Ash Dark red White Light brown Easy to work with Not very durable tough/flexible Uses - bars, veneers, Uses - kitchens, Uses - Indoor furniture. Indoor work, handles, sports Red furniture equipment, Pale red Light colour ladders Heavy / strong Hard Use - structural Easy to work with Uses - furniture, toys Tool handles, can be Light brown steam bent Difficult to work Natural with Uses - high MATERIALS class furniture, beams Bonded under high Manufactured board pressure Chipboard Strong + thin Wood particles + Similar to MDF

Plywood Flexi-ply resin Laminated (layered) (see ugly/weak/cheap MDF veneers set at a 90* ) *often covered in a + resin angle. Able to veneer, this makes Damaged by Natural finish + grain bend it stronger + more moisture Uses - interior and aesthetically * Takes well exterior. pleasing *Easy to finish *Smooth surface PROCESSES

Laminating

Type1

This is quite an accurate method of shaping wood. It involves building up a curved form with layers. The layers may be thin veneers, thicker constructional veneers or -cut strips. They are assembled so that the grain of each layer is running in the same direction, following the curve .

The layers are glued together with a strong adhesive and are sandwiched between the waxed faces of a former or a using cramp pressure. The layers bend to the shape of the jig and ‘set’ together.

Another way of producing curved laminates is to use a ‘bagpress’.

Type2

Creating larger board of wood from natural timber by gluing them together side by side. Within this process each piece of wood is placed with the facing the opposite direction. PROCESSES

Bag Press

The simplest type of vacuum press uses a sealable bag and some form of vacuum generator. By placing materials in the bag over a mold or former, sealing it and then sucking out most of the air, a pressure differential is created between the reduced pressure inside the bag and atmosphere on the outside. PROCESSES

Steam Bending

Steam bending is a technique where strips of wood are steam heated using a . The applied heat and moisture makes the wood pliable enough to easily bend around a former to create a specific shape. The moulding process is usually done by clamping the strips of wood to a positive form, with the strips of wood often reinforced on the outside with a metal band to prevent blowout. The method has been used in the manufacturing of a diverse range of products, some examples being wooden where it is used in the shaping of hull's ribs and musical instruments such as .

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Turning (WOOD LATHE)

The wood lathe can be used for turning in 2 ways – on the headstock or between centres. Either side of the headstock is suitable for turning, using a flat plate to produce such ‘flat’ products as bowls, dishes, formers and bases. To handle longer pieces of work, such as legs and spindles, you need to turn between centres. To do this, a drive centre is pushed into the to turn the work which is supported at the other end by a ‘dead centre’ located in the tailstock. JOINING METHODS ADHESIVES JOINTS The main permanent method of joining wood is through wood PVA GLUE . There are many different types of joint that can be used Polyvinyl acetate (PVA) glue is the most depending on the type of product. Below are some examples of common type of glue out there. It’s so common joints used for box-like structures and for frame structures. that if you have a bottle of glue in your house, it’s likely to be PVA glue. The advantage of Through PVA glue is that it is readily available at your housing local store. But after you glue up your project, joint bits of dried PVA glue can interfere with your finish if you’re not careful to get rid of all of it.

EPOXY Epoxy comes in two parts: a resin and a hardener. Both are liquid, but when mixed together a chemical reaction occurs that causes the epoxy to harden. Epoxy has the advantage of being waterproof and does a good job filling gaps in wood. Most other glues will not hold well if there is a gap between the pieces of wood that you are gluing together. JOINING METHODS

Standard Components Knock Down fittings

Anything that is bought as a simple component from other Special fittings to join furniture parts together, mechanical fixings using companies - nuts, bolts, washers. standard components.

Advantages -

Standard components can be manufactured in vast quantities, keeping costs down.

