As

Question 1

What is the process of bonding timber together?

Answer 1

Lamination

Question 2

How is lamination performed?

Answer 2

Wood veneers or thin MDF are glued together before being bent over a former.
As the glue dries the materials set in the former shape.
Clamps or a vacuum bag prevent any movement
Glue of choice is usually cascamite

Question 3

How is using a vacuum bag in lamination beneficial and how does it work.

Answer 3

Prevents any gaps forming.
Veneers and former placed under polythene sheet.
Edges are then taped down to the table.
A valve and vacuum pump suck out all the air and so the resulting pressure pulls the laminates hard together

Question 4

Benefits of lamination

Answer 4

Aesthetically pleasing
Versatility, can make whatever thickness desired
Affordability, much cheaper than buying solid wood and cutting it out (less wastage too)
Less liable to warping and cracking as reinforced
Increased strength

Question 5

Disadvantages of lamination

Answer 5

Potentially more labourious as mould needs to be created

Question 6

What is an adhesive?

Answer 6

A substance used to stick materials together

Question 7

What are the two main types of adhesives?

Answer 7

Cascamite

PVA

Question 8

What is cascamite?

Answer 8

Strong glue used when laminating flexible plywood together.
3 parts cascamite and one part water
Sanded once dry for smooth finish
Dries in 24-48 hours

Question 9

Advantages of cascamite?

Answer 9

Weatherproof

Strong even at high temp

Question 10

Advantages of PVA?

Answer 10

Waterproof
Readily available
Dries clear
Affordable

Question 11

Why cascamite over PVA?

Answer 11

Stronger under sharp temp changes
Weatherproof not just water proof
Stronger in general

Question 12

Why PVA over cascamite?

Answer 12

More readily available
Dries clear and faster
Still waterproof
Versatile

Question 13

Cascamite typical uses

Answer 13

Anything outdoors

etc, boats, dinghy’s

Question 14

Name three types of composite wood

Answer 14

MDF
Hardboard
Chipboard
Plywood (flexy ply)

Question 15

Advantages of using composite wood

Answer 15

Cost effective when needing curves (don’t have to buy big lump of timber or machinery)
Versatility
Doesn’t have weak points which natural wood is prone to having (no warping or cracking)
Normal woods can have splits and shakes

Question 16

Uses and features of plywood

Answer 16

Odd number of layers of veneer glued together at right angles
Can be stained or painted
Used in shelving and construction due to its strength

Question 17

Uses and features of chipboard

Answer 17

Compacted wooden chips which is laminated
Strong, but not water resistant
Protects items better than corrugated in shipping
Used in flooring and veneered worktops

Question 18

Hardboard features and uses

Answer 18

Made from exploded wood fibres to increase the density
Less durable and unnatural finish but can be painted and oiled
Quite cheap
Used in furniture and construction

Question 19

MDF uses and features

Answer 19

Made from normal wooden fibres
Dense but not as dense as hard board
Not water resistant
Commonly used in decorative furniture etc

Question 20

Who is related to the arts and craft movement and what did he do?

Answer 20

William Morris

British textile designer, poet, novelist, translator, painter, and social activist. Significant in the revival of British textile arts and textile construction methods.

Question 21

What are the features of the arts and craft movement?

Answer 21

Raw materials with natural qualities and beauty
Designs, motifs and patterns inspired by nature
Natural materials
Craftsmanship (eg hand printing) and experimentation
Natural colour tones
Belief that all objects that surround a person should be of good quality and well made
Simplicity
Form follows function
Affordability to appeal to wider community
Proportionality

Question 22

What years did the arts and crafts movement last

Answer 22

1880-1920

Question 23

What are the 5 polymer processes

Answer 23

Injection moulding
Rotational moulding
Blow moulding
Extrusion
Vacuum forming

Question 24

What is anodising?

Answer 24

Enhance the natural oxide layer via electrolysis to increase hardness and toughness

Question 25

MIG welding over one solid piece

Answer 25

More wastage of material | Individual parts can be adjusted and used elsewhere

Question 26

Solid over MIG

Answer 26

Faster cycle times on CNC Aesthteivally pleasing Less labour time

Question 27

Benefits of ABS

Answer 27

Hard | Non toxic

Question 28

Rotational moulding

Question 29

What is die casting?

Question 30

Advantages of high pressure die casting?

Answer 30

Ability to create thin walls of exact dimensions Create large volumes of complex products in short times leading to lower lead times which is more cost effective Has a good surface finish

Question 31

Disadvantages of high pressure die casting?

Answer 31

Porosity caused by entrapped gases, resulting in weak points and potentially ruining aesthetic High startup costs, not effective for small scale production runs Finished products cannot be fully heat treated

Question 32

Setup of CNC machine

Answer 32

Design product on CAD software Ensure machine knows which tool is being used (number of teeth, size etc) Tell machine which material is being used and the speed (rpm) feed rate and speed Align tool to the datem point (origin 0,0) Test cut without material If all is ok then put material in and line up with datem point Send around at a 50% rate to ensure it works Carry out an inspection (quality check) and then peer assess

Question 33

Advantages of sand casting

Answer 33

Simple production process Low cost moulds and therefore low production costs with short lead times Wide material choice with complex shapes able to be made Easily repeatable Ideal for one off production

Question 34

Disadvantages of sand casting

Answer 34

Low dimensional accuracy Rough surface finish Predominantly handmade so more liable to small errors which could result in unstable casting quality

Question 35

How does rotational moulding?

Answer 35

1. A hollow mould created using CAD software 2. Mould with plastic in pellet form or powder 3. This is heated to 300 degrees Celsius and then rotated about 2 axes 4. During the rotation the mould is heated causing the polymer to melt and then “lay up” on the sides of the mould, evenly dispersing it. 5. Once fully melted it is moved into the cooling station where cool air surrounds the mould 6. This causes the plastic to solidify, once solid rotation stopped and product removed

Question 36

Advantages of rotational moulding

Answer 36

Even stress levels so walls have even thickness limiting number of weak points Can make very large components Low mould equipment costs Easy colour and mould changes High strength and stability due to thick corners and lack of exposure to external pressure

Question 37

Disadvantages of rotational moulding

Answer 37

Only simple shapes Limited material choice, as has to be in powder form Limited mechanical properties due to thick walls High cycle times Poor dimensional tolerance control

Question 38

Positive obsolescence

Answer 38

Newest products, apple iPhone, status symbol | Safety, after length of time products can be harmful (eg a battery), risk to your health as user