3.1 polymers paper processes,techniques,specialist tools

Question 1

What is Resin casting

Answer 1

-a process for casting polymers

Question 2

What does the resin casting process involve

Answer 2

-pouring the polymer resin into a pre made mould and then allowing the resin to set into shape
-the mould can be gently vibrated to expel any air bubbles from the casting

Question 3

What are the most commoly used resins in resin casting

Answer 3

acrylic ,polyester and epoxy

Question 4

When can resin casting be done and with what moulds

Answer 4

-can be done at room temperature,fairly simple process
-moulds made from materials like MDF or silicon rubber

Question 5

What can be added to the resin in resin casting

Answer 5

pigments can be added to the resin to give a colour to products such as toys ,jewellery ,prototype models and dentistry

Question 6

Different types of moulding processes to manafacture thermoplastics ino products

Answer 6

-blow moulding
-injection moulding
-vacuum forming
-extrusion
-rotational moulding

Question 7

Features of blow moulding

Answer 7

-for making hollow thin walled components
-has a high intial tooling cost
-used for continuous production
-uses a thermoplastic tube ‘parison’

Question 8

products from blow moulding

Answer 8

drink bottles, shampoo bottles, detergent bottles etc

Question 9

Figure of Blow moulding

Answer 9

Question 10

Features of Injection moulding

Answer 10

-complex 3D shapes can be quickly and easily made
-fast industrial production method
-high intial tooling cost
-used for large scale mass or continous production
-uses thermoplastic granules

Question 11

products of injection moulding

Answer 11

electrical product casings (computers, TVs, vacuum cleaners, calculaters etc)

Question 12

Figure of injection moulding

Answer 12

Question 13

Features of vacuum forming

Answer 13

-moulds are easy to make but need a draft angle,air holes and rounded corners
-not cost effective for one off manufacture
-good for small scale batch production
-uses thermoplastic sheet up to abt 6mm in thickness

Question 14

products of vacuum forming

Answer 14

lightweight trays, box inserts and liners, takeaway coffee cups and yogurt pots

Question 15

figures of vacuum forming

Answer 15

Question 16

features of extrusion

Answer 16

-similar to injection moulding but the polymer is forced through a die at the end
-good for continous production
-uses thermoplastic granules

Question 17

products of extrusion

Answer 17

solid rods,tubing, angle sections, curtain track

Question 18

Figure of extrusion

Answer 18

Question 19

Features of rotational moulding

Answer 19

-produces seamless hollow components with a large wall thickness
-mould is continuously rotated through heating and cooling stages
-used in large scale batch or mass production
-uses thermoplastic powder or granules

Question 20

Products of rotational mouding

Answer 20

traffic cones,kayaks, water tanks, kerosene tanks, children’s play equipment

Question 21

Figure of rotational moulding

Answer 21

Question 22

polymer lamination example

Answer 22

the lay up lamination process
for GRP and CFRP( fibre based composite sheets)

Question 23

features of the lay up lamination process

Answer 23

-a former is needed to mould the material around
-polyester resin is used as the polymer and a top gel coat can provide pigment colour
-CFRP requires an autoclave for the product to ‘cure’ to shape

Question 24

products made from the lay up lamination process

Answer 24

kayaks, boat hulls, train carriages, theatre props, theme park rides

Question 25

Figure of the lay up lamination process

Answer 25

Question 26

What to use to mark up polymers

Answer 26

a dry wipe pen or a chinagraph pencil