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CHOICE OF MATERIALS - SCHOOL PRODUCTION LINE

QUESTIONS AND POSSIBLE ANSWERS

V. Ryan 2011

 

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Name one of the materials you intend to use in the production of your product.
 
Perspex
 
Explain why you have chosen your selected materials. The key words / phrases may help you answer this question.
 
STRONG - INEXPENSIVE - TOUGH - RANGE OF COLOURS - EASY TO CUT - EASY TO FILE - CAN BE POLISHED - NATURAL FINISH - CAN BE VARNISHED
 
Perspex has been chosen because it is lightweight, comes in a range of colours (including transparent and translucent) and it is relatively easy to cut and shape. It can be cut on a fretsaw or by hand and filed to a smooth finish. When polished on a polishing machine, a high quality finish is produced. Perspex is reasonably cheap and readily available. All this makes the material suitable for young children to use, on a small production line.
 
STAGES OF MANUFACTURE
 
With notes and diagrams explain how you would make the product.

Explain how quality checks could be made at each stage of manufacture
 
The perspex front is protected with masking tape and the curves drawn on with a pencil.

QUALITY CHECK: The accuracy of the curves is checked with a circle template.
 
2.
The MDF back is marked out with a pencil. A card template cut to the correct shape is used for this purpose,

QUALITY CHECK: Once the shape is drawn on to the MDF the card template is used a second time to check the accuracy of the curves.
   
3.
A fretsaw is used to shape the perspex and MDF.

QUALITY CHECK: Card templates are used to check the accuracy of the cut shapes.
   
4.
The perspex is through filed, draw filed and finally smoothed with wet and dry paper.

Glass paper is used in the same way to produce a smooth finish on the edges of the MDF.

QUALITY CHECK: A visual check of the surfaces is carried out, to ensure that they are not scratched or damaged.
   
 
   
5.
The perspex is polished on a polishing machine.

QUALITY CHECK: Visual check to ensure the surface is polished to a high degree.
   
6.
A pre-made shape, manufactured from vinyl is cut on a vinyl cutter.

QUALITY CHECK: Visual check for faults and imperfections.
   
7.
The vinyl shape is pressed on to the MDF back. The front base and back are assembled using industrial standard double sided tape.

QUALITY CHECK: A visual check followed by a strength test to ensure that the assembled letter rack stays together.
 
 
 
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