Commercial Manufacturing

Question 1

Injection moulding (5)

Answer 1

• Very common method of commercial manufacturing
• Can be used to create intricate detail in the products itself or to aid assembly e,g clips/fixing points
• Suitable for high volume production
• Initial costs of moulds likely to be high
• Once setup, fast and consistent production

Question 2

Blow moulding (4)

Answer 2

• Common way of commercial manufacturing
• Forming hallow shales is a way it can be used
• Relatively detailed process
• Volume output is high with large quantities

Question 3

Vacuum forming (thermoforming) (5)

Answer 3

• One mould required for shell construction
• Moulds are cheaper
• Suitable for high or low volumes of production
• Sheet material in a stock form is used
• Individual products die cut from the plastic sheet

Question 4

Extrusion (4)

Answer 4

• Manufacture products with a fixed profile
• Can be cut to desired lengths
• As the plastics exits the extruder the plastic has to be cooled
• To prevent it from deforming it must be handled carefully

Question 5

Calendaring (3)

Answer 5

• Is a process where a material is passed through a series of rollers to create a consistent, flat sheet
• Large rolls is what excluded material is usually connected on
• The rolls can be used to create other stock forms

Question 6

Rotational moulding (4)

Answer 6

• Used to manufacture (often very large) products
• Plastics graduals are placed in the mould and the mould is heated and rotated on two axis so the molten plastic covers the surface of the mould
• Very consistent thickness of plastic and complex shapes
• Moulds much cheaper than injection or blow moulding as pressure is not required for the process

Question 7

Compression moulding (4)

Answer 7

• Process used for thermosetting plastics
• The exact amount of plastic is placed in the mould
• Pressure is used to force the plastic in the shape
• Heat is used to cure the plastic into a permanent shape