1. Knowledge Organiser Year 9 Materials and their Working Properties
Paper and boards are usually made from wood pulp and convert to their final forms at a paper mill. Other cellulose sources can include textiles such as cotton, where resulting paper, known as rag paper, can be very high quality and can last many hundreds of years.
Common Boards: Board thickness is usually quoted in microns or grams per square metre (gsm) microns is equal to 1mm of thickness. The lower the number, the thinner the paper or card.
Name
Appearance
Image
Characteristics
Uses
Corrugated cardboard (fibreboard)
Natural brown board finished on one or both sides with bonded paper
microns, strong, lightweight and rigid perpendicular to corrugations. Insulative and easily printed on.
Packaging, boxes and impact protection
Duplex Board
Two layers of card bonded together, often with a white external layer
gsm, stiff, lightweight coatings to improve functionality
Cheaper version of white card used for packaging boxes. Often given a waxy coating and used for food and drinks containers
Foil Lined Board
White card, usually coated or laminated with aluminium foil bonded on one side
gsm, stiff, lightweight coatings to improve functionality
Takeaway containers and lids, used to retain heat for longer
Foam Core Board
Smooth board surface front and back, foam inner core, limited variety of colours and thicknesses
3-10mm thick, lightweight and rigid in all directions. Can crease and crack under pressure, expanded polystyrene centre
Architectural models, model making prototyping, mounting and framing of photographs and art work
Ink Jet Card
Brilliant white card treated for a smooth finish
gsm, medium to thick card treated to hold a high quality photo image. Ink dries on the surface to create deeper colours
High quality photographic images
Solid White Board
High quality card, brilliant white smooth finish on both sides
gsm, stiff board, holds colour well, easily cut or creased
Many uses including greeting cards, packaging and advertising, hot foil stamping and embossing
Common Papers: Paper is measured by weight in grams per square metre (gsm).
Name
Appearance
Image
Characteristics
Uses
Bleed proof paper
Coated white cartridge paper that can be slightly textured
70gsm sheet, coated to stop solvent-based markers staining through the page. Deeper colours are achieved as ink stays on the surface.
Used with marker pens for design ideas and final designs.
Cartridge Paper
Thick white paper with a slightly rough texture
gsm, completely opaque and more expensive than photocopier paper.
Pencil and ink drawings, sketching and watercolour
Grid Paper
White paper with a printed grid of squares, isometric lines or other patterns.
Usually printed onto 80gsm paper with faint lines often in a light blue ink. Lines can be printed darker for use under plain paper as a guide.
Used for scientific and mathematical diagrams, particularly in conjunction with a light box as a drawing guide.
Layout Paper
Off white, medium opacity sheet with a smooth finish. Translucency decreases as gsm increases.
40-60gsm, semi-translucent, takes pencil and most media well. Some inks can smear on heavily coated papers.
Creating sketches and working ideas; copying and tracing images with a variety of media.
Tracing Paper
Off white, low opacity sheet. Translucency decreases as gsm increases.
40-120gsm, semi-translucent, takes pencil and most colours well.
Copying and tracing images. Used with a light box, overlays for design adaptations and working drawings.

2. Common Hardwoods Natural Wood Common Softwoods
Name
Appearance
Image
Characteristics
Example Uses
Ash
Pale brown/cream
Flexible, tough and shock resistant, laminates well
Sports equipment and tool handles
Beech
Dense/close grain with an attractive pink hue
Fine finish, tough and durable
Children’s toys and models, furniture and veneers
Mahogany
Rich reddish brown
Easily worked, durable and finishes well
High end furniture and joinery, veneers
Oak
Light brown with an interesting and variable grain
Tough, hard and durable, high quality finish possible
Flooring, furniture, railway sleepers and veneers
Balsa
Pale cream/white. An open grained, large and unusually fast growing hardwood tree
Very soft and spongy, very lightweight but can snap in thin sections
Prototyping and modelling – especially model aircraft
HARDWOOD comes from Deciduous trees which loses there leaves in winter.
