16 Materials Processing in Industry

Content

• Shaping

– die cutting, creasing and folding

– turning (wood and metal lathes)

– calendering

– plasma cutting.

• Forming

– blow moulding (from a pre-form and extrusion)

– steam bending

– laminating

– press forming

– spinning.

• Redistribution methods

– sand, resin and die casting

– injection moulding

– extrusion

– rotational moulding

– compression moulding

– 3D printing.

• Wasting

– CNC milling

– stamping.

• Fabrication.

• How similar and dissimilar materials are joined:

– permanently

○ with nails and pins

○ by heat (soldering, brazing and welding)

○ with adhesives

– spray mount

– hot melt glue

– polystyrene cement

– PVA (polyvinyl acetate)

– all-purpose glue

– two-part epoxy resin

– temporarily

○ nuts and bolts

○ screws

○ knock down (KD) fittings

○ standard components (plastic rivets/split pins/staples/Velcro®)

○ tabs/flaps/locking tabs used on thin sheet material.

Content

• How materials are enhanced through processes and additives, including:

– metal enhancement

○ work hardening

○ annealing

○ case hardening

○ hardening and tempering

– polymer additives

○ plasticisers

○ pigment

○ fillers

○ anti-static

○ flame retardants

○ stabilisers

○ bio-batch.

• The different methods of printing and common applications for these methods, including:

– offset lithography

– flexography

– gravure

– sublimation printing

– pad printing.

• The CYMK colour separation method.

• The advantages and disadvantages of the colour separation method during printing.

• The advantages/disadvantages of applying finishes to a material to improve:

– performance

– aesthetics.

• Types of finish and methods of application, including:

– embossing/debossing paper and card

– UV varnishing/spot varnishing on paper and card

– hot foil blocking on paper and card

– paints

– sealants

– varnishes

– anodising

– plating

– coating.

• Physical tests to determine the suitability of materials and components for the application of a finish.