Author: Miss K McGee

@ Norton College

Thermoplastics:
ABS, PET, PMMA (acrylic), Polypropylene, High Impact Polystyrene, Expanded Polystyrene, Low and High Density Polyethylene, Nylon, UPVC.
Applications; mobile communication products, toys, car parts, packaging.
Biodegradable polymers:
Oxodegradable, biodegradable—”bio-batch” additives
Compostable polymers; cellulose based (Biopol) corn starch based (polylactide –PLA)
Applications for biodegradable polymers; plastic bags/bottles, detergent sachets
Absorbable or water soluble polymers; lactide, glycolide and Lactel or Ecofilm
Medical applications; slow release meds, bone fix repairs, detergent washing up sachets.
Plastic forming; vacuum forming, thermoforming, line bending
Moulding; injection moulding, blow moulding, rotational moulding, compression moulding.
Finishing; pigments and stabilisers; acrylic paints amd chrome effects
Joining; plastic welding, bonding with adhesives
Elastomers; Thermoplastic elastomers (TPE), Thermoplastic rubber (TPR), Liquid Silicon Rubber (LSR).
Applications for elastomers; car bumpers/trims and grips or over moulding.

Task	Date
1, 2 & 3	5th January
4, 5 &6	12th January
7, 8 & 9	19th January
10, 11 & 12	26th January

Thermosets:
Definition:
Thermoset plastics are materials which, once formed with heat and pressure cannot be reshaped. They has a cross linked polymer structure which does not allow reshaping with heat like the structure of thermoplastics.
Exam featured:
Epoxy resins, polyester resins, urea formaldehyde, melamine formaldehyde.
Applications:
Decorative laminates, casting and encapsulation, electrical fittings.
Task One:
Find the polymer structure of thermosets—link why they have the ability to change shape with heat in relation to their structure.

Definition:
Thermoplastics are materials of which their shape can be changed with the application of heat. When heated the plastics become pliable and upon cooling will stay in that set form, if you apply heat again they will return to their original form. (plastic memory).
Exam featured:
PET, ABS, PMMA (acrylic), Polypropylene, High Impact Polystyrene, Expanded Polystyrene, Low and High Density Polyethylene, Nylon and UPVC.
Applications:
Mobile communication products, toys, car parts, packaging, kitchen ware, pipes and window frames.
Task two:
Find the polymer structure of thermoplastics—link why they have the ability to change shape with heat in relation to their structure.
Find the polymer structure of thermosets and describe why they do not have the ability to change shape after curing time.

Task three:
Environmental Issues with Plastics:
Create a mind map to explain the issues with the environment.
Biodegradable polymers:
Oxodegradable, biodegradable—”bio-batch” additives
Compostable polymers; cellulose based (Biopol) corn starch based (polylactide –PLA)
Applications for biodegradable polymers; plastic bags/bottles, detergent sachets
Absorbable or water soluble polymers; lactide, glycolide and Lactel or Ecofilm
Medical applications; slow release meds, bone fix repairs, detergent washing up sachets.

Task four:
Joining and Finishing
The following finishes are applied to plastics;
pigments and stabilisers,
acrylic paints,
chrome effects.
For each finish explain why and how the finish is applied and then give 2 examples of products that use this.
Joining;
There are two main methods of joining plastics, these are;
plastic welding—draw a diagram of this process and explain the advantages of using this method.
bonding with adhesives—give a list of appropriate adhesives and explain the process of bonding them. Give diagrams where appropriate.

Elastomers:
What are the differences between the following materials;
Thermoplastic elastomers (TPE),
Thermoplastic rubber (TPR),
Liquid Silicon Rubber (LSR).
Why are the above elastomers added to products?
Give examples of products that have elastomers applied; e.g. car bumpers/trims and grips or over moulding.

Task five:
Materials and Properties:
For the materials on the left side of the page create a table similar to the example below, be sure you understand the differences between them and why the may be chosen to create products with over other materials.
Try to give at least 3 products for each material.
Plastics often come up in the exam so it’s worth understanding why they are used.

Investigation:
Look around your house and find five examples of different plastics; common objects such as milk bottles, bleach bottles, Tupperware boxes, plastic toys etc.
For each product explain why that particular plastic has been chosen and is an appropriate material to manufacture that product out of. Use key terms and technical language.

Material	Properties	Process	Products	TP/TS?
Acrylic	Durable, clean cut edges, available in many colours and transparencies. Can be cast or in sheet form.	Laser cut	Signage	Thermoplastic

Task six: Rotational Moulding

•You have explained the process step by step in an easy to read way (imagine you are explaining this to Year 7 students).
•You have included diagrams of the process.
•You have given an overview about how it is currently used and what specific materials are used with it (e.g. PET plastic).
•You have weighed up the advantages and disadvantages of manufacturing with this method.
•You have the three subtitles; overview, applications and process.
•You have included some images of it’s current applications.

Task seven: Vacuum Forming

•You have explained the process step by step in an easy to read way (imagine you are explaining this to Year 7 students).
•You have included diagrams of the process.
•You have given an overview about how it is currently used and what specific materials are used with it (e.g. PET plastic).
•You have weighed up the advantages and disadvantages of manufacturing with this method.
•You have the three subtitles; overview, applications and process.
•You have included some images of it’s current applications.

Task eight: Injection Moulding

•You have explained the process step by step in an easy to read way (imagine you are explaining this to Year 7 students).
•You have included diagrams of the process.
•You have given an overview about how it is currently used and what specific materials are used with it (e.g. PET plastic).
•You have weighed up the advantages and disadvantages of manufacturing with this method.
•You have the three subtitles; overview, applications and process.
•You have included some images of it’s current applications.

Task nine: Compression Moulding

•You have explained the process step by step in an easy to read way (imagine you are explaining this to Year 7 students).
•You have included diagrams of the process.
•You have given an overview about how it is currently used and what specific materials are used with it (e.g. PET plastic).
•You have weighed up the advantages and disadvantages of manufacturing with this method.
•You have the three subtitles; overview, applications and process.
•You have included some images of it’s current applications.

Task ten: Blow Moulding

•You have explained the process step by step in an easy to read way (imagine you are explaining this to Year 7 students).
•You have included diagrams of the process.
•You have given an overview about how it is currently used and what specific materials are used with it (e.g. PET plastic).
•You have weighed up the advantages and disadvantages of manufacturing with this method.
•You have the three subtitles; overview, applications and process.
•You have included some images of it’s current applications.

Task eleven: Calendaring

•You have explained the process step by step in an easy to read way (imagine you are explaining this to Year 7 students).
•You have included diagrams of the process.
•You have given an overview about how it is currently used and what specific materials are used with it (e.g. PET plastic).
•You have weighed up the advantages and disadvantages of manufacturing with this method.
•You have the three subtitles; overview, applications and process.
•You have included some images of it’s current applications.

Task twelve: Exam questions