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Jake Product Design > Unit 7 Working With Polymers > Flashcards

Unit 7 Working With Polymers Flashcards

1
Q

What are the scales of production associated with plastic products?

A

Polymers are used at all scales of production.

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2
Q

What production methods are commonly associated with plastic products?

A

Mass and continuous production methods.

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3
Q

What is one-off production?

A

One-off production involves crafts people and artists creating handmade, bespoke products such as sculptures and furniture.

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4
Q

What are the characteristics of one-off production?

A

One-off production is usually time-consuming, requires a high level of skill, and is typically expensive to produce.

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5
Q

What materials are commonly used in one-off production?

A

Resins are commonly used for their decorative qualities.

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6
Q

What application might you use polyurethane varnishes in a school workshop?

A

Polyurethane varnishes can be used for various finishing applications in a school workshop.

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7
Q

What is batch production?

A

Batch production is a broad term for production runs of anything from ten to tens of thousands of products.

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8
Q

What is vital for consistency in batch production?

A

Consistency is vital; therefore, jigs, templates, and patterns are used to aid replication.

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9
Q

How does the mechanisation of batch production compare to one-off production?

A

Processes are more highly mechanised than in one-off production.

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10
Q

What are some examples of products that are often batch produced?

A

Moulded furniture and toys are often batch produced.

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11
Q

Why is batch production ideally suited to the production of some packaging products?

A

This question prompts consideration of the efficiency and consistency benefits of batch production for packaging.

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12
Q

What are jigs used for in manufacturing?

A

Jigs aid manufacture and speed up repeat processes, adding increased accuracy.

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13
Q

How do jigs assist in line bending?

A

Jigs can help make accurate angles when line bending.

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14
Q

What is one use of a jig with polymer sheets?

A

A jig might be used to help fold a polymer sheet and ensure that folds run perpendicular to the edges of the sheet.

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15
Q

How do jigs assist with drilling?

A

Jigs may help with positioning and dimensioning, for example, when drilling a hole.

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16
Q

How does the use of jigs increase efficiency in batch production?

A

Jigs increase efficiency by providing consistent and accurate setups for repetitive tasks.

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17
Q

What are patterns in resin casting?

A

Patterns are the positive forms used in resin casting to produce negative moulds.

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18
Q

What is the purpose of moulds in resin casting?

A

The moulds enable identical copies to be made.

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19
Q

What materials can patterns be made from?

A

Patterns can be made from a range of materials including clay, wood, and silicone rubber.

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20
Q

What are patterns usually sprayed with before they are cast?

A

Patterns are usually sprayed with a release agent before they are cast to create moulds.

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21
Q

What factors influence the materials used for moulds?

A

The materials used for moulds depend on a variety of factors including how many times the mould will be used and what is being cast or moulded.

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22
Q

What materials can be used to make moulds?

A

Materials used include Plaster of Paris, silicon rubber, latex, and GRP.

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23
Q

What materials are commonly used for moulds in school vacuum forming?

A

Moulds used for vacuum forming in school may be made from wood, MDF, and Styrofoam.

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24
Q

What is the common material for industrial moulds?

A

In industry, moulds are frequently made from tool steel.

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25
Q

What advantage does tool steel provide for moulds?

A

Tool steel ensures durability and longevity of the moulds.

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26
Q

What is mass production?

A

Mass production uses a production line to produce high numbers of identical products quickly.

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27
Q

How does mass production compare to batch production?

A

It is more highly automated than batch production and requires less skilled labour.

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28
Q

What are common products that are mass produced?

A

Common day to day products such as food packaging, plastic bags, and cups are usually mass produced.

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29
Q

How are materials for mass production typically purchased?

A

Materials for mass production are generally purchased in bulk.

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30
Q

What is a drawback of mass production?

A

Set-up costs are high, so what factors help to lower unit costs?

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31
Q

What is continuous production?

A

Continuous production is similar to mass production using a production line to manufacture quantity.

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32
Q

What is a characteristic of continuous production?

A

Only one product is made with very few, if any alterations.