Tend to have a tighter grain
They can be very Expensive
These are usually quite hard but not always
They are slower growing trees it can take 100 years to grow fully
SOFTWOOD comes from Coniferous trees which keep there leaves in winter
They have a looser grain structure
These grow quite faster so are cheaper
These are usually softer, easy to work
They are often used as building material
The trees grow tall and straight, easier for the manufacturer to cut long straight planks of timber
Manufactured boards are usually sheets of processed natural timber waste products or veneers combined with adhesives. They are made from waste wood, low-grade timber and recycled timber. Manufactured boards have a pale brown natural finish, but can be covered with thin slices of high quality wood to give the appearance of solid wood. This covering is called a veneer. Veneers are produced by taking thin slices of a natural wood from the trunk of a tree. They are then bonded to the surface of cheaper sheet materials, such as medium density fibreboard (MDF) or plywood.
Felling is a term used for cutting down a tree. Traditionally this was done by hand using an axe or a very long saw. Trees are now felled using chainsaws and modern chainsaw attachments are available for agricultural machines that can fell a tree, de-branch it and cut it into equal-length logs in one action.
Common Softwoods
Name
Appearance
Image
Characteristics
Example Uses
Larch
Pale to reddish brown with a contrasting grain
Durable, tough, good water resistance, good surface finish and machines well. Issues with loose knots.
Exterior cladding, flooring, machined mouldings, furniture and joinery
Pine
Pale yellow to pale brown, attractive grain that darkens with age
Lightweight, easy to work, can split and be resinous near knots.
Interior construction (and exterior if treated), cheaper furniture decking
Spruce
White cream with a fine even grain
Easy to work, high stiffness to weight ratio. Variable results when staining.
Construction, furniture and musical instruments
Manufactured Boards
Name
Appearance
Image
Characteristics
Example Uses
Medium Density Fibreboard (MDF)
Smooth, dull, light brown finish available in many veneered options. Edges can be hard to finish well.
Rigid and stable, good value with a smooth, easy to finish surface. Very absorbent so not good in high humidity or damp areas.
Flat pack furniture, toys, kitchen units and internal construction.
Plywood
Alternating layers of natural grain veneers with the outer material usually of a higher quality for aesthetics
Very stable in all directions due to alternate layering at 90 degrees, with outside layers running in the same direction.
Furniture shelving, toys and construction. Interior
Chipboard
Pale grey/brown with no natural grain. Frequently covered with a laminate such as melamine formaldehyde
Good compressive strength, not water resistant unless treated, good value but prone to chipping on edges and corners.
Flooring, low-end furniture, kitchen units and worktops

3. Common Non-Ferrous Metals
Metals and Alloys
Metals are found in the earth's crust. Some pure metals are mined as a whole metal but many are extracted as an ore
Ore is a type of rock that contains a pure metal in small quantities. The ore is gathered through mining, then the metal is often extracted through using large furnaces
The extreme heat of the furnace separates the metal from the ore and it is drawn off as molten liquid and processed into metals we commonly use
Ferrous Metals
All contain Iron (ferrite)
Most are magnetic
Will rust if exposed to moisture without a protective finish
Alloys are a mixture of at least one pure metal and anther element. The alloying process combines the metals and other elements in such a way as to improve the working properties or aesthetics.
Common Ferrous Metals
NAME
APPEARANCE
CHARACTERISTICS
E.G.USES
LOW CARBON STEEL
(Mild Steel) carbon content %
Bright grey with a smooth texture that quickly oxidises (rusts) if not protected
Tough and ductile easily machined, formed, brazed or welded
Construction girders, screws, nuts and bolts. Many car bodies and bike frames
HIGH CARBON STEEL
(Tool Steel) carbon content %
Very similar to mild steel but does not rust as easily, very smooth texture
Less ductile and harder than mild steel due to higher carbon content. Very hard wearing and keeps an edge well
Garden or workshop tools, blades, scissors, wood and metal cutting tools
CAST IRON carbon content 2.4-4%
Dull, varying shades of grey depending on type, texture unless machined, less prone to rust
Hard but brittle in thin sections. Easily cast into complex shapes, but some types are hard to machine
Kitchen pots and pans, machine bases and bodies, vices, manhole covers, post boxes
Common Alloys Metals
NAME
APPEARANCE
CHARACTERISTICS
E.G.USES
Brass
Yellowish gold, polishes well and oxidises to a dark antique brown
(Alloyed Copper 65%, Zinc 35%)
A heavy alloy of copper and zinc that is malleable easy to cast and machine, and has naturally low friction
Musical instruments, brushes, plumbing fitments, ornate artefacts and hardware
Stainless Steel
Silver hue that can be polished to mirror finish. Resists rust well
(Alloyed Low carbon % Chromium %)
A ferrous alloy with chromium, nickel and manganese. Hard, very smooth but difficult to weld
Cutlery, kitchen and medical equipment
High Speed Steel
Varies depending on the combination of metals alloyed with steel
(Alloy can include: Chromium, Molybdenum, Tungsten, Vanadium, Cobalt, Carbon)
Able to withstand the high temperatures created when machining at high speed, keeps its cutting edge well
Cutting tools such as drill bits, mill cutters, taps and dies
Non-Ferrous Metals
Not magnetic
Does not contain iron
Does not rust but can oxidise
Oxidation causes the metal to change colour and dull with time
For example Copper turns a deep turquoise called verdigris and is used for bespoke roofing material.