Standard components are supplied in standard sizes. Advantages - Buying directly from suppliers, over the counter, at hardware stores such as B & Q, is easier as standard components such as Knock-down fittings can be put together easily, normally using only a screws, bolts, nails and fixings are often displayed in order. This screwdriver, a , a /hammer and other basic . They are temporary makes it easier to find the component the customer requires. joints although many are used to permanently join together items such as pieces of furniture that are purchased in a flat pack. Manufacturers usually assemble their products from standard components. This allows them to concentrate on the development Advantages to the manufacturer - Fittings manufactured in large numbers are of their specialised product, rather than having to design each cheap. They are tried and tested joints and work efficiently. Customers often individual component. This speeds up product development. already know how to use these joints and do not need help putting furniture together. TOOLS

Marking out Wooden mallet Used with for better control.

Try Marking 90 angles Measuring parallel to the edge hole for Hole Cutter Cuts large Forstner bit holes Drills a straight flat-bottomed through Tenon Mitre hole the wood Best for straight cuts best for curved cuts best for cutting at an angle (see mitre joint)

Countersink Paddle bit Auger Drill Bit widens the Large wide Bits These cut opening of a edge Mortise Smoothing Jack Rebate hole large, deep hole so a General use chisel For mortise joints For straightening and General use Best for lap joints and accurate holes screw can sit Smoothing wood Through housing flush. FINISHING

Staining Varnish is a transparent, hard, protective Staining should enhance the appearance of finish or film that is primarily used in wood by reducing colour variation. It also . Varnish finishes are provides a way of giving bland looking the usually glossy but may be designed to appearance of prized furniture woods such as produce a satin or semi-gloss sheen. mahogany or walnut. Stains are also available in Varnish has little or no color, is a wide variety of colours for example, blues and transparent, and has no added pigment, greens.

as opposed to or . However, staining wood is difficult to control are also applied over wood because some parts of the wood absorb more stains as a final step to achieve a film stain than others, which leads to problems such for gloss and protection. as blotchiness and streaking.

Wax Paint Wax is rubbed onto the wood Paint has to be applied to a smooth even using a cloth. It gives the wood surface, MDF is good for this. a dull even sheen. Before painting, sand the wood down to create a Was however is a short term smooth surface. Between coats of paint the wood finish meaning its has to be should be sanded. The process should be reapplied regularly either repeated until there is a nice smooth finish. weekly/monthly or yearly The wood is normally then finished with a clear coat of varnish to seal it and protect the paint. ENVIRONMENT

Making a product uses resources, such as raw materials and energy. This has an impact on the environment. Sustainable wood comes from sustainably There are a number of things that a designer might think about to reduce managed forests. It's renewable because the forest environmental impact: stewards manage the landscape to prevent damage to ecosystems, watersheds, wildlife and the trees ● The material used to make the product. themselves, taking a long term rather than short term ● The life of the product. view of the resource. ● What happens to the product at the end of its life.

Companies could also redesign their Materials and the environment products to use material smartly as to stop wasting material. One way to reduce impact on the environment is to use less material in the product. This might mean asking questions about what is needed or whether it This chair uses the whole sheet could be made smaller (or thinner) and still do the same job. It could also without wasting material mean using an alternative material with better properties, so that not as much of the material is required. Wood

Timber is a renewable resource, which means that if forests and woodlands are carefully managed, we will never run out of it. Timber is easy to reuse and can be burnt to produce heat when at the end of its natural life. It is also biodegradable.

Brass (Alloy) Copper + zinc Mild steel Gold colour Tough Corrosion resistant Low cost Hard Wearing Good for large quantities Strong / machinable ie, construction Uses - plumbing, High Carbon Steel Uses- construction, instruments Copper High water resistance chains, bolts, fittings Turns green when Uses- high impact tarnished tools Easily bent Planes,knives,blades Conduct heat NON-FERROUS Very expensive NO RUST

Iron/cast iron Low melting point FERROUS Wear resistant Stainless steel (alloy) Resistant to Iron + chromium METAL deformation Corrosion resistant Uses- cookware, drain Very strong Aluminum covers,outdoor Easy to form Silver furniture, construction Uses- Strong/ light/ recyclable cutlery/cookware/kitchen Uses - cars, food appliances containers, foil PROCESSES

METAL LATHE METAL LATHE TOOLS PROCESSES PROCESSES PROCESSES PROCESSES

DROP FORGING Machined Dropped forged

Drop Forging is the process of heating metal and hammering it in to a special die (cast die) to produce a final product. Manufacturers use the drop forging process to produce hardware products which need to be strong and durable.

