Hello, my name's Mrs. Taylor.

It's great that you can join me today for our lesson.

Our lesson today is "Deforming manufacturing processes," and this is part of the unit "Principles of materials and manufacturing." There are five keywords.

State, the form of matter; gas, liquid, or solid.

Malleable, can be pressed into shape without breaking, and this is usually in reference to metals.

Brittle, breaks or fractures easily without deforming or stretching.

Laminating, sticking several layers of material together.

Plasticity, can be pressed into shape without breaking, and this is usually in reference to polymers.

We have three learning cycles in the "Deforming manufacturing processes" lesson.

The first one is "Deforming," the second is "Laminating," and the third, "Vacuum forming." Let's get started.

Deforming is about changing the shape, not the state.

There are three states materials can be in.

Liquid, gas, or solid.

Here we have a check.

Which of these are states which materials can be? Is it A, liquid; B, water; C, ice; or D, solid? Pause the video and have a go.

Let's check.

That's right, it's liquid and solid.

Deformed materials remain solid, often flexible and malleable but still solid.

Malleable means to be pressed or bent without breaking.

Gold is malleable.

It can be beaten into very thin sheets known as gold leaf.

A material that breaks easily without bending or stretching is described as brittle.

Ceramics are brittle.

Imagine what would happen if you dropped the tea cup.

Another check, which definition describes the word malleable? Is it A, to be pressed or bent without breaking; B, to be pressed or bent without tools; C, to be pressed or bent resulting in breaking; or D, to be pressed or bent by hand? Pause the video and have a go.

Brilliant, let's check.

That's right, the word malleable means to be pressed or bent without breaking.

Some materials are easy to bend and shape in a solid state and can be formed by hand.

For example, paper and card can be deformed easily by folding.

Other materials such as polymers and metals are easier to deform when heated.

The polymer acrylic is very brittle.

The plasticity increases when acrylic is heated and can therefore be deformed without breaking.

If we tried to bend the acrylic when cold, it would snap.

Here we have your first task.

Define the word deforming.

Explain what material properties prevent acrylic being cold bent.

And explain what properties are evident when acrylic is heated.

Pause the video.

Fabulous, let's have a look at some of the answers you may have come up with.

Deforming is when a material changes shape but does not change state.

They are always solid materials and do not become liquid even when heated.

Explain what material properties prevent acrylic being cold bent.

Acrylic is very brittle when cold.

This means if we try to deform it or bend it, it will snap.

And the third part, explain what properties are evident when acrylic is heated.

When heated, the plasticity of acrylic increases and it can easily be bent or shaped, fabulous.

And now we move on to the second learning cycle, "Laminating." Laminating means sticking several layers of material together.

This is often confused with encapsulation, which is where polymer is used to cover a piece of paper.

This is an encapsulation machine.

Perhaps you have one in your school.

Laminating thin sheets of timber, which is called veneer, enables us to deform timber.

It is possible to deform timber using the process of laminating veneer.

Veneer is cut from logs of timber.

The sheets or rolls of veneer are very thin, usually only one millimetre thick.

Because are thin, they are flexible.

However, they are also fragile and can break easily.

When layers are glued together and compressed in a mould, they are much stronger and can be deformed in shaped moulds.

A quick check.

Which of these describes veneer? Is it A, a thin sheet of timber; B, a piece of timber; C, a log of timber; or D, a one-millimeter-thick sheet of timber? Pause the video and have a go.

Let's check.

That's right, it's A and D.

They are thin sheets of timber and they are usually one millimetre thick.

Here is a picture of some veneer.

When preparing the veneer, it is important to ensure the grain of each layer goes in the same direction.

The grain is the lines or pattern we can see on timber.

This is where the fibres in the wood have grown.

Working with the grain means the timber will curve.

Working across the grain, the timber is much more likely to split.

Here we can see an arrow indicating the direction of the grain, so this would be working with the grain, or this would be working across the grain.

And now we have a check.

Why is the grain direction important when laminating? A, the timber will curve when working with the grain.

B, the timber will curve when working across the grain.

C, the timber will split when working with the grain.

Or D, the timber will split when working across the grain.

Pause the video and have a go.

Okay, let's have a look.

That's right, it's A and D.

The grain direction is important when laminating because the timber will curve when working with the grain and the timber would split if working across the grain.

Here is the laminating veneer process.

We prepare the veneer and we gather the two-part mould, some PVA glue and a G clamp.

Laminating veneer process continued.

Part three, we add the PVA glue to one side of each piece of veneer, and we're now going to watch a video of that.

Part four, we clamp the veneer into the mould and place in a vice, or like I have, use G clamps to clamp the mould.

Part five, when the PVA has dried, you can take the deformed veneer out of the mould.

And here is a video showing that part of the process.

