This page will focus on bringing a range of processes used across material groups.
Starting with casting, one of the first main processes used for metals, we humans have developed a range of casting processes and much more!
The commercial method of casting metals, the use of wax to form the void that metal is poured into.
The traditional method using 'green sand' or silicon sand to pour metal into a void/space in the sand.
Die Casting
What is die casting?
Hot pressure die casting
Cold pressure die casting
Types of casting shown above with several other options availible comercially. Consider the implications of the energy use (melting point of Aluminium or Iron varies and therefore the costs will change. The material must be suitable for the purpose of the design
Note the full process here. Casting, Heat treatment including quenching, CNC lathe, testing, finishing with spray 'paint' before brought in components are added.
Yep - it is a process for sheet metal called punching. But blanking creates a blank for use on something else, Piercing allows the left sheet to be used and punching... click on the youtube video to find out more...
Lets take a closer look at these metal sheet object creating processes
The actual machines on a different material
The industrial approach to school vacuum forming.
An example of thermal forming. Additional use of GRP for strength
Vacuum forming or THERMAL forming used in schools is explained here
Note the vacuum and infusion approach to this design
A 'must know' process
Note the use of vinyl stickers to enhance
Note the principle is almost the same as injection molding until the use of air to 'blow' the material to the form
This is simply the greatest toy on earth! Yet the Danish company has come along way from play.
What makes injection moulding so suitable for this toy/product and how has it come along?
This section takes a further look at polymer and high tech carbon fibre processes:
Large rotational moulding
Compression Moulding
Processing Carbon Fibre