Sheet Processes

Question 1

Vacuum Forming (Plastics)

Answer 1

A hot plastic sheet is sucked onto a mould.

Used to Make: Packaging, toys, trays.

Identifying Features: Open, tray-like shape, large draft angles, large round corners.

Used if: I needed open, tray-like designs and I wasn’t bothered about high accuracy. Easily automated.

Question 2

Laser Cutting (Metal, Plastic, Wood)

Answer 2

A laser cuts and engraves thin, sheet materials.

Used to Make: Sheet objects, puzzles, jigsaws, decorations.

Identifying Features: Thin sheets, high quality edges, high accuracy, burn marks on wood.

Used if: I had thin sheets of material that needed to be repeatedly cut out with great accuracy.

Question 3

Line Bending (Plastic)

Answer 3

A hot wire heats plastic. Bends in a straight line.

Used to Make: Acrylic lecterns, riot shields, COVID screens.

Identifying Features: Straight line bends, some distortion at the corners.

Used if: I had thin sheet material that needed a few simple bends and I wasn’t bothered about high accuracy.

Question 4

Blanking and Piercing (Metal)

Answer 4

A cookie cutter (blanking) or a punch (piercing) creates parts or holes

Used to Make: Metal boxes and chassis such as inside PCs. Sinks, collanders.

Identifying Features: Very accurate, high quality edges that require no further finishing.

Used if: I wanted an automated, quick and accurate process to cut shapes or holes from metal. Relatively inexpensive.

Question 5

Press Forming (Metal)

Answer 5

A former hammers and presses metal into shape.

Used to Make: Bowls, sinks, car body panels.

Identifying Features: Thin sheet material, rounded corners and radiused curves. Good surface texture.

Used if: I wanted an automated, quick and accurate way to form simple shapes in metal. Creates v. strong product.