fit systems in toy assembly.
Limitations of Plastic Fasteners
and Solutions
Plastic fasteners have limitations in heat resistance, UV durability,
and mechanical strength. This section explores how to address
these challenges.
Examples:
Specialized plastics (e.g., polyamide) for high-temperature
applications.
UV-resistant plastic fasteners for solar panels.
Advantages and Applications of
Metal Fasteners
Metal fasteners provide high mechanical strength, durability, and
aesthetic appeal. This section focuses on their role in joining
heavy-duty structures.
Examples:
Screws and rivets in the automotive industry.
Metal connectors in furniture design.
Limitations of Metal Fasteners
and Solutions
Metal fasteners are heavier, costlier to produce, and prone to
corrosion. This section offers solutions to mitigate these drawbacks.
Examples:
Stainless steel screws and connectors.
Lightweight alloy fasteners (e.g., aluminum rivets).
Hybrid Solutions: Combining
Plastic and Metal Fasteners
Using plastic and metal fasteners together can achieve both
durability and lightweight design. This section examines hybrid
solutions and applications.
Examples:
Combination of plastic clips and metal screws in electronic devices.
Hybrid assembly solutions in the automotive industry.
DES 2033
3. Adhesives and
Mechanical Fasteners:
Applications in Product
Design
Adhesives and mechanical fasteners (e.g., screws, rivets) are
complementary methods in product design, catering to different
needs. This section examines the advantages, disadvantages, and
appropriate use cases for both methods. The focus will also be on
their effects on product performance, aesthetics, and manufacturing
processes.
Subtopics:
● Advantages and Disadvantages of Adhesives
● Advantages and Disadvantages of Mechanical Fasteners
● Performance Comparison: Adhesives vs. Mechanical Fasteners
● When to Choose What? Selection Criteria
● Hybrid Bonding Techniques: Combining Adhesives and Mechanical Fasteners
Advantages and Disadvantages
of Adhesives
Adhesives are ideal for lightweight and aesthetically pleasing
designs. This section explores their benefits in stress distribution,
surface protection, and speeding up production. However,
limitations related to temperature, humidity, and chemical resistance
are also discussed.
Examples:
Adhesive-mounted screens in electronic devices.
High-strength epoxy adhesives in automotive applications.
Advantages and Disadvantages
of Mechanical Fasteners
Mechanical fasteners offer high strength, easy disassembly, and
reassembly. This section highlights their importance in products
requiring heavy load-bearing or frequent maintenance, while
addressing drawbacks like aesthetics, weight, and production
complexity.
Examples:
Screws used in furniture design.
Riveting techniques in aerospace applications.
Performance Comparison:
Adhesives vs. Mechanical
Fasteners
This section compares the tensile, shear, and torsional strength of
adhesives and mechanical fasteners. It also examines their
durability under environmental factors.
Examples:
Tensile strength performance of adhesives in testing.
High-pressure resistance of mechanical connections.
When to Choose What?
Selection Criteria
Factors such as material type, production cost, application area, and
product lifespan determine the choice between adhesives and
mechanical fasteners.
Examples:
Reducing adhesive use in recycling-focused designs.
Preference for screws in high-vibration devices.
Hybrid Bonding Techniques:
Combining Adhesives and
Mechanical Fasteners
Combining adhesives and mechanical fasteners increases durability
while maintaining aesthetics and ease of production. This section
explains the design advantages of hybrid solutions.
Examples:
Adhesive and rivet combination in aircraft wing assembly.
Use of adhesives and screws together in electronic devices.
DES 2033
4. Mechanical Durability
and Performance of
Joining Materials
This topic examines the mechanical properties of joining materials
(e.g., adhesives, screws, rivets) in detail. It focuses on load-bearing
capacity, deformation tolerance, impact resistance, and
performance under environmental conditions. Practical examples
are provided to illustrate how different joining methods meet specific
mechanical requirements in product design.
Subtopics:
● What is Mechanical Durability? Key Concepts
● Mechanical Performance of Adhesives: Advantages and Limitations
● Performance of Mechanical Fasteners: Balance of Strength and Flexibility
● Durability Against Environmental Conditions: Material Selection
● Load-Bearing and Deformation Tolerance: Which Material for Which Case?
● Testing and Optimizing Joining Material Performance
What is Mechanical Durability?
Key Concepts
Mechanical durability defines how well a joining material can resist
applied forces. This section covers key concepts such as tensile,
shear, and torsional strength, along with the standards and methods
used in durability testing.
Examples:
Tensile strength testing results of an adhesive.
Torsional resistance of rivets in aerospace applications.
Mechanical Performance of
Adhesives: Advantages and
Limitations
Adhesives are evaluated for their ability to provide uniform stress
distribution. Their tolerance to heat, humidity, and long-term loads is
also assessed.
Examples:
Durability of epoxy adhesives in electronic devices.
Vibration-resistant adhesives in automotive applications.
Performance of Mechanical
Fasteners: Balance of Strength
and Flexibility
The resistance of screws, rivets, and other fasteners to various
forces is detailed. Their performance in heavy-load or impact-prone
products is particularly emphasized.
