polymer process

Question 1

vacuum forming

Answer 1

trays, yoghurt pots

requires draft angles
round corners and air holes
not cost effective for one off
small scale batch or mass

Question 2

thermoforming

Answer 2

bath, food packaging

like vacuum forming but additional mould pressed on surface at the same time as vacuum
fine detail e.g. logos
slow

Question 3

calendaring

Answer 3

thin polymer sheets and film

heated rollers squash and stretch polymer to make it thinner
industrial process for continuous production

Question 4

line bending

Answer 4

acrylic boxes
point of sale displays

electrically heated element
provides heat along a line
slow and labour intensive
one off or limited

Question 5

laminating

Answer 5

kayaks, theme park carriages
requires former to mould around
uses polyester resin
top gel coat
may contain pigment

Question 6

injection moulding

Answer 6

electrical product casings, computers, tvs, vacuum cleaners

complex 3d shapes
fast
high initial cost
large scale mass or continuous

Question 7

blow moulding

Answer 7

drinks bottles, shampoo, detergent

makes hollow, thin walled
high initial cost
continuous production

Question 8

rotational moulding

Answer 8

traffic cones, childrens play equipment

seamless hollow components with large wall thickness
mould continuously rotated through heating and cooling
large scale batch or mass

Question 9

extrusion

Answer 9

solid rods, tubing, curtain track

like injection moulding but polymer forced through die, industrial, continuous

Question 10

compression moulding

Answer 10

electrical light fittings, switches, plugs

pre-weighed slug of polymer
polymer remove from moulds while still warm
large scale batch