2. 1. Describe any two of the following: Veneer, Plywood, Laminating Theory Answers. Veneer refers to thin slices of wood. A Natural Veneer is produced as a thin sheet of wood of the same thickness by peeling or slicing logs. One method has been illustrated bellow: The log is mounted centrally in the lathe and turned against a razor sharp blade, like unwinding a roll of paper. Veneer layers are usually glued and pressed onto panels of different materials, to make products such as; Kitchen worktops,unit doors and furniture How are they made? Where are they used. What are they ? Veneer Rotary Cut

3. Theory Answers. An answer to this is to use thin veneers that can be bent easily. These layers are glued together and placed in a jig or former. When the glue is set, the shape is removed from the jig and the veneers retain their shape. The chair bellow is an example. Laminating Why do we need laminating? Forming wood by bending can produce strong shapes, however it is difficult to bend thick pieces of wood. How are they made?

4. Theory Answers. strength. Plywood is made up of a number of layers of veneer, each layer glued with its grain at right angles to adjacent layers for strength. Plywood How are they made?

5. Theory Answers. 2. Name and briefly describe two methods of shaping metal: Casting is a metal-forming process. Molten metal is poured into a mould, when cooled it solidifies and takes on the characteristic shape of the mould. Casting Casting is used to produce intricate shapes in metal and is used for mass production. Such as car engines and workshop vices. What is it? Products made Where are they used.

6. Theory Answers. Extrusion The principle of this process is very similar to squeezing toothpaste from a tube. Extrusion is a manufacturing process used to create long objects of a fixed cross-sectional profile. What is it? A material, often in the form of a billet, is pushed through a die of the desired profile shape. Extrusion may be continuous (producing indefinitely long material) or semi-continuous (producing many short pieces). How is it done?

7. FEED BACK Blow Moulding Theory Answers. 3. Name and briefly describe two methods of shaping plastic: Blow moulding of plastic bottles. A molten polymer is extruded into a hollow, tube-shaped parison. A split mould is closed around the parison, which is expanded against the sides of the mould by a stream of air. Once the plastic has solidified, the mould is opened and the shaped bottle released. Parison How are they made?

8. Theory Answer. Injection Moulding Polystyrene, nylon, polypropylene and polythene. Materials used: 1.Granules of plastic are poured into a hopper. 2. A motor turns a thread which pushes the granules along the heater section which melts then into a liquid. 3. The liquid is forced into a mould where it cools into the shape. 4. The mould then opens and the shape is removed. How it works. Products made: Electronic cases, mp3, Wii, etc,

9. FEED BACK Vacuum Forming Theory Answers. How is it works?

10. Theory Answers. 4. Name and briefly describe 1. A smart material, 2. A composite material. 1. A smart material Shape Memory Alloy (SMA) is a smart material that is able to remember its original shape. It can be easily bent when cool, but when heated returns to its original shape. For example ‘Smart Wire’ changes shape when electricity passes through it. It is used in robotic hands to make the fingers grip objects. A robotic hand has ‘stretched muscle wires’ attached to the base of each finger. When current is applied to the muscle wire it contracts to its ‘natural’ length, pulling on the ordinary wire,making the fingers look as if they are moving. Smart materials have been developed to change their properties in response to changes in their environment. What is a Smart material? Shape Memory Alloy (SMA) How is it works?

11. Theory Answers. Name and briefly describe 1. A smart material, 2. A composite material. 2. A composite material. Carbon Fibre Fibreglass (glass reinforced polyester, GRP) is made from thin glass fibres stuck together with polyester resin. It is a very strong material that can be formed into complex shapes. Surf boards, boat hulls, swimming pool water chutes and some car bodies Fibreglass Products made: Carbon Fibres are stronger than glass fibres and produce a material which is strong and lightweight. Carbon fibre is used for racing car bodies, crash helmets and bullet proof vests. Products made:

12. Theory Answers. Name and describe THREE methods of production: One off products are usually very expensive and production is very labour intensive. It takes time to produce a one off and highly skilled workers are needed. One off production suits complex products or luxury items. One Off Production Surf boards, guitars, hand made furniture and bridges. Products made: Quantity Advantages Disadvantages A one off product, means what is says, one product is produced, to suit an individual customers needs. The look and function are tailored to suit the customers needs.

13. Theory Answers. Batch Production In batch production, small quantities of identical products are produced. The size of a batch can vary hugely, from twenty to a few thousand. Batch produced include aircraft, CD’s, and books. Quantity Advantages Products made: The machinery used is adaptable and small changes can be made to the product, from batch to batch, variations on a theme.

14. Theory Answers. High Volume Production (Mass Produced) Quantity Advantages Disadvantages Products made: Products are manufactured in very large quantities. Cheaper than one off or batch produced items as materials and components are bought in bulk which makes them cheaper. This type of production often uses expensive, specialised equipment and machinery, including CAM and industrial robots. Production is often continuous, running 24 hours per day. Mass production suits products for which there is a high demand and affordable to a wide range of people. Mass produced items include cars, fridges, washing machines and electrical goods.

15. Theory Answers. Which of the three methods of production would be used to produce this design? Describe using sketches how you think this outdoor seat could be created in industry. Mass Produced Extrusion

16. Theory Answers. Describe using sketches how you think this outdoor seat could be created in industry. Which of the three methods of production would be used to produce this design? Mass Produced Injection Moulding