1. 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.

2. 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