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AQA A-Level Design & Technology: Product Design > 1.19 The Use of Finishes > Flashcards

1.19 The Use of Finishes Flashcards

1
Q

Paper and Board Finishing

Lamination via encapsulation

A

A desktop laminator and the sheet of paper is encapsulated by a polymer pouch or film roll

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2
Q

Paper and Board Finishing

Lamination via a surface coating

A

Liquid lamination (for signage) or film lamination (meu cards)

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3
Q

Paper and Board Finishing

Embossing

A

Creates a raised design on the surface of the paper or card to give a visual and tactile effect (greetings cards, chocolate box lettering)

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4
Q

Paper and Board Finishing

Debossing

A

Produces an imprinted depression that sits below the surface of the paper or card

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5
Q

Paper and Board Finishing

UV varnishing

A

Provides a very smooth finish, usually high gloss or matt and chemcial resistant. Applied to a sheet via a set of rollers, then passed under UV light to cure

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6
Q

Paper and Board Finishing

Spot varnishing

A

Applied in specific areas or spots rather than to the whole surface area

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7
Q

Paper and Board Finishing

Foil blocking

A

Heat and pressure applied to a metallic paper (foil) to create areas of depth and texture to add aesthetic impact

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8
Q

Paper and Board Printing

Screen Printing

A
  • Can be carried out in a workshop with minimal set-up costs due to the use of basic screens and printing inks
  • A different is required for each colour
  • Quite a slow process with a reasonably high cost per product
  • Used for small print runs of items such as posters, display boards and textile T-shirts
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9
Q

Paper and Board Printing

Flexographic printing

A
  • Four colours (cyan, magenta, yellow, key (black)) are printed on top of one another in various quanties on to the substrate surface to create the print colour required.
  • It is used for newspapers, comics, catalogues, folding packaging cartons, labels, carrier bags and continous pattern products such as wallpaper and gift wrap.
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10
Q

Paper and Board Printing

Advantages of flexographic printing

A
  • High print speed
  • Ideally suited for the long run
  • Prints on a wide variety of substrate materials
  • Low cost of equipment and consumables
  • Low maintenance
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11
Q

Paper and Board Printing

Disadvantages of flexographic printing

A
  • The cost of the printing plates is relatively high, but they last for millions of print runs
  • Takes a large amount of substrate to set up the job; excess material may be wasted
  • Time consuming to change for any alterations to the print content
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12
Q

Paper and Board Printing

Offset lithographic printing

A
  • Extremely versatile printing process of producing one colour, five colours and a ten colours
  • Used for printing medium and long print runs of products such as books, business forms and documentation, magazines, posters and packaging.
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13
Q

Paper and Board Printing

Advantages of offset lithographic printing

A
  • Consistently high image quality
  • Suited to higher-volume print runs of 1000 or more
  • Quick and easy production of printing plates
  • Long life of printing plates because they only come into contact with the printing blanket, which is softer and less abrasive than substrate
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14
Q

Paper and Board Printing

Disadvantage of offset lithographic

A
  • Expensive set-up and running costs for small quantities
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15
Q

Paper and Board Printing

Digital printing

A
  • Produces full-colour, highly detailed print runs with the option of different designs on each page, both front and reverse sides
  • Widely utilised resources for printing products, due to their speed and efficiency
  • Can be used for low and high volume print runs
  • Used for mass customisation, such as the printing of specific names on drinks cans.
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16
Q

Polymer Finishing

Overmoulding

A

Overmoudling is moulding a second polymer over specific parts of a products

  • TPE (thermoplastic elastomer) is often used
  • Overmouldings provide areas of grip or texture
  • Overmoulding can highlight different colours for different component Polymer Finishing parts on the product
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17
Q

Polymer Finishing

Two injection moulding moulds

A
  • One mould for the product and one mould for the grip areas
  • Product is injection moulded, then placed into a second mould where the overmoulding polymer is injection-moulded on to the body
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18
Q