The thin oxide layer is know as a patina
Polymers
Plastics are mainly synthetic materials made from polymers.
Traditionally derived from finite petrochemical resources such as oil, gas and coal.
Sustainable sources such as vegetable starches are becoming more popular.
There are some naturally occurring plastics such as amber and rubber.
There are two types; thermoforming and thermosetting plastics.
Common Non-Ferrous Metals
NAME
APPEARANCE
CHARACTERISTICS
E.G.USES
Aluminium
Light grey, can be polished to a mirror finish but often has brushed matt finish
Lightweight, high strength to weight ratio, ductile but can be difficult to weld
Pots and pans, sports and car body panels, bike frames, drinks cans, foil or takeaway trays
Copper
Light reddish brown, polishes well, oxidises to an attractive green-grey shade
Ductile, malleable and a good electrical conductor that is easily joined by soldering
Plumbing supplies, electrical cables, bespoke roofing and guttering
Tin
Silvery white, often plated onto steel with a shiny finish achievable
Soft, malleable and ductile; a good electrical conductor
Can production –used for plating surfaces to preserve contents, soft solder, alloyed with copper to form bronze
Zinc
Silvery grey with bluish-white hue, matt finish
Fair electrical conductivity, malleable and ductility; however all are improved when alloyed
Mainly used to galvanise steel, to prevent rusting, easily die cat or used in alloys

4. Type of Thermoforming Polymer Type of Thermosetting Polymer
Polymers
Thermoforming Plastics known as thermoplastics are more flexible when heated. Polymers chains are quite loosely entangled with very few cross links. This allows them to easily slide past each other when heated. They can be formed into complex shapes and reformed multiple times.
Thermo plastics are commonly used in processes such as vacuum forming, injection moulding and blow moulding.
They are also easier to recycle.
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
Thermosetting plastics or thermosets are more rigid and once they are set they cannot be reformed. The long polymer chains have many more cross links between them which stops the molecular chains in the plastic moving. As a result they are generally harder and more brittle than thermoplastics.
They make excellent electrical insulators and have good resistance to heat and chemicals. When thermosets are heated, they tend to burn rather than melt making most thermosetting plastics difficult to recycle.
New types of recyclable thermosetting plastics are being developed. This technology has the potential to reduce waste.
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

5. Textiles Synthetic Fibre Appearance Image Characteristics Example Uses
Natural fibres come from plants and animals, cotton comes from plants and wool comes from Sheep. These are Renewable resources. They are also biodegradable and recyclable, which makes natural fibres fairly sustainable.
Synthetic Fibre
Appearance
Image
Characteristics
Example Uses
Polyester
Can be made into different fabrics including satin, rip-stop, tent and sail material, and brushed Polartec fleece.
Tough, strong, hard wearing, very versatile, holds colour well, non-absorbent so quick drying, machine washes well. Often blended with other fibres. Easily coloured.
Clothing, fleece garments, bedsheets, carpets, wadding, rope threads, backpacks, umbrellas and sportswear.
Polyamide (Nylon)
A very versatile fibre, woven into many different forms including rip-stop. Easily coloured.
Good strength, hard wearing, non-absorbent, machine washes well, easily and frequently blended.
Clothing, ropes and webbings, parachutes and sports material. Used as a tough thread on garments.
Elastane (Lycra)
Smooth to touch with a sheen and easily takes colour
Added to fabrics to enhance working properties particularly to add stretch. Allows freedom of movement, quick drying holds colour well, machine washable.
Sportswear, exercise clothing, swimsuits, hosiery, general clothing, surgical and muscular supports
Synthetic fibres come from polymers. These molecules come mainly from oil and coal. These are non-renewable resources, therefore synthetic fibres are not very sustainable.