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33
Q

What is a key feature of continuous production?

A

As the name suggests, there is no downtime.

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34
Q

What types of products are ideal for continuous production?

A

Continuous production is ideal for products such as HDPE milk bottles, PET drinks bottles, and film used for refuse sacks and other plastic bags.

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35
Q

Why is continuous production suitable for certain products?

A

Continuous production is suitable for these products due to the high demand and the efficiency of the production process.

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36
Q

What is calendaring?

A

Calendaring is a production process using a series of rollers to produce a thin polymer sheet or film.

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37
Q

What happens to polymer pellets during calendaring?

A

Polymer pellets are heated and softened.

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38
Q

What is done with the softened polymer feedstock in the calendaring process?

A

The softened polymer feedstock is extruded through a series of heated rollers.

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39
Q

What effect do the heated rollers have on the polymer?

A

The rollers flatten and stretch the polymer.

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40
Q

What happens to the polymer sheet after it is processed by the final rollers?

A

The final rollers cool the sheet, and it is either rolled or cut to length.

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41
Q

What is calendared plastic sheet or film used to manufacture?

A

Calendared plastic sheet or film is used in various manufacturing processes.

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42
Q

What is extrusion?

A

Extrusion is a production method used to create a continuous flow of plastic that is pushed through a die to create a specific profile.

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43
Q

What products are created using extrusion?

A

Extrusion is used for cables, pipes, mouldings, tubes, seals, and window and door frames.

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44
Q

What types of plastic products are made using extrusion?

A

It is used to create the plastic film used for bags and packaging, as well as the plastic filament used for 3D printing.

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45
Q

Is much waste produced during the extrusion process?

A

Yes, much waste is produced during the extrusion process.

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46
Q

What is the starting point of the extrusion process?

A

The extrusion process starts off in a similar way to injection moulding, using a die instead of a mould.

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47
Q

What does the die do in the extrusion process?

A

The die sets the profile of the extruded plastic and must be made to a very precise tolerance.

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48
Q

What is required for the flow of softened plastic during extrusion?

A

A continuous flow of the softened plastic passes through the die at just the right temperature and flow rate to hold the shape.

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49
Q

What is the form of polymers before processing?

A

Polymers in powder or granule form are processed to produce usable stock forms for manufacture.

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50
Q

What factors influence the formation of polymers?

A

Polymers can be formed in various ways depending on factors such as the manufacturing location, product type, production scale, and polymer material used.

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51
Q

Where can polymers be manufactured?

A

Polymers can be manufactured in a school workshop or in an industrial facility.

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52
Q

What aspects determine the method of forming polymers?

A

The method of forming polymers is determined by the product or part being formed, the scale of production, and the type of polymer material.

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53
Q

What methods of forming are commonly used in school workshops?

A

The text does not specify the methods, but it implies that there are common methods used in school workshops.

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54
Q

What is vacuum forming?

A

Vacuum forming is a process used to create products by shaping plastic sheets over a mold using vacuum pressure.

Vacuum-formed products include items such as plastic yoghurt pots and bath tubs.

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55
Q

What is the most commonly used plastic for vacuum forming in schools?

A

HIPS (high impact polystyrene) is the most commonly used plastic to vacuum form within schools.

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56
Q

What other materials are used for vacuum forming in industry?

A

In industry, polyester, ABS, and acrylic are also used for vacuum forming.

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57
Q

Why is vacuum forming suited for use in the school workshop?

A

Vacuum forming is suited for use in the school workshop due to its simplicity and the availability of materials like HIPS.

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58
Q

What is the first stage of the vacuum forming process?

A

A sheet of thermoplastic is heated and pressed onto the former (mould) by atmospheric pressure as a vacuum reduces the pressure below the softened thermoplastic.

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59
Q

What happens to the plastic during the vacuum forming process?

A

The plastic takes on the shape of the mould, then cools and sets in position before the mould is removed.

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60
Q

What is a suitable mould/former in vacuum forming?

A

A suitable mould/former is carefully manufactured.

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61
Q

What is the role of the electric heater in the vacuum forming process?

