Tools used with Polymers Commercial manufacturing processes Year 7 Polymer Tools used with Polymers Drilling parts Files Monomers are chemicals joined together. Polymers are monomers joined to make chains Drill bit Flat file Countersink bit Triangular file Commercial manufacturing processes Laminating This involves strips/ sheets of a material being bonded together. It is used to either create a strong structure, to create a tough and flexible product or to improve the aesthetics of the product. Flat drill bit Half round File Hole saw Casting Is using thermosetting polymers and setting them in to mould. As thermosetting polymers take a permanent shape the casting uses to parts: resin and a hardener known as a catalyst. PCB drill bit Round file Line bending Bending most plastics involves heat. A strip heater is used for line bending. It creates a permanent fold in a piece of thermoforming polymer. Saws Finishes Coping saw Wet and dry paper Vacuum forming Vacuum forming is when a sheet of thermoforming polymers is heated and pressed against a former by pressure. As the pressure is reduced on the softened polymer the polymer takes the shape of the mould. Hacksaw Brasso 3D printing This process used computer aided design and computer aided manufacturing to produce a thermoforming polymer object. A design is produced on computer software which is then sent to a printer that produces the finished product. Junior hacksaw Definitions Sustainability is about not causing permanent damage to the environment and not using up non-renewable resources Finite is non-renewable resources such as fossil fuels Non-Finite is renewable resources such as wind power Biodegradable means they will break down over time Planned Obsolescence is when product is no longer useable and needs replacing Carbon Footprint is the amount of gases that are released into the atmosphere during the lifetime of a product Blow moulding This uses a tube of softened polymers, which is inserted into a solid mould. Air is then injected into the mould which forces the polymers to expand to the shape of the mould. Drape forming A sheet of thermoforming polymer is heated until it softens. The sheets is then placed over the mould and as it cools it takes the form of the mould. Extrusion moulding This is used to create a continuous flow of plastic that is pushed through a die. To create a specific shape. It uses a die.

Type of Thermoforming Polymer Properties Usage Image Acrylic (PMMA) Hard, stiff, shiny. Weather resistant. Brittle Motorcycle helmet visors Baths, signs, display stands High-density polyethylene (HDPE Stiff, strong, lightweight Washing up bowl, baskets, folding chairs, gas pipe, water pipe Polyvinyl chloride (PVC) Brittle, cheap, durable Blister packs, window frames, vinyl records, clothing Polyethylene terephthalate (PET) Light, strong, tough. Drink bottles, or clothing fibres High impact Polystyrene (HIPS) Rigid, fairly cheap Vacuum forming, fabricating boxes such as CD cases, smoke detector casing Polypropylene (PP) Tough, flexible, can be colourful Plastic chairs, containers Low Density Polyethylene (LDPE) Flexible, tough, high strength to weight ratio Plastic carrier bags, refuse sacks Type of Thermosetting Polymer Properties Usage Image Epoxy Resin (ER) Rigid, durable, corrosion-resistant Good electrical insulator Circuit boards wind turbine rotor blades, enrapture items Urea-Formaldehyde (UF) Hard, brittle Plug sockets, cupboard handles Melamine-Formadehyde (MF) Strong, scratch resistant Laminate chipboard, plates bowls, Kitchen equipment Phenol-Formaldehyde (PF) Hard, heat-resistant, easily moulded Bottle caps, snooker balls, telephones Polyester Resin (PR) Hard, stiff, cheap Kayaks, shower stalls, garden furniture. Enrapture artefacts