Examples:
High-strength screws in construction applications.
Rivet durability in vibration-heavy environments.
Durability Against
Environmental Conditions:
Material Selection
The resistance of joining materials to temperature, humidity, UV
radiation, and chemicals is discussed. This section highlights how
appropriate material selection impacts product lifespan.
Examples:
UV-resistant adhesives in solar panels.
Stainless steel fasteners in marine applications.
Load-Bearing and Deformation
Tolerance: Which Material for
Which Case?
The selection of joining materials in product design is based on
load-bearing capacity and deformation tolerance. This section
explores the performance of various joining materials in this context.
Examples:
Elastic properties of adhesives after deformation.
High-load screws in metal structures.
Testing and Optimizing Joining
Material Performance
Performance tests are a critical step in selecting joining materials for
product design. This section explains various testing methods and
optimization techniques.
Examples:
Tensile, shear, and torsional tests.
Adhesive test results in recyclable materials.
DES 2033
5. Selection of Joining
Materials from a
Sustainability
Perspective
This topic examines the environmental impact and recyclability of
joining materials. It highlights the criteria for selecting sustainable
joining solutions in product design. Examples demonstrate the
carbon footprint, recycling compatibility, and contribution to
long-lasting designs of different materials.
Subtopics:
● Environmental Impact of Joining Materials
● Recyclable Joining Materials and Their Applications
● Sustainability Criteria in Material Selection
● Role of Joining Materials in Long-Lasting Designs
● Innovations in Sustainable Joining Technologies
Environmental Impact of
Joining Materials
The environmental impact of joining materials during production,
usage, and disposal phases is explored. Materials with low carbon
footprints are emphasized.
Examples:
Biodegradable adhesives: Eco-friendly solutions derived from
agricultural waste.
Recycled plastics used in screws and their environmental benefits.
Recyclable Joining Materials
and Their Applications
This section evaluates the compatibility of joining materials with
recycling processes. Reusable fasteners and easily detachable
adhesive technologies are highlighted.
Examples:
Use of removable screws in electronic devices.
Soluble adhesives facilitating recycling processes.
Sustainability Criteria in
Material Selection
Criteria for sustainable joining material selection are defined,
focusing on durability, toxicity, production energy, and environmental
impact.
Examples:
Use of low-VOC adhesives in wooden furniture.
The role of lightweight metals in reducing carbon emissions as
fasteners.
Role of Joining Materials in
Long-Lasting Designs
The impact of joining materials on extending product lifespan is
discussed. Technologies that enable reuse and repairability are
examined.
Examples:
Modular designs in electronics supported by adaptable joining
materials.
Durable adhesives in automotive applications ensuring extended
service life.
Innovations in Sustainable
Joining Technologies
Recent innovations and trends in eco-friendly joining technologies
are discussed, with a focus on their integration into the design
world.
Examples:
Nano adhesives: High performance with less material.
Heat-dissolvable adhesives enhancing recycling compatibility.
DES 2033
6. Use of Joiners in the
Design Process:
Examples and
Applications
This topic focuses on the role of joiners in real-world product
designs. It examines how joiners are selected, applied, and
integrated into the design process across different industries.
Examples highlight the creative and technical approaches designers
adopt when choosing joiners.
Subtopics:
● Role of Joiners in Electronic Devices
● Joiner Solutions in Furniture Design
● Advanced Joiner Technologies in the Automotive Industry
● Joiners in Packaging Design
● Joiners in Medical Device and Healthcare Design
Role of Joiners in Electronic
Devices
The importance of joiners in the compact structure of electronic
devices is explored. Design criteria such as durability, lightweight
properties, and detachability are discussed.
Examples:
Double-sided adhesive tapes used in smartphones: Enhance
lightweight construction and aesthetics.
Screws and clips enabling modular design in laptops.
Joiner Solutions in Furniture
Design
The advantages of mechanical and adhesive joiners in furniture
design are compared. Ease of assembly and durability are
examined as key factors.
Examples:
IKEA’s screw and snap-fit systems for user-friendly assembly.
Natural glue types used in wooden furniture.
Advanced Joiner Technologies
in the Automotive Industry
The application of adhesives and mechanical joiners in automotive
design is evaluated. The focus is on bonding lightweight materials
and ensuring structural integrity.
Examples:
Structural adhesives used in vehicle body production: Enable lighter
and stronger vehicles.
Detachable fasteners in seat systems.
Joiners in Packaging Design
Joiners used in packaging design are examined for their aesthetic
and functional properties. The reasons for choosing eco-friendly
adhesives and snap-fit mechanisms are highlighted.
Examples:
Fast-drying adhesives used in foldable cardboard packaging.
Snap-fit connections in reusable plastic packaging.
Joiners in Medical Device and
Healthcare Design
The materials used for joiners in medical devices are assessed for
sterilization, biocompatibility, and durability.
Examples:
Ultrasonic welding methods used in disposable syringes.
Adhesive tapes in medical devices and their effects on patients.