Drop forging alters the metal grains making much stronger tools. Joining Methods

Welding Welding is where two pieces of metal are melted along Rivets the joints, fusing together as they cool. Rivets are components used for joining metal (and sometimes plastics and plywood). A hole is drilled through both pieces of work, the rivet is placed through it, and its end beaten into a dome. A tool called a rivet gun. With most rivets you need to get at both sides of the work to make the joint. Pop rivets enable you to complete the joint while only having access to one side of the work. They are usually used for joining thin sheets together

Spot welding Spot welding is used to join sheet metal together. The sheets are placed on top of one another and put inside the spot welders electrodes.Forcing a large current through the spot will melt the metal and form the weld. Joining Methods

Taps and Dies

Taps and dies are tools used to create screw threads, which is called threading.

A tap is used to cut or form the female portion of the mating pair (e.g. a nut).

A die is used to cut or form the male portion of the Tap The process of cutting or forming threads mating pair (e.g. a bolt). using a tap is called tapping.

Die Die

Tap The process using a die is called threading. Tools

Inside calipers Outside calipers Engineers Accurately measures the Accurately measures the Scriber inside distance between distance between two opposite Used to mark two opposite sides like sides like the outside of a out metal the inside of a Engineers hole/pipe. cylinder. square Center Marking punch out 90 Used to mark angles the exact Odd leg calipers point for used for scribing drilling. lines at a specified distance from a flat or curved surface

Rawhide hammer Helps to maintain the surface condition of the item as much as possible. Hacksaw Saw for cutting Useful in delicate metal Junior Hacksaw metal. Such as work where minimal Saw for cutting pipes Engineers files deformation of the metal metal. Such as Smoothing sheets is required. pipes Finishing

Polishing Dip coating

Metal can be polished with . Many sandpaper Dip coating is the process of heating up metal in an oven and plunging it manufacturers sell finishing paper specifically designed for into a machine full of fine plastic. The dip coat machine pumps air polishing metal. Most experts suggest starting with 600-grit through the plastic making it light for better coverage. sandpaper and moving up to finer sandpaper, along the lines of 1000-grit or even 2500-grit. The plastic dip coat comes in a variety of colours. The plastic is soft giving a nice cover for a handle. Or a polishing fluid like brasso.

Melamine formaldehyde Expensive Range of colours PLASTIC Heat resistant Thermosetting Used as worktop veneers, Cannot be melted down again tableware - Non toxic / non smell CANNOT BE RECYCLED or taste onto food. Urea formaldehyde hard/unbreakable Range of colours Warm to the touch Electrical insulating properties Low water absorption Stain resistant Thermoplastics Can be melted down again

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ABS Acrylic Many Colours / shiney Sheet / rod / tube Tough / hard Many colours - Scratch resistant Solid / transparent / Easy to process translucent Low cost Aesthetically pleasing Polypropylene (PP) Recyclable Brittle Range of colours Resistant to weathering Easy to work with High impact Polystyrene Inexpensive Good for bending Expanded Polystyrene Recyclable Easy to process Lightweight White Safe for food storage Pre expanded beads Resistant to high Impact resistant Strong Impact absorbing temperatures. Thermal insulating Good for products that need to be thin/strong and bashed about. PROCESSES PROCESSES PROCESSES PROCESSES PROCESSES PROCESSES PROCESSES Adhesives

Contact adhesive can be used to Epoxy resin hardens when join plastics. The adhesive is applied a second chemical is added to both surfaces and when the (called a catalyst). It can bond surfaces appear to be dry they are most materials including pushed together. If the two pieces of some plastics. The two tubes material are left for a number of hours, can be seen in the diagram. they are virtually impossible to take An equal amount of each tube apart. are mixed together and then applied to the material to be glued. Finishing

The plastic is usually filed smooth then sanded using a wet and dry sandpaper.

Plastic edges should be finished before bending or forming. One of the reasons for this is that the straight plastic can be held in the vice securely.

If the edges were to be finished after the bending/ forming process it has a higher risk of snapping.