Plant Based
Appearance
Image
Characteristics
Example Uses
Cotton
White fluffy ‘boil’ taken from the cotton plat; contains fibres that are combed and spun into yarn. Takes dye readily.
Soft and strong, absorbent, cool to wear and easily washable. Cotton fabrics can be given a brushed finish to increase their thermal properties.
Most clothing, especially shirts, underwear and denim can be made from cotton. Also used for towels and bed sheets.
Animal Based
Appearance
Image
Characteristics
Example Uses
Wool
Animal fleece, most commonly from sheep, is spun into yarn. It is easy to dye and available in many colours and textures.
From fine and soft to thick and coarse, it is warm and naturally crease resistant. Can shrink. Often blended to add functionality.
Jumpers, coats, suits and accessories worn for warmth. Specialist wools are very soft and expensive.
Silk
Very fine natural protein fibre from the cocoon of the silkworm. The thread has a natural shine due to its triangular structure and readily takes dye.
Very soft and fine finish, gentle on skin, can feel cool in the summer yet warm in winter, drapes well, absorbent, strong when dry (weaker when wet), tricky to wash, can crease easily and is usually expensive.
Luxury clothing including nightwear and underwear, soft furnishings, bed sheets, silk painting and wall hangings.
Blended Material
Appearance
Image
Characteristics
Example Uses
Polycotton
Cotton like look, easily printed and dyed, creases less than pure cotton.
More durable than pure cotton but not as breathable. Can be produced more cheaply than cotton alone. Many blends are available; 65% cotton 35% polyester to 50/50 are common
General clothing, sheets and bedding. Can be used as an alternative to most cotton products.

6. Woven Textiles Knitted Textiles Weft Knitting Warp Knitting
The commonly used types are plain weave and twill weave
A loom weaves two threads – the warp and the weft - at right angles to each other
The self-finished edge is known as the selvedge, which stops the fabric from fraying
Weft knit fabrics are made by hand or by machine using a single yarn that form interlocking loops across the width of the fabric.
They tend to by quite stretchy due to the method of interlocking and can therefore loose their shape quite easily.
Weft knit fabrics are very warm owing to the amount of air trapped.
Name
Appearance
Image
Characteristics
Example Uses
Plain Weave
Threads are interlaced at 90 degrees to each other, warp threads run the length. Same pattern on the front and reverse.
Simple and cheaper to produce than more complicated weaves, stronger than other weave patterns.
Used on textiles such as cotton calicos, cheesecloth and gingham, found on table cloths, upholstery and clothing.
Warp Knitting
The loops in warp knit fabrics interlock vertically and are less prone to unravelling and laddering which makes them easier to cut into sections and sew together for the construction of complex garments.
They are less stretchy than weft knits and tend to hold their shape more effectively.
Warp knit fabrics are complex structures, often using multiple yarns ad are therefore made by machine rather than by hand.
Non-Woven Textiles
Non-woven fabrics are made directly from fibres without being spun into yarns. The most commonly available non-woven fabrics are bonded fabrics made from a web of fibres held together with heat or adhesive.
Common uses of non-woven fabrics include disposable products such as garments worn by surgeons and crime scene investigators, dishcloths and interfacing.
Can be given special treatments such a flame resistance to make head rest covers on trains and aircraft.
Name
Appearance
Image
Characteristics
Example Uses
Knitted fabric
Loops of yarn are interlocked with each other using needles. Plain or very decorative patterns can be produced
Warm to wear, different knits have different properties such as stretch and shape retention. Weft knits ladder and unravel more easily
Jumpers, cardigans, sportswear and underwear fabrics, socks, tights and leggings, craft items such as soft toys.
Name
Appearance
Image
Characteristics
Example Uses
Bonded fabric
Random laid fibres are visible in the fabric, it can have small holes or a textured surface.
Fabrics lack strength, they have no grain so can be cut in any direction and do not fray.
Disposable products such as protective clothing worn for hygiene purposes, tea bags, dish cloths and dusters
Felted fabric
Matted fibres randomly interspersed, wide range of colours and thicknesses
Can be formed with moisture and heat; once dry it has no elasticity or drape, and can pull apart easily. Woollen varieties can be expensive.
Hats, handicraft, pads under furniture to prevent scratching, soundproofing and insulation.