A

The electric heater is turned on to warm the plastic sheet.

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62
Q

What occurs to the air during the vacuum forming process?

A

The air is pumped out below the plastic and mould.

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63
Q

What features must a mould have to ensure a good product is formed?

A

A mould must have rounded corners and edges with a small radius.

This helps in preventing stress concentrations and ensures better flow of the material.

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64
Q

What is the required positive draft angle for a mould?

A

A mould must have a positive draft angle greater than 3° to ensure easy removal.

This angle helps in reducing friction during the removal process.

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65
Q

Why are vent holes necessary in a mould?

A

Vent holes must be drilled where there are dips in the profile.

This allows trapped air to escape, preventing defects in the final product.

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66
Q

What should be avoided regarding the profile depth of a mould?

A

A mould must not have too deep a profile.

Deep profiles can complicate the moulding process and lead to defects.

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67
Q

What finish should a mould have?

A

A mould must have a smooth finish.

A smooth finish reduces friction and improves the quality of the final product.

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68
Q

What feature should a mould avoid to ensure product quality?

A

A mould must avoid undercuts.

Undercuts can make it difficult to remove the product from the mould.

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69
Q

What is line bending?

A

Line bending is a means of creating a permanent fold in a piece of thermoplastic such as acrylic.

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70
Q

What equipment is used for line bending?

A

Strip heaters are used for line bending.

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71
Q

What types of products are often created using line bending?

A

Line bending is often used to create small products in the school workshop.

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72
Q

What are some examples of products made using line bending?

A

It is ideal for creating display stands, menu holders, and photo frames.

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73
Q

What scales of production does the line bending process lend itself to?

A

The text does not provide specific information on the scales of production for line bending.

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74
Q

What should be done before placing the polymer sheet on the strip heater?

A

Marking out should be done carefully and accurately.

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75
Q

How is the line marked on the polymer sheet?

A

A line is marked on the polymer sheet often using a chinagraph pencil or non-permanent marker.

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76
Q

What is the first step in the line bending process?

A

The strip heater is heated to temperature.

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77
Q

What is done with the marked line on the workpiece?

A

The marked line on the workpiece is placed across the heating strip.

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78
Q

What should be considered when using a strip heater in the workshop?

A

Health and safety considerations.

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79
Q

What factors influence the heating time of a polymer sheet in the line bending process?

A

The type and thickness of the polymer sheet.

None

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80
Q

What is done to the polymer sheet during the line bending process?

A

The polymer sheet is allowed to heat through.

None

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81
Q

How is the flexibility of the line tested in the line bending process?

A

The line is tested for flexibility and when ready, bent to the required angle.

None

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82
Q

What is done to the workpiece after it has set in the line bending process?

A

It can be cooled in a water tray.

None

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83
Q

What can be made to help ensure the polymer sheet is bent accurately?

A

A jig or template can be used to ensure accuracy.

None

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84
Q

What factors influence the heating time of a polymer sheet in the line bending process?

A

The type and thickness of the polymer sheet.

None

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85
Q

What is done to the polymer sheet during the line bending process?

A

The polymer sheet is allowed to heat through.

None

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86
Q

How is the flexibility of the line tested in the line bending process?

A

The line is tested for flexibility and when ready, bent to the required angle.

None

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87
Q

What is done to the workpiece after it has set in the line bending process?

A

It can be cooled in a water tray.

None

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88
Q

What can be made to help ensure the polymer sheet is bent accurately?

A

A jig or template can be used to ensure accuracy.

None

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89
Q

What can thermosetting polymer resins be combined with?

A

Thermosetting polymer resins can be combined with fibres to produce a variety of products.

90
Q

What types of products can be created using laminating or layup?

A

This process is used to create rigid three-dimensional products like speed boats, rowing boats, canoes, caravan panels, and even bumper cars.

91
Q

What is the advantage of a fibre-based composite over a moulded thermoplastic?

A

The advantage of a fibre-based composite over a moulded thermoplastic is not specified in the text.

92
Q

What materials are used to create composites in the layup process?

