Specialist Techniques And Processes
Overview
There are only three things you can do to a material. You can take some away, you can add some on, or you can push what is there into a new shape. Every process in a workshop and every process in a factory is one of those three, and the specification uses exactly those headings: wastage, addition and shaping. Learn them as three families and thirty processes become manageable.
This is the largest topic in the specialist technical principles and it earned three questions on the specimen paper, worth thirteen marks between them. You will learn how to use measurement and reference points, templates, jigs and patterns; the wastage, addition and shaping processes by name and by what each is for; how products are made to a tolerance by manufacturing to minimum and maximum measurements; the application and use of quality control, which the specification defines differently for each material area; and the commercial processes for papers and boards, timbers, metals and polymers. This is specialist technical principles content, examined in Section B of Paper 1.
Objectives
- The use of production aids
- How to use measurement/reference points, templates, jigs, and patterns where suitable
- Tools, equipment and processes
- A range of tools, equipment and processes that can be used to shape, fabricate, construct, and assemble high quality prototypes, as appropriate for the materials being used including: wastage, such as:
- die cutting
- perforation
- turning
- sawing
- milling and routing
- drilling
- cutting and shearing
- addition, such as:
- brazing
- welding
- lamination
- soldering
- 3D printing
- printing
- shaping such as:
- vacuum forming
- creasing
- pressing
- drape forming
- bending
- folding
- blow moulding
- casting
- injection moulding
- extrusion.
- How products are made to a tolerance
- Manufacturing to minimum and maximum measurements.
- The application and use of quality control
- Papers and boards (registration marks).
- Timber based materials (dimensional accuracy using go/ no go fixture).
- Metal based materials (dimensional accuracy using measuring equipment).
- Polymers (dimensional accuracy by selecting correct laser cutting settings).
- Commercial processes
- Papers and boards (offset lithography and die cutting).
- Timber based materials (routing and turning).
- Metal based materials (milling and casting).
- Polymers (injection moulding and extrusion).
Mind map
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Lesson Note
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Lesson Evaluation
Congratulations on completing the lesson on Specialist Techniques And Processes. Now that youve explored the key concepts and ideas, its time to put your knowledge to the test. This section offers a variety of practice questions designed to reinforce your understanding and help you gauge your grasp of the material.
You will encounter a mix of question types, including multiple-choice questions, short answer questions, and essay questions. Each question is thoughtfully crafted to assess different aspects of your knowledge and critical thinking skills.
Use this evaluation section as an opportunity to reinforce your understanding of the topic and to identify any areas where you may need additional study. Don't be discouraged by any challenges you encounter; instead, view them as opportunities for growth and improvement.
- Which one of the following is an addition process? A. Blow moulding B. Brazing C. Milling D. Shearing Answer: B
- In vacuum forming, the softened sheet is forced onto the mould by A. a hydraulic ram. B. atmospheric pressure. C. the weight of the sheet. D. an injection screw. Answer: B
- A dimension is given as 40 millimetres with a tolerance of plus 0.3 and minus 0.2. What is the total tolerance? A. 0.1 millimetres B. 0.2 millimetres C. 0.3 millimetres D. 0.5 millimetres Answer: D
- Registration marks are used as a quality control method for A. metal based materials. B. papers and boards. C. polymers. D. timber based materials. Answer: B
- Which process produces a continuous length of constant cross section? A. Blow moulding B. Die casting C. Extrusion D. Pressing Answer: C
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