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A-Level Design > Other Manufacturing Processes > Flashcards

Other Manufacturing Processes Flashcards

1
Q

How are carbon fibres produced?

A

Heating polyacrylonitrile filaments through a range of temperatures up to 2000°C.

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2
Q

What is the first stage of manufacture using carbon fibre?

A

Carbon fibre matt is cut to shape using ceramic scissors.

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3
Q

What is the second stage of manufacture using carbon fibre?

A
  • The matt is the placed into a mould half.

- Resin is added and the material is forced into the shape of the mould.

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4
Q

What is the third stage of manufacture using carbon fibre?

A

The mould halves are fixed together and cooked for 8 hours at 170°C in order to promote cross links in the resin.

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5
Q

What is the first stage of manufacturing a GRP product?

A

The mould is coated with a releasing agent.

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6
Q

What is the second stage of manufacturing a GRP product?

A

A gel coat is applied to the mould with a 1mm thickness.

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7
Q

What is the third stage of manufacturing a GRP product?

A

The gel coat and hardener are coloured in order to catalyse the gel.

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8
Q

Describe the process of steam bending.

A
  • The timber is moistened until pliable.

- The wood can then be held in shape until dry

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9
Q

Describe the process of glass blowing.

A

An air bubble is blown into the glass and then enlarged to produce the final product.

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10
Q

What is slumping?

A

A process in which glass is heated until it becomes soft allowing it to take the shape of a mould.

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11
Q

What is a lehr?

A

A furnace used for annealing glass.

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12
Q

How is toughened glass produced?

A
  • The glass is heated uniformly and rapidly cooled by air jets.
  • The surface is then under compressive stress whilst the inside is under tension.
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13
Q

What is slip moulding?

A

The process of pouring slip into plaster of Paris moulds.

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14
Q

What is jiggering?

A

A process in which clay is rotated and moulded.

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15
Q

Describe the process of jiggering.

A
  • Clay dust is spread into the lower mould.

- A hydraulic ram lowers the flexible membrane.

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16
Q

Give five examples of printing processes.

A
  • Lithography
  • Letterpress
  • Flexography
  • Gravure
  • Screen printing
17
Q

Give two examples of electrostatic printing processes.

A
  • Electrophotographic

- Inkjet

18
Q

What are the four process colours?

A
  • Cyan
  • Magenta
  • Yellow
  • Black
19
Q

Describe the process of letterpress printing.

A

Raised letters are coated in ink and pressed onto the material.

20
Q

What is the first stage of offset lithography?

A

Printing material is fed into the machine as a sheet or web-fed.

21
Q

What is web-feeding?

A

Printing onto a continuous roll of paper.

22
Q

What is the second stage of offset lithography?

A
  • Printing plates are produced from photosensitive aluminium.
  • The plates are fitted onto the machine and a test run is carried out.
23
Q

What is the third stage of offset lithography?

A

The plate cylinder rotates onto a blanket roller which becomes coated with ink.
-The ink is then transferred onto the material.

24
Q

Give an advantage of using flexography.

A

Poor quality materials can be printed onto.

25
Q

Give two uses of screen printing.

A
  • Transferring designs onto paper and ceramics.

- PCBs can be produced.

26
Q

Give two advantages of using screen printing.

A
  • Able to print thick deposits of ink on uneven surfaces.

- Non-impact method of printing.

27
Q

Describe the process of gravure.

A
  • A stainless steel cylinder is engraved with thousands of holes with varying depth.
  • Ink collects in the holes as the cylinder rotates and excess is removed leaving only the desired image which can be printed onto the material.
28
Q

Describe the process of electrostatic printing.

A
  • The amount of toner deposited is controlled by the varying electrostatic properties.
  • The toner is fixed by absorption, heat or chemical reaction.
29
Q

Describe the process of inkjet printing.

A

Electrostatically charged ink droplets are sprayed onto the substrate.

30
Q

Give two advantages of digital printing.

A
  • Economical for short print runs.

- Ideal for “on demand” printing.

31
Q

Describe the process of thermal transfer printing.

A

Process colours are added individually by heating wax to leave colour on the substrate.

32
Q

Describe the process of dye sublimation printing.

A

The thermal printing head changes the temperature of the dye which controls the amount of dye being printed onto the substrate.

33
Q

Describe the process of die cutting.

A
  • One blade is the cutter.

- The other has a rounded edge which creases the cardboard allowing the material to be folded.

A-Level Design (8 decks)

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