A

Fibre strands or matting, such as glass fibre, carbon fibre, or Kevlar.

93
Q

What materials can be used to make the mould in the layup process?

A

Timber, board, or metal.

94
Q

What is applied to the mould before the layup process?

A

A release agent.

95
Q

What is applied and cured on the mould in the layup process?

A

Polyester resin gel coat.

96
Q

What is done after matting is laid into the mould?

A

The resin is mixed with a catalyst and brushed onto the matting.

97
Q

How may chopped strands be applied in the industry?

A

They may be mixed with resin and sprayed onto the mould.

98
Q

What is done to remove air bubbles after applying the resin?

A

The mixture is rolled to remove air bubbles and then allowed to set.

99
Q

What is thermoforming?

A

Thermoforming is the process of forming a heated, softened polymer sheet.

100
Q

How does thermoforming differ from vacuum forming?

A

Thermoforming uses both male and female moulds, while vacuum forming typically uses only one mould.

101
Q

What is the role of the male mould in thermoforming?

A

The male mould is lowered into the heated sheet, pressing it into the female mould.

102
Q

What assists in pulling the polymer into the mould during thermoforming?

A

A vacuum assists in pulling the polymer into the mould.

103
Q

What types of products can be manufactured using thermoforming?

A

Various packaging products can be manufactured using thermoforming.

104
Q

What is injection moulding?

A

Injection moulding is commonly used in industrial production to produce complex shapes.

105
Q

What are moulds generally constructed from in injection moulding?

A

Moulds are generally constructed from steel and are in two parts.

106
Q

Which polymers are suitable for injection moulding?

A

A number of different polymers are suitable for injection moulding and include ABS, acrylic, and PVC.

107
Q

Why is it important that moulds are very accurate?

A

It is important that moulds are very accurate and any blemishes are removed to ensure quality in the final product.

108
Q

What starts the injection moulding process?

A

The injection moulding process starts with the thermoplastic granules being fed into a hopper.

109
Q

What does the hopper do in the injection moulding process?

A

The hopper feeds an Archimedes screw that drags the granules past a heater where they are plasticised.

110
Q

What happens when the plastic reaches the end of the screw?

A

A hydraulic piston forces it into the mould.

111
Q

What is the role of the Archimedes screw in the injection moulding process?

A

The Archimedes screw drags the granules past a heater for plasticisation.

112
Q

What is used to cool and set the plastic quickly in the ejection and finishing process?

A

Water is used to cool and set the plastic quickly.

113
Q

What happens after the mould is separated in the ejection process?

A

Ejector pins release the moulding; the process is then repeated.

114
Q

What is done with any excess polymer flashing?

A

Any excess polymer flashing is trimmed and usually recycled.

115
Q

How does injection moulding lend itself to mass production?

A

Injection moulding is efficient and allows for rapid production of identical items.

116
Q

What are the tell-tale signs that a product has been injection moulded?

A

Signs include visible seams, uniformity in shape, and the presence of ejector pin marks.

117
Q

What is blow moulding?

A

Blow moulding uses a two-part mould and compressed air to make hollow shapes.

118
Q

What types of polymers are used in blow moulding?

A

Polymers like HDPE, PET, PP, and LDPE are used.

119
Q

What products are made using blow moulding?

A

Hollow plastic products including garden water butts, bins, and some hollow plastic toys.

120
Q

What packaging is created through blow moulding?

A

It is used to create packaging such as bottles and containers.

121
Q

Why is a two-part mould used in blow moulding?

A

A two-part mould is essential for shaping the hollow structures.

122
Q

What is the first step in the blow moulding process?

A

Polymer granules are heated and extruded to create a plastic tube known as a parison.

123
Q

What happens after the parison is created?

A

The parison is fed into the mould and is pinched at the bottom as the mould closes tightly.

124
Q

How is the parison inflated to fill the mould?

A

It is filled with heated compressed air until the parison inflates to fill the mould.

125
Q

What occurs after the parison fills the mould?

A

The plastic cools and takes on the shape of the mould.