Polymer Finishing

Twin-shot injection moulding

A
  • The injection moulding machine has a mould designed to produce the product in one cycle
  • The mould has two separate component cavities and can be rotated through 180° so that they line up with the twin injection points
  • First, the main product part is created in the first mould cavity
  • The mould opens slightly and rotates 180° to the secondary position
  • The mould closes and the second injection applies the overmould
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19
Q

Polymer Finishing

Acrylic spray paints

A
  • Fast-drying
  • Water-soluble paint
  • Water resistant when dry
  • Improves aesthetics and provides additional protection against the effects of UV light and weathering
  • Often used for mass customisation, particularly in the automotive industry, such as colour coding bumpers and wing mirrors on cars.
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20
Q

Polymer Finishing

Adding pigments

A
  • Provide colour to the polymer
  • Smart pigments such as thermochromic or phosphorescent pigments can be added
  • Can also be added to gel coats when laying up GRP
21
Q

Metal finishing

Cellulose and acrylic paints

A
  • Provide colour and a textured finish
  • Provide a barrier against corrosion
  • Specialist paints provide texture or special graphic effects such as pearlescence
  • Primarily used on low-cost metals such as steel.
22
Q

Metal finishing

State the method of application of cellulose and acrylic paints

A
  • Paints are primarily used on low-cost metals such as steel. The surface of the metal is cleaned and degreased, which ensures that the primer coat has a sound surface to ‘key’ (or grip) to
  • Red oxide primer is often used, followed by an undercoat in a similar colour to the final top coats
  • Paints can be applied by brush or spray
23
Q

Metal finishing

Electroplating

A
  • A protective layer, a more hardwearing finish, and enhanced aesthetics
  • The product and donor material are placed in a container with an electrolyte solution. As the direct current is applied, the product attracts the donor metal and the product is electroplated.
  • Metals for electroplating include sliver, gold, zinc, copper and tin
24
Q

Metal finishing

State the method of application of electroplating

A
  • The product and donor material are placed in a container with an electrolyte solution
  • As the direct current is applied, the product attracts the donor metal and the product is electroplated
  • Metals used are sliver, gold, zinc, copper and tin
25
Q

Metal finishing

Polymer dip coating

A

1) Used on products such as wire coat hangers, kitchen dish drainers, coat hooks, dishwasher racks, and outdoor play equipment frames

26
Q

Metal finishing

State the method of application of polymer dip coating

A
  • The metal product is heated to approximately 230°C
  • The hot product is then dipped into a tank of fine polymer powder, which has air blowing through it (fluidisation bath) to provide an even coating on the product.
  • The retained head from the product melts the polymer powder over the product, which is then air cooled allowing the coating to set evenly
27
Q

Metal finishing

Metaldip coating

A

1) Provides a barrier against corrosion
2) Tin plating: often used to provide a non-corrosive coating to food cans
3) Zinc plating: used for many industrial and agricultural applications such as beams, gates, and animal pens. Also, like the first protective layer in car bodies made from low carbon steel.

28
Q

Metal finishing

State the method of application of metaldip coating

A
  • Metals are coated by dipping the product into a tank of molten plating metal (the donor metal)
    -The metals must be clean and degreased
  • Tin plating:
    • pass sheets of steel through a tank of molten tin at approximately 320°C
  • Zinc plating (galvanising):
    • dipping steel into molten zinc at approximately 460°C
29
Q

Metal finishing

Powder coating

A
  • Protection from corrosion and aesthetic appeal, more hardwearing than paint
  • Used on washing machine bodies, dishwasher bodies and refrigerator bodies, metal gates, fencing, and railings.
30
Q

Metal finishing

State the method of application of powder coating

A
  • The product to be coated is statically charged (negative)
  • Thermoset polymer resin (positively charged) is then sprayed through an airgun
  • The use of charge results in a strong attraction between the powder and the product
  • The product is then baked in a oven; the heat melts the powder over the product to give an even coating
31
Q

Metal finishing

Metal varnishing

A
  • Protects the metal and allows the colour of the base metal to show through.
  • Used on aluminium, brass, and copper
32
Q

