Specialist Techniques and Processes

• Tools, Equipment and Processes

  • Wastage
  • Addition
  • Deforming and reforming materials
• Die cutting


  1. Cutting of a shape by pressing a die cut shape through the material

  2. Dies are a sharp metal blade fixed into a block in the shape of the cut, rounded metal edges can also be in the block to create creases

  3. Can be used on paper, thin wood and polymer sheets
• Perforation


  1. A line of cuts through thin material which create an easily folded and ripped line

  2. A perforating blade can roll over the material or press down like a die cutter
• Turning (Lathes)


  1. Turning a long length of material with specialist shaped tools

  2. Spinning the material round whilst layers are shaved off

  3. Used for items like furniture and stair spindles
• Milling


  1. A thin layer of metal is removed each turn at a carefully measured depth and speed

  2. Can produce a really accurate finish
• Sawing


  1. Cutting away material

  2. Different saws are available for different materials, which have a variety of shaped blades depending on what you're cutting

  3. Tenon, jigsaw, scroll and coping are all different types of saws
• Drilling


  1. Using a circular bit to create holes in materials

  2. Hand or electric drills can create holes through all materials

  3. Drill bits come in a variety of standard sizes to fit other standard components

  4. The tip of a drill is shaped differently to suit different materials such as wood and stone
• Shearing


  1. Cutting sheet material, particularly metal or flexible polymers

  2. Shears use the same method as scissors but stronger to cut through tougher materials
• Brazing


  Joining metal together using molten metal
• Soldering


  1. Joining metal together using solder melted at a relatively low temperature

  2. Particularly used for electrical circuits and plumbing joints
• Welding


  1. Joining metal together using an electrical current to melt welding rod to flow together and cool between joints

  2. The strongest of all of the addition joints
• Polymer welding


  Joining polymer together using plastic rod
• Lamination


  1. Sandwiching layers together to strengthen or protect

  2. Examples: plastic laminated paper, foam board, goretex fabric and plywood
• 3D printing


  1. Adding material in layers squirted through a nozzle to print the CAD drawing sent to it

  2. Mainly prints plastic but metal, resin and food printing is all being developed
• Batik


  1. Decorative textile technique where hot wax is painted onto cotton fabric with a brush or Tjanting tool, creating a resist where dye cannot soak in

  2. The areas around the wax are dyed and when dry the wax is ironed and melted off
• Sewing


  1. Adding material by hand or on a sewing machine

  2. Can be used to join fabric or add decoration on the fabric
• Bonding


  1. Using adhesive glue to stick materials together

  2. Different glues are developed for different jobs, PVA for wood and paper, epoxy resin for most materials and liquid solvent cement for polymers
• Printing


  1. Adding ink to decorate paper and board

  2. Lithography, Flexography, Screen printing, Digital printing
• Vacuum forming


  Heating sheet polymer until it is flexible and then sucking out the air between it and the mould to create a vacuum and an accurate copy
• Creasing, bending and folding

  1. Creating shape in fabrics, card, plastic, metal and paper

  2. Can be decorative or strengthen a structure

  3. Fabric can be pleated and gathered to form shape in clothing and upholstery
• Pressing


  Forming metal between an upper and lower mould under high pressure to create an accurate and intricate shape
• Drape forming


  Shaping thermoforming polymer by heating sheet plastic until it is soft enough to drape over a mould, when it cools it sets into the shape and the mould is removed
• Blow moulding


  Taking softened polymer and blowing it into a mould with air like a balloon, used to mould bottles and containers
• Casting


  Pouring molten material into a mould (the die), can be used with metal, plastic or plaster
• Injection moulding


  Injecting liquid plastic into a mould under high pressure, creates accurate and quick products
• Extrusion


  Squeezing molten plastic or metal through a nozzle to create a long continuous shape
• Tolerance


  Allowances of accuracy that need to be followed to keep the quality of the product high and the ability to accurately join pieces together
• Quality control


  • Measurable and quantitive systems during manufacture
  • Paper, board and fabric printing rely on registration marks
  • Go/No go fixtures are used to check whether a part fits within its limits
  • Depth stops are used for machine drilling and cutting
  • Polymers cut on a laser cutter need the laser to be focused and set to the correct feed rate and power
  • PCBs manufactured through chemical etching all need the same exposure time