126
Q

What happens to the cooled moulding in blow moulding?

A

The cooled moulding is then released and finished.

127
Q

What is done with excess or flashing created during blow moulding?

A

Any excess or flashing created is automatically trimmed.

128
Q

What happens to the waste material from blow moulding?

A

This waste material is recycled and reused.

129
Q

How are products tested after blow moulding?

A

Products are tested to ensure they are air and water tight.

130
Q

What happens to rejected products in blow moulding?

A

Any rejects are sent for recycling.

131
Q

What is a common feature of high production moulds?

A

High production moulds are often water cooled.

132
Q

How does water cooling contribute to blow moulding?

A

Water cooling contributes to the efficiency of the process.

133
Q

What is rotational moulding used for?

A

Rotational moulding is used to create hollow plastic forms.

134
Q

What types of polymers are commonly used in rotational moulding?

A

Polymers like HDPE and PP are commonly used.

135
Q

What is a key characteristic of products made by rotational moulding?

A

The process produces a seamless product.

136
Q

What are some examples of heavy duty items made using rotational moulding?

A

Examples include water tanks, communal recycling bins, kayaks, and plastic slides.

137
Q

Why isn’t blow moulding used to create heavy duty items?

A

Blow moulding is not suitable for these products due to their design and structural requirements.

138
Q

What is the first step in the rotational moulding process?

A

Polymer granules or powder is weighed, depending on the desired wall thickness and put into the mould.

139
Q

What happens to the mould after the polymer is added?

A

The mould is then placed on a rig in a huge oven and heated.

140
Q

How is the polymer distributed inside the mould?

A

As it is heated, the mould is rotated slowly in two axes, allowing the polymer to coat the inside of the mould evenly.

141
Q

What occurs once the desired thickness is reached?

A

The mould is cooled.

142
Q

What is a consequence of cooling the polymer?

A

There is slight shrinkage as the polymer cools.

143
Q

What is the advantage of the slight shrinkage of the polymer?

A

The slight shrinkage helps in the easy removal of the finished product from the mould.

144
Q

What is the compression process in polymer forming?

A

The compression process uses two separate moulds, a male and female, which when pressed together create a void.

145
Q

What is placed between the moulds during the compression process?

A

A charge or preform of polymer is placed between the moulds.

146
Q

What happens to the moulds during the compression process?

A

The moulds are heated, and pressure is exerted on them, forcing the charge into the void.

147
Q

What occurs after the polymer part is formed in the mould?

A

The part is left to cool before being removed using an ejector pin.

148
Q

Why is the amount of polymer used slightly greater than needed?

A

The amount of polymer used is slightly greater than that needed to fill the void to ensure complete filling.

149
Q

What does it mean for most plastics to be self-finishing?

A

It means they do not require any further finishing and are ready to go straight from production.

150
Q

How is the texture of polymers determined?

A

The texture comes from the surface finish of the moulds used to form them or the die profiles used when extruding.

151
Q

Why are polymers often considered to be self-colouring?

A

This is related to their ability to maintain color without additional finishing processes.

152
Q

What are thermochromic pigments?

A

Thermochromic pigments can be added to polymers to create a colourful reaction to thermal changes.

153
Q

How do temperature sensitive thermochromic pigments react?

A

They can change from one colour to another or from colour to clear as temperature rises and falls.

154
Q

What are some applications of thermochromic pigments?

A

Applications include plastic cutlery, bowls, and cups for babies and young children, and plastic films used in thermometers.

155
Q

Where might non-reversible thermochromic pigments be used?

A

Non-reversible thermochromic pigments can be used in various applications where a permanent colour change is desired.

156
Q

What are phosphorescent pigments?

A

Phosphorescent pigments are charged by exposure to natural light.

157
Q

How do phosphorescent pigments work?

A

The phosphors in the pigment release the energy they have stored while exposed, producing a visible glow in the dark.

158
Q

What are some applications of phosphorescent pigments?

A

Applications include watches, toys, and recreational items like frisbees, balls, wall decals, and ceiling stars.

