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This lesson covers the specialist tools and equipment used when working with metals and polymers, as required by AQA GCSE Design and Technology (8552), Section 3.2.8. You must know the correct tools for marking out, cutting, shaping, joining and finishing both metals and polymers.
| Tool | Use |
|---|---|
| Scriber | Scratching fine lines on metal surfaces (more accurate than pencil) |
| Engineer's square | Checking and marking 90° angles on metal |
| Centre punch | Creating a small indentation to prevent a drill bit from wandering |
| Odd-leg calipers | Scribing lines parallel to an edge |
| Dividers | Marking circles and arcs on metal |
| Surface plate | Providing a perfectly flat reference surface for marking out |
| Tool | Use | Example |
|---|---|---|
| Hacksaw | Cutting metal bar, rod and sheet by hand | Cutting mild steel rod for a candle holder |
| Junior hacksaw | Cutting small sections of thin metal and wire | Trimming brass rod |
| Tin snips (aviation snips) | Cutting thin sheet metal | Cutting aluminium sheet for a phone stand |
| Bandsaw (metal-cutting) | Cutting thick sections of metal | Cutting steel bar stock |
| Abrasive disc cutter | Fast cutting of metal sections | Cutting steel tube for a bike rack |
| Plasma cutter | Cutting metal sheet using an ionised gas arc | Cutting steel plate in industry |
| Tool | Use |
|---|---|
| Centre lathe | Turning metal to produce cylindrical shapes (shafts, spindles) |
| Milling machine | Cutting flat surfaces, slots and complex profiles in metal |
| Metal files (flat, half-round, round, triangular) | Hand finishing and shaping metal to size |
| Ball-peen hammer and stake | Shaping sheet metal by hand (planishing, raising) |
| Bending jig / folding bars | Creating accurate bends in sheet metal or bar |
| Fly press | Punching holes and pressing shapes in sheet metal |
AQA Exam Tip: A common 3-mark question is: "Describe how you would mark out and drill a hole in a piece of mild steel." The expected answer: mark the position with a scriber, use a centre punch to create an indent, then drill using a pillar drill at the correct speed with the workpiece clamped in a machine vice.
| Method | Tools/Equipment | Suitable Metals |
|---|---|---|
| Soldering | Soldering iron, solder, flux | Copper, brass, tin plate, electronic components |
| Brazing | Brazing hearth, brazing rod, flux, blowtorch | Steel, brass, copper |
| Welding (MIG) | MIG welder, wire feed, shielding gas | Mild steel, stainless steel, aluminium |
| Riveting | Rivet gun (pop riveter), rivets | Aluminium, steel sheet |
| Nuts and bolts | Spanners, socket sets | All metals (temporary/permanent joint) |
| Adhesive bonding | Epoxy resin (Araldite) | All metals (where heat distortion must be avoided) |
| Tool | Use | Example |
|---|---|---|
| Coping saw | Cutting curves in thin acrylic or polystyrene sheet | Cutting a decorative shape in 3 mm acrylic |
| Hacksaw | Cutting straight lines in acrylic rod or sheet | Cutting acrylic for a photo frame |
| Scroll saw | Cutting intricate curves in thin polymers | Detailed profiles in HIPS sheet |
| Laser cutter | Precision cutting and engraving acrylic, MDF, card | Cutting acrylic parts for a lamp |
| Strip heater (line bender) | Heating a line in thermoplastic sheet for bending | Bending acrylic for a phone stand or leaflet holder |
| Hot wire cutter | Cutting expanded polystyrene foam | Shaping foam for modelling or packaging |
| Process | Equipment | Description |
|---|---|---|
| Vacuum forming | Vacuum former, oven, mould | Heating a thermoplastic sheet and sucking it over a mould |
| Line bending | Strip heater | Heating along a line to create a fold (e.g. 90° bend in acrylic) |
| Injection moulding | Injection moulder | Forcing molten polymer into a mould under pressure |
| 3D printing (FDM) | 3D printer, PLA/ABS filament | Building up layers of polymer to create a 3D shape from a CAD file |
| Blow moulding | Blow moulder | Inflating a heated polymer tube (parison) inside a mould |
AQA Exam Tip: You should be able to describe the step-by-step process for vacuum forming and line bending, as these are frequently tested. Include heating, forming and cooling stages.
graph TD
A[Material area] --> M[Metals]
A --> P[Polymers]
M --> M1["Marking out<br/>scriber / centre punch / engineer’s square"]
M --> M2["Cutting<br/>hacksaw / tin snips / bandsaw / plasma"]
M --> M3["Shaping<br/>centre lathe / milling machine / files / fly press"]
M --> M4["Joining<br/>solder / braze / MIG weld / rivet"]
P --> P1["Marking out<br/>chinagraph / felt-tip / scriber"]
P --> P2["Cutting<br/>coping saw / scroll saw / laser / hot wire"]
P --> P3["Forming<br/>strip heater / vacuum former / injection mould / 3D print"]
P --> P4["Joining<br/>Tensol cement / mechanical fixings"]
| Factor | Metals | Polymers |
|---|---|---|
| Typical cutting tools | Hacksaw, tin snips, bandsaw | Coping saw, laser cutter, hot wire cutter |
| Typical joining methods | Welding, brazing, soldering, riveting | Adhesive (Tensol cement for acrylic), mechanical fixings |
| Typical forming methods | Casting, forging, bending | Vacuum forming, injection moulding, blow moulding |
| Key safety concern | Hot metal, sharp edges, fumes from welding | Fumes from heated polymers, burns from strip heater |
| Risk | Control Measure |
|---|---|
| Burns from hot metal or heated polymers | Wear heat-resistant gloves, use tongs, allow cooling time |
| Fumes from welding or heated polymers | Use fume extraction, work in well-ventilated areas |
| Sharp edges and swarf | Deburr edges, wear gloves when handling sheet metal |
| Eye injury | Wear safety goggles (cutting), welding visor (welding) |
| Entanglement in lathe/milling machine | Remove loose clothing, tie back hair |
Metals require robust tools for marking out (scribers, centre punches), cutting (hacksaws, bandsaws) and shaping (lathes, milling machines). Polymers require careful heat management and use tools such as strip heaters, vacuum formers and laser cutters. Choosing the right tool depends on the material properties, the required accuracy and the production scale.
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