Specialist Techniques And Processes + Material Management

Question 1

What is a tape measure used for.

Answer 1

Measure longer pieces of material or measuring distances e.g. length of a room

Question 2

How are steel rulers used?

Answer 2

Accurate measurements on smaller material. Steel provides consistency and a flat end allows you to measure from the edge of a piece of material easily.

Question 3

How are protractors used?

Answer 3

Measuring angles to be drawn on any materials

Question 4

How are french curves used?

Answer 4

Used to draw curves - different shapes and sizes are available to be selected as required.

Question 5

How are compasses used?

Answer 5

Used to draw circles on paper, card and timber. A similar tool with two spikes is used to mark out metal (called a divider)

Question 6

How are outside calipers used?

Answer 6

Used to measure the outside diameter or thickness of metal. Often used when turning material on a lathe so a quick and accurate measurement check can be made.

Question 7

How are scribers used?

Answer 7

Used to scratch the surface of metal to indicate where the material should be cut (as you would a lencil in wood)

Question 8

How are try squares used?

Answer 8

Used to draw lines at 90° to an edge. Similar products are used for metal and called an engineer’s square.

Question 9

How are marking gauge used?

Answer 9

The adjustable block is placed against a piece of wood and the spike (on the left) is dragged along the edge of the material to create a mark.

Question 10

Scenario: drill two holes in pieces of wood for an accurate dowel joint. This needs to be done over 100 times to make a batch of products

What manufacturing aid do I use?

Answer 10

The pieces of wood would be placed into a jih that has been set up to drill each hole in exactly the right place.
The jig may have a metal hole locator to prevent it from getting worn hpgiven the number being made.

Question 11

Scenario: Flower design to be cut out of thin plywood using a fret saw. Each flower should be the same and 20 are needed?

What manufacturing aid would you use and why?

Answer 11

Cut out one of the flower designs using card and then draw around it carefully using pencil on the sheet of the plywood.
Use the lines to carefuuly cut them out using the fret saw.

Question 12

Scenario: Star featured on a birthday card produced in a batch of 1000. The star is cut out to reveal a picture inside. The star must be cut accurately and be in the exact position.

Answer 12

Use a die cutter to stamp out the star design.
A jig could be used in conjunction to ensure the star is cut out in the exact place.
Die cutter may need to be manufactured specifically or there may be an off-the-shelf option available.

Question 13

Scenario: Fairy design to be laser cut in acrylic as part of a gift set. 30 products are required and they should be cut to minimise material wastage

What manufacturing aid would you use?

Answer 13

Design should be prepared on CAD and copied and pasted to ensure an exact replica.
Design should be tessellated to fit as many fairies on one piece of material to minimise waste.

Question 14

What is wastage?

Answer 14

Wastage is the process of cutting away material with tools and equipment.

Question 15

Name 3 examples of wastage?

Answer 15

• Die cutting
• Sawing
• Milling
• Drilling
• Turning

Question 16

What is addition?

Answer 16

Additin is the process of adding on material

Question 17

Uses of addition?

Name 3

Answer 17

• Brazing
• Welding
• Lamination
• Soldering
• 3D printing

Question 18

Deforming and reforming

Answer 18

Materials are shaled and formed using specialist machines and equipment to create new products

Question 19

Deforming and reforming uses

Answer 19

Materials are shaped and formed using specialist machines and equipment to create new products

Question 20

Uses of deforming and reforming

Answer 20

• Vacuum forming
• Bending
• Blow moulding
• Casting
• Injection moulding
• Extrusion

Question 21

Why is material management vital?

Answer 21

• Manufacturers will lose money if too much scrap raw material is produced during cutting
• Profits could be increased if they are able to find ways to lower the cost per product by saving material.

Question 22

What are the different methods of marking out effectively?

Answer 22

Tesselating
Nesting
Marking out 
Datum references
Marking out

Question 23

Tesselating

Answer 23

A method to used arrange items to be cur so that, when fitted together, as many as possible can be cut out a sheet of material

Question 24

Marking out

Answer 24

This improves the accuracy of a finished product

Question 25

Datum references

Answer 25

When marking out an object, datum references are used as a point for all measure,ents to be taken from and can be chosen by the manufacturer.

Question 26

Marking-out tools (jigs)

Answer 26

Jigs are toold made specifically to help place a material in the same llace repeatedly.