Here is Task B.

Describe the process of laminating veneer.

Use words and pictures, and remember to name the tools and equipment used.

Let's have a look at some of the answers you may have come up with.

One, we cut and prepare the veneer working with the grain.

Two, we glue the veneer on one side with PVA glue.

And three, we place it in the mould.

Four, we clamp the mould, or you may use a vice.

And five, remove the clamp when dry.

The third learning cycle of this lesson is "Vacuum forming." Vacuum forming is a way of heating polymer sheets and shaping over a mould.

Here is an example of a vacuum for mould made from MDF, which stands for medium-density fiberboard.

It has a draught angle, and this means tapered sides, and smooth corners.

This will allow the polymer to be removed easily once it has been deformed.

Here we can see a cross-section diagram of a vacuum form mould.

The features of a vacuum form mould are that it must have a draught angle.

That's tapered sides.

It must have rounded edges.

And there must be no undercuts.

This is a feature which would prevent the polymer being removed from the mould, as it would fold under itself.

What is a draught angle on a mould? Is it A, rounded edges; B, tapered sides; or C, undercuts? Pause the video and have a go.

Let's look.

That's right, it's tapered sides.

Products manufactured using vacuum forming have the following characteristics.

A hollow shape, a simple shape, and usually a large shape with tapered sides.

An acrylic bath is an example of a product made using vacuum forming.

The most common polymer used in schools is high-impact polystyrene sheets, or HIPS.

In industry, acrylic can be vacuum formed.

Let's have a check.

In order to extract the mould from the polymer sheet once formed, the mould must have, A, smooth edges, B, sharp corners, or C, straight sides? Pause the video.

Let's look.

That's right, smooth edges, well done.

Here's a picture of a vacuum-forming machine, and here is a cross-section diagram showing a vacuum-forming machine.

The heater, the chamber, the platen.

This is the name of the bed in the machine where we place the mould.

And here is the mould.

The stages of vacuum forming are, one, to prepare the mould.

Two, place the mould on the platen and lower this within the chamber of the machine.

Clamp the polymer on the machine.

Heat the polymer.

Here we have a picture of an MDF vacuum form mould.

And now we're going to watch a video of clamping the polymer sheet to the vacuum former and heating.

The HIPS is placed on the vacuum-forming machine, the frame is lowered, and the toggle clamps squeezed to secure this in place.

The heater is then rolled over the polymer.

And the vacuum forming stages continued.

Number five, remove the heat.

Number six, raise the platen and turn on the vacuum.

Number seven, wait for the polymer to cool a little and then release from the machine.

And we now have two videos.

The first, a video of forming the polymer sheet, and the second, a video of unclamping the polymer sheet and removing from the machine.

The heater is rolled back, the lever is used to raise the platen with the mould on, and then the vacuum is turned on to remove the air from the cavity of the machine.

The vacuum pump is turned off, the toggle clamps are opened and the frame lifted.

This allows the deformed polymer to be removed from the vacuum form machine.

It is important to note that the vacuum does not suck the polymer.

The removal of the air in the machine chamber increases the atmospheric pressure above the polymer, forcing the polymer to take the shape of the mould.

Here we can see in a cross-section diagram that the vacuum removes air from the chamber and the atmospheric pressure forces the polymer over the mould.

Let's have a check.

What forces the polymer over the mould? Is it A, suction; B, atmospheric pressure; C, vacuum; D, fluid pressure? Pause the video and have a go.

Great, let's check.

That's right, it's atmospheric pressure, well done.

Task C, annotate the diagrams to explain the process of vacuum forming.

And part two, choose one of the products and explain why it was produced using vacuum forming.

It could be a car dashboard, a meal tray, a shower tray, or a bath.

Pause the video.

Well done, let's have a look.

So number one, we prepare the mould.

Number two, we place the mould on the platen and lower.

Number three, we clamp the polymer on the machine.

And number four, we heat the polymer.

Part five, remove the heat.

Part six, raise the platen and turn on the vacuum.

Part seven, wait for the polymer to cool a little and then release from the machine.

Part two, choose one of the products and explain why it was produced using vacuum forming.

The car dashboard is both large and hollow.

The curves are quite simple with no undercuts.

The meal tray is curved and hollow.

The shower tray is hollow with draught angles.

And the bath is a large simple shape.

These reasons make these products suitable for vacuum forming, well done.

Here we have a summary of our learning today.

Deforming is about changing the shape, not the state.

Deformed materials remain a solid, often a flexible and malleable solid.

Paper and card can be deformed easily by folding.

Thin timber, called veneer, can be deformed using the laminating process.

Other materials such as polymers and metals are easier to deform when heated.

If not heated, some polymers and metals are likely to break as they are brittle.

I'm so pleased you could join me today, well done.