159
Q

How can phosphorescent pigments improve product function or safety?

A

Suggest products where phosphorescent pigments are used to improve the function or even increase the safety of the product.

160
Q

What is hydrographic printing?

A

Hydrographic printing is a process where colour images are printed onto water soluble film that floats in a tank.

161
Q

How does hydrographic printing work?

A

The product is submerged in the tank, and the image wraps around it, giving a colourful and potentially dramatic finish.

162
Q

What is the main benefit of hydrographic printing?

A

It provides a colourful and potentially dramatic finish to products.

163
Q

What is electroplating?

A

Electroplating is the process of covering plastics in a conductive layer or etching them before plating with a metal.

164
Q

In which industries is electroplating predominantly used?

A

Electroplating is predominantly used in the automotive industry for car trims, as well as in electronics, bathroom fixtures, and various household goods.

165
Q

What benefits does electroplating have?

A

Electroplating provides enhanced durability, corrosion resistance, and improved aesthetic appearance.

166
Q

What is electroplating?

A

Electroplating is the process of covering plastics in a conductive layer or etching them before plating with a metal.

167
Q

In which industries is electroplating predominantly used?

A

Electroplating is predominantly used in the automotive industry for car trims, as well as in electronics, bathroom fixtures, and various household goods.

168
Q

What benefits does electroplating have?

A

Electroplating provides enhanced durability, corrosion resistance, and improved aesthetic appearance.

169
Q

What is rubberising spray?

A

A slightly textured coating with a matt finish that can be sprayed onto various materials to provide grip.

170
Q

Where might rubberising sprays be used?

A

Rubberising sprays can be used on various materials to enhance grip.

171
Q

What happens to plastic when processed?

A

Plastic can become rough or scratched when processed and can become weathered or faded if left outside.

172
Q

What are polishing techniques used for?

A

Polishing techniques are used to restore a high quality finish.

173
Q

What product is commonly used to polish plastics?

A

Brasso® is often used to give a lustrous shine to plastics and is commonly used in a school workshop.

174
Q

What happens to plastic when processed?

A

Plastic can become rough or scratched when processed and can become weathered or faded if left outside.

175
Q

What are polishing techniques used for?

A

Polishing techniques are used to restore a high quality finish.

176
Q

What product is commonly used to polish plastics?

A

Brasso® is often used to give a lustrous shine to plastics and is commonly used in a school workshop.

177
Q

What is a common method for joining polymers?

A

Solvent cements are more commonly used to form a chemical weld than heat welding.

178
Q

In which industry are solvent cements commonly used?

A

Solvent cements are used in the plumbing industry.

179
Q

What types of pipes are joined using solvent cements?

A

Solvent cements are used to join PVC and ABS pipes.

180
Q

What happens when solvent cement is brushed on the surfaces?

A

The surfaces soften and permanently fuse together.

181
Q

What is the process used to create rigid three-dimensional products from thermosetting polymer resins and fibres?

A

Laminating or layup

This process is used in various applications, including speed boats and caravan panels.

182
Q

List three products that can be formed using laminating or layup with thermosetting polymer resins.

A
  • Speed boats
  • Rowing boats
  • Canoes
  • Caravan panels
  • Bumper cars

These products benefit from the strength and rigidity provided by the composite materials.

183
Q

True or False: Thermosetting polymer resins can be combined with fibres to produce flexible products.

A

False

Thermosetting polymer resins are used to create rigid products.

184
Q

What are the two main categories for applying finishes to polymers?

A

The two main categories are protection and aesthetics, with some finishes offering both.

185
Q

How can polymer finishes be applied?

A

Polymer finishes may be brushed on, sprayed on, or applied.

186
Q

What is a concern with some spray-on polymer products?

A

Some spray-on products are solvent based and contain high levels of volatile organic compounds (VOCs), making them not very environmentally friendly.

187
Q

What precautions should be taken when using solvent based products?

A

Precautions should be taken to ensure safety and minimize environmental impact.

188
Q

What are UV hardening resins used for?

A

UV hardening resins have been used in dentistry for many years and have also been developed for use in 3D printers and as a separate adhesive.