Metal finishing

State the method of application of metal varnishing

A
  • The metal is polished to a shine and any surface grease removed
  • The varnish is then applied by either a spray or with a fine brush
33
Q

Metal finishing

Sealants

A
  • Tough polymer-based sealant coatings to protect polished surfaces from decay and tarnishing.
  • Often used in the automotive industry against the effects of weathering, road salts, and insect attack
34
Q

Metal finishing

State the method of application of sealants

A
  • The sealant is applied with a cloth or machine pad to produce a film that is then allowed to cure for up 15 minutes
  • It is then buffed with a cloth to a shone
35
Q

Metal finishing

Preservatives

A

1) Can provide temporary in-processes or final post-processing, medium to long term protection for metal surfaces
2) Often used on moulds and dies for preventing fingerprints showing on surfaces, minor atmospheric corrosion, or condensation build-up

36
Q

Metal finishing

State the method of application of preservatives

A
  • Applied by wiping on with a cloth, spray, or immersion of the product
  • Silicon sealants can also be classed as preservatives and can be used on machine beds to provide a smooth, snag-free surface to allow materials to be pushed across the bed more easily and safety
37
Q

Metal finishing

Anodising

A
  • Commonly used for aluminium products to enhance the natural oxide layer, resulting in increased hardness and toughness
  • Can also provide colour
  • Used in the outer casings of torches, external hard drives covers, and casings for mobile phones or digital music players
38
Q

Metal finishing

State the method of application of anodising

A
  • The electric current passes through the sulphuric acid electrolyte solution from the part to be treated to a negative cathode
  • As the current flows from the part to be treated (positive anode) to the negative cathode, the aluminium oxide layer builds upon the treated part, producing the anodised finish
  • Anodised products can then be finished with a clear lacquer or varnish to seal the finish and provide further protection against surface scratches
39
Q

Metal finishing

Cathodic protection

A

A method used to control the rate of corrosion of metals

40
Q

Wood finishing

Polyurethane varnish/acrylic varnish

A
  • Provides a hard, tough, heatproof, waterproof finish

- Clear finish allows the grain of the wood to be seen through the finish

41
Q

Wood finishing

Water-based paints

A
  • Paint provides both protection and colour. It can be applied for both indoor and outdoor use and is predominantly used for softwoods
  • Paint makes surfaces more aesthetically pleasing, tougher, harder and resistant to moisture
42
Q

Wood finishing

Stains

A
  • Help colour and enhance the grain
  • Stains can be used to colour an inexpensive wood to make it look more expensive or to add colour
  • Stains do not have any specific protective properties
43
Q

Wood finishing

Colour wash

A
  • Used to help colour the wood to make it more aesthetically pleasing or to add a vintage style while allowing the grain to show
44
Q

Wood finishing

Wax

A
  • Can be buffed to provide a high gloss finish
  • Increases the surface hardness and toughness
  • Clear finish allows the grain of the wood to be seen through the finish
45
Q

Wood finishing

Yacht varnish

A
  • Suitable for woods that are outside all year round such as doors, window frames or boat parts
  • Increases toughness, hardness, and weather resistance
46
Q

Wood finishing

Teak oil

A
  • Primarily used for outdoor wood products to improve weather resistance and resistance to fungal and insect attack
  • Aesthetically pleasing as grain is enhanced
47
Q

Wood finishing

Pressure-treating

A
  • Helps protect the wood for up to 50 years from rot, insect and fungal attack, and weathering
  • Suitable for products such as decking, overhead cable poles, harbour or bridge construction
48
Q

Wood finishing

Danish oil

A
  • Maintains the natural appearance of the timber, soaks into the wood, and enhances the grain
  • Not a hardwearing finish but regular application and subsequent coats build up a matt, water-resistant finish
49
Q

Wood finishing

Yacht varnish

A
  • Suitable for woods that are outside all year round such as doors, window frames or boat parts
  • Increases toughness, hardness, and weather resistance

AQA A-Level Design & Technology: Product Design (52 decks)

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