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Production Processes (Plastic (Injection Moulding (1. Plastic pellets or…
Production Processes
Plastic
Injection Moulding
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2. Heaters along the barrel heat the plastic to melt it as it is moved forwards by an Archimedes screw.
3. Once enough melted plastic is built up, the screw is hydraulically forced forwards, injecting the plastic into the mould.
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Blow Moulding
1. Air is blown into an extruded section of the tube, but the mould remains open.
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Rotational Moulding
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2. The mould then closes and is rotated on all axis, pulling the plastic to the outside of the mould.
3. The plastic cools, solidifying, and the mould is then opened to allow the ejection of the product.
Vacuum Forming
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2. The mould is moved up to just under the plastic and all the air between sucked out. The vacuum created sucks the plastic down, forming it to the shape of the mould.
3. The plastic cools and air is then allowed back in to allow the mould to drop down and the plastic to be removed.
Extrusion
1. The technique for melting the plastic and moving it used here is the same as the injection moulding (without the hydraulic injection part).
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Bending
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2. Once sufficiently heated the plastic is bent - often around a mould - then left to cool and harden in that shape.
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Metals / Alloys
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Lost Pattern Casting
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3. The molten metal instantly burns away the polystyrene foam and then fills the cavity left behind, producing the casting.
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Die Casting
1. First, a cast is made from two blocks of steel by spark eroding them while water cooling it to control the temperature.
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3. A hydraulic ram pushes a quantity of molten metal into the mould and pressure is then maintained until the metal has solidified.
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Wood
Sawing
Jigsaw
Jigsaws move the blade up and down to cut in a reciprocating motion. The work is cramped to the bench and the saw moved through it.
Bandsaw
Bandsaws rotate a continuous strip of saw blade in a loop to cut wood. They are used for mid to large sized cuts.
Powered Hacksaw
These saws use a horizontal motion (forwards and backwards) to cut the wood. They are driven by a crank slider mechanism.
Circular Saw
The saw spins while the material is moved across the table, blades can be very large so must be fixed in place.
Scroll Saw
Blade is held in tension and uses a reciprocating motion to cut. The bed can be angled to allow for angled cuts to be made into the wood.
Hand Saw
A saw which is hand powered, almost always just a handle attached directly to a blade. The blade can also be tensioned - like in a coping saw.
Chiselling and Planing
Chiselling
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Turing Lathe
Used for chiselling circular dowels or for getting circular patterns into rectangular dowels - like a banister rail / support ting.
Planing
A wedge shaped cutting blade is used to shave off specific amounts of wood, depending on the angle the blade is set at.
Drilling
Power Drills
Portable drills that can be used for a wide variety of purposes. Can be very easy to use, although the material must be firmly held in place.
Pillar Drills
Stationary drills also known as pedestal drills, require the material to be clamped to the bed before drilling.
Drill Bits
Centre Bits
These and jennings bits are used with a carpenters brace which is like a had drill, sorta.
Forstner Bits
Used on woods and some plastics to create clean, flat-bottomed holes.
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