Blending and
Category
Casting or compacting Mould
(Metal, Examples of Secondary Sustainability
Moulding (ceramics), features/parameters
Ceramic suitable operations topics for this Advantages Disadvantages
process & additives for for casting and
or materials required process
applications metals & polymer moulding
Polymer)
polymers
Component 1 Metal Aluminium Finishing Surface Temperature of mould Materials chosen Die casting can Production of this process
7050 finishing is crucial as it prevents should be produce high precision is expensive also comes
Name of defects like porosity. recycled or be parts, excellent surface with limited material
component Copper alloys Heat made from finish and complex selection and high
Aluminium alloy treatment Gate design of which recycled content shapes operating temperatures
skateboard zinc alloys the metal flows to reduce
inspection influence the material energy
What Process? and effect part quality. consumption.
Die casting
Component 2 Oxide ceramics Lubricants Heat Powder characteristics Highly efficient Allows the change of Sintering can mostly be
binders can be treatment like can influence the because it materials state from used to make small to
Name of Ceramic Silicon nitrides done by annealing and properties of powders. allows use of powdered to a more medium sized components
component milling machining. powdered solid dense object and requires special
Tungsten carbide Mixed ceramics Also, the temperature materials, which have high machinery
tool inserts which sintering occurs minimizing accuracy and can
o is important for the waste and their create complex designs
What Process? bonding products are
Sintering often recyclable
Component 3 Polyethene Colourants Decorating the Clamping force is used Energy efficient Sintering is recyclable Again, the size of the
could be used and pigments product in to Mould halves techniques can and cost-effective product cannot be too big
Name of Polymer low costs and used to colour colours may together during cooling reduce energy method and can exhibit and surface finish may not
component? versatility the plastic be used and phases. Injection, consumption high temperatures be as smooth and mostly
Abs model part for laser marking cooling time need to be used with metals and
building blocks ABS good desired intricate watched carefully to ceramics
impact aesthetics designs. solidify the material
What Process? resistance and
Injection durability
moulding
Unit 42 Primary Forming process
, Characteristics
For the suitable manufacture of the aluminium alloy skateboard, We will have to use a process that can be mass produced which means it must be cheap,
which makes die casting most suitable because, It is a metal casting process where it uses pressure to push molten metal at high speeds into a mould cavity.
The mould is made from hard steel dyes that is shaped into the mould. The reason why is most suitable because it has good surface finishing and all these
properties are beneficial for the manufacture of the skateboard There are two types of die casting machines cold chamber and hot chamber machines. Cold
chamber machines are used for alloy such as aluminium and other alloys with high melting points. Advantages of Cold-Chamber over Hot-Chamber 1) Alloys
such as aluminium or zinc-aluminium alloys and certain magnesium alloys can only be cold-chamber processed. 2) Higher injection pressures and speed can
be achieved producing denser castings. 3) Lower maintenance costs. The process of die casting includes a die casting machine, furnace, a mould, a crucible,
tongs, and a furnace, a torch, and the process work by filling a mould with molten metal under high pressure and speed, and then the metal crystallizes and
solidifies under this high pressure to form the casting.
Category
Casting or compacting Mould
(Metal, Examples of Secondary Sustainability
Moulding (ceramics), features/parameters
Ceramic suitable operations topics for this Advantages Disadvantages
process & additives for for casting and
or materials required process
applications metals & polymer moulding
Polymer)
polymers
Component 1 Metal Aluminium Finishing Surface Temperature of mould Materials chosen Die casting can Production of this process
7050 finishing is crucial as it prevents should be produce high precision is expensive also comes
Name of defects like porosity. recycled or be parts, excellent surface with limited material
component Copper alloys Heat made from finish and complex selection and high
Aluminium alloy treatment Gate design of which recycled content shapes operating temperatures
skateboard zinc alloys the metal flows to reduce
inspection influence the material energy
What Process? and effect part quality. consumption.
Die casting
Component 2 Oxide ceramics Lubricants Heat Powder characteristics Highly efficient Allows the change of Sintering can mostly be
binders can be treatment like can influence the because it materials state from used to make small to
Name of Ceramic Silicon nitrides done by annealing and properties of powders. allows use of powdered to a more medium sized components
component milling machining. powdered solid dense object and requires special
Tungsten carbide Mixed ceramics Also, the temperature materials, which have high machinery
tool inserts which sintering occurs minimizing accuracy and can
o is important for the waste and their create complex designs
What Process? bonding products are
Sintering often recyclable
Component 3 Polyethene Colourants Decorating the Clamping force is used Energy efficient Sintering is recyclable Again, the size of the
could be used and pigments product in to Mould halves techniques can and cost-effective product cannot be too big
Name of Polymer low costs and used to colour colours may together during cooling reduce energy method and can exhibit and surface finish may not
component? versatility the plastic be used and phases. Injection, consumption high temperatures be as smooth and mostly
Abs model part for laser marking cooling time need to be used with metals and
building blocks ABS good desired intricate watched carefully to ceramics
impact aesthetics designs. solidify the material
What Process? resistance and
Injection durability
moulding
Unit 42 Primary Forming process
, Characteristics
For the suitable manufacture of the aluminium alloy skateboard, We will have to use a process that can be mass produced which means it must be cheap,
which makes die casting most suitable because, It is a metal casting process where it uses pressure to push molten metal at high speeds into a mould cavity.
The mould is made from hard steel dyes that is shaped into the mould. The reason why is most suitable because it has good surface finishing and all these
properties are beneficial for the manufacture of the skateboard There are two types of die casting machines cold chamber and hot chamber machines. Cold
chamber machines are used for alloy such as aluminium and other alloys with high melting points. Advantages of Cold-Chamber over Hot-Chamber 1) Alloys
such as aluminium or zinc-aluminium alloys and certain magnesium alloys can only be cold-chamber processed. 2) Higher injection pressures and speed can
be achieved producing denser castings. 3) Lower maintenance costs. The process of die casting includes a die casting machine, furnace, a mould, a crucible,
tongs, and a furnace, a torch, and the process work by filling a mould with molten metal under high pressure and speed, and then the metal crystallizes and
solidifies under this high pressure to form the casting.