189
Q

How does UV hardening adhesive work?

A

The liquid adhesive is applied to the surfaces that require bonding and UV light is shone on it, which cures it.

190
Q

What is the result of using UV hardening adhesive?

A

The resulting bond can be very strong and is permanent.

191
Q

What is the purpose of gel coating in the layup process?

A

A gel coat creates a coloured finish for a rigid GRP shell.

192
Q

What is added to the polyester resin during the gel coating process?

A

Pigment is added to the polyester resin.

193
Q

Where is the gel coat applied in the moulding process?

A

The gel coat is applied to the inside of the mould.

194
Q

What happens to the gel coat after it is applied?

A

It is allowed to cure hard before layup continues.

195
Q

What is the result of using a gel coat?

A

The result is a pre-coloured high shine surface finish.

196
Q

Is any additional finish required after gel coating?

A

Is any additional finish then required?

197
Q

What are acrylic spray paints used for?

A

Acrylic spray paints are sometimes used to protect and colour moulded plastic parts and products.

198
Q

Where are acrylic spray paints commonly used?

A

They are used on body coloured bumpers where ABS parts are mass produced and sprayed after production to match the vehicle.

199
Q

What are the characteristics of acrylic spray paint?

A

Acrylic spray paint is water based and fast drying.

200
Q

What benefits does acrylic spray paint provide?

A

It adds additional UV protection and improved weather resistance.

201
Q

When does acrylic spray painting make better financial sense than adding pigments?

A

This question prompts consideration of the financial implications of using acrylic spray painting versus adding pigments.

202
Q

What is required to achieve a good painted finish on polymers?

A

Preparation is required as most polymers are self finishing, smooth, and therefore not an ideal substrate for paint.

203
Q

What is the first step in preparing an ABS moulding for painting?

A

The surface first needs to be thoroughly washed and dried.

204
Q

What should be done after washing and drying the ABS moulding?

A

It should then be abraded to provide a key.

205
Q

What must be done after abrading the ABS moulding?

A

It must then be cleaned again and any residual dust removed.

206
Q

What is applied after cleaning the ABS moulding?

A

A primer is then applied and allowed to dry before applying several even coats of acrylic paint.

207
Q

What is overmoulding?

A

Overmoulding is a process that enhances both the look and feel of a polymer-based product.

208
Q

What materials are often used in overmoulding?

A

Thermoplastic elastomers (TPEs) are often used to create an additional grip or texture.

209
Q

How does overmoulding improve ergonomics?

A

Overmoulding can indicate where to grasp a product, improving ergonomic design.

210
Q

In which products is overmoulding commonly used?

A

Overmoulding is commonly used in tool handles, sports equipment, toothbrushes, torches, sports bottles, and power cables.

211
Q

Why use TPEs rather than other thermoplastics?

A

TPEs provide enhanced grip and texture, making them preferable for certain applications.

212
Q

What is required to achieve a good painted finish on polymers?

A

Preparation is required as most polymers are self finishing, smooth, and therefore not an ideal substrate for paint.

213
Q

What is the first step in preparing an ABS moulding for painting?

A

The surface first needs to be thoroughly washed and dried.

214
Q

What should be done after washing and drying the ABS moulding?

A

It should then be abraded to provide a key.

215
Q

What must be done after abrading the ABS moulding?

A

It must then be cleaned again and any residual dust removed.

216
Q

What is applied after cleaning the ABS moulding?

A

A primer is then applied and allowed to dry before applying several even coats of acrylic paint.

217
Q

What are overmoulded products usually made through?

A

Overmoulded products are usually injection moulded.

218
Q

What is one method for creating overmoulded products?

A

Two separate moulds can be used, one for the substrate and a second with a cavity for the overmoulding.

219
Q

What is another method for creating overmoulded products?

A

A single, dual cavity mould with two separate injection heads can be used in a continuous production line.

220
Q

What is the term for the method using a dual cavity mould?

A

This method is called twin shot injection moulding.

Jake Product Design (13 decks)

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