IGCSE Design & Technology

9S​ haping
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9. ​Shaping
● Shaping ​is any process which defines or moulds or changes the shape of an object
● Wastage ​is done by removing unwanted bits of material​Deforming and reforming​ is to
modify the shape without removing or combining material
● Bending​: plastic is heated in the line of strip heater for few minutes according to
thickness, then placed in a jig with block to hold it position as it cools
● Sand casting​: Pattern/object is covered with casting sand on two
drag box, the pattern is then removed and molten metal fills the mould to
create the shape through a hole
● Laminating​: strips of plywood (thin) are glued together using PDF
and G clamped to the mold
● Vacuum forming​: plastic sheet (ABS & HIP) are heated
then placed on the vacuum former with wood mold beneath, air
suction forces the plastic to form their shapes
● Blow moulding​: ​HDPE granules are places in hooper, through
rotating thread it is heated, compressed air blows the fluid into
the mould, cools and solidify, excess is trimmed
● Injection moulding​: ​polystyrene, nylon, polypropylene and
polythene are used, powder is heated, liquid is forced into the
mould, mould opens to remove it
● Extrusion​: ​like injection moulding but liquid plastic passes
through steel die to form tubes
● Press forming​: ​blank (plastic or steel, brass, aluminium) is heated
and clamped to press former, die is pressed into the sheet to form the shape
● Wastage/Addition

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● Plane ​is used to smoothen and straighten surface of wood along the
wood grain, the longer the plane the better as it takes in the high point
and bridges the low point. Checked by trisquare or steel rule
○ Jack plane: ​straighten or reduce wood after going
through jointer/ thicknesser (machine to thin wood)
○ Fore plane: ​(true)straighten wood further after jack
○ Jointer plane: ​longest bench plane for stock removal
(remove thickness) and accurately truing long edges or wide board
○ Smoothing plane: ​last plane to smooth fine surface better
than sandpaper
● Saws ​is used to smoothen and straighten surface of wood along the wood
grain, the longer the plane the better as it takes in the high point and bridges
the low point. Checked by trisquare or steel rule
○ Back saw: ​Saw wood in straight line on surface not through edge (wood held on
woodworking vice), have metal spine to add weight and keep blade
rigid
○ Tenon saw is for general use, wider, longer and thicker, cut across
grain with cross cut teeth (angled blade like mini iknife)
○ Dovetail saw is specifically for dovetail joint has shorter thinner blade, cut along
grain with rip teeth (chisel)
○ Coping saw: ​Saw thin wood in shapes and curves, blade pins point towards
handle, pull inward to cut, cut in middle though hole and remove
blade
○ Piercing saw: ​cut sheet metal in curves like coping saw
○ Hack saw: ​Cut steel and other metal, length of frame adjustable by
stud
● Abrasive cutter
● Hand snips
○ Tin snip​: used for cutting through tough material like
metal sheets and plastic sheets, durable, less likely to
be replace
○ Aviation snip​: reduces user fatigue, often spring loaded,
cannot cut in middle used to cut metal sheet for aircraft,
not for hardened skill, colour coded for straight, left & right
● File ​is used to smooth rough edges for metal (brass, steel) and wood
○ Rasp​: used to shape wood, shape
teeth
○ Hand file​: general usem have safe
edge
○ Half round file​: internal curved surface
○ Knife file​: little spaces and small gaps

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 ○ Square file​: thin, fit into corner and slots
● Computer-aided manufacture​ (CAD)
○ Laser & plasma cutter
○ Milling machine
○ Routing machine
○ Computer numeric control (CNC)
lathes machine
○ 3D printer like fusion deposition modelling
(FDM) ​(addition)
● Drilling​ is a method for through hole or blind hole,
hole boring or drilling can be done by hand or
machine
● Hand Drill Bench drill and Pillar drill
○ Pilot hole​: smaller hole drilled ahead of a full size hole as a guide
○ Clearance hole​: hole drilled on top of material to prevent jacking and allow the full
body of screw to fit through but the head remains on surface
○ Tapping​: screw thread is added to pilot hole so screw can be
accepted/twisted into the material through T handle
(generally in metal)
■ “Tap” tool for interior hole
■ “Die” tool for outside of rod
○ Countersunk hole​: conical shaped hold at 90° for counter headed screw “flush”
with the surface
○ Counterbored hole​: large diameter hole on top of pilot to accept cheese or fillister
head screw which recessed below surface

● Chisels​ is used to chip wood by applying mallet to the wooden of

plastic handle
○ Bevel chisel​: edged with slight undercut to push into corners,
used for finishing dovetail joints
○ Firmer chisel​: blade with rectangular cross-section, stronger
for tougher/heavier work
○ Paring chisel​: longer thinner for longer joint (housing joint),
cleaning joint for accurate fit
○ Mortise chisel​: chop out mortise joint, with side strong mallet
blow
● Gauge

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 ○ Marking gauge​: mark line parallel to a straight edge
○ Mortise gauge​: like marking gauge but has 2 spurs (point) to mark
mortise and tenon joint
● Rasps ​are used for shaping or finishing wood
● Cabinet rasps, Round rasps, Horse rasps (rasp and file side), Needle
rasps(precision)

● Sanding
○ Abrasive mops​: finish detail surfaces and
crisp edge, remove loose fibre, attached
pillar/bench drill
○ Disc sander​: smooth material such as
wood and plastic, remove small amount of
waste, before finishes and prime
○ Belt sander​: remove more material quickly eg strip paint, smooth
wood filler
● Lathe ​is used to manufacture cylindrical shapes from wood steel to plastic
○ Centre lathe​: works on metal, has more precision, can be computer
controlled (CNC machine)
○ Facing off: Steel attached to chuck, cross slide moves by
handle to cut surface of steel
○ Turning long taper: material held between two center, long
taper turns/moves to cut the cylindrical shape
○ Wood turning lathe​: works on wood and some plastic

● Portable power tools

○ Corded hammer drills​: used to drill holes into surface, drill speed depend on
material, normal setting: for wood and board in clockwise, hammer setting: for
brick & masonry, drives backward and forward
○ Sheet sander​: used to sand/smooth surface, vibrate at 1200 rpm, attached to sand
paper

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○ Machine routers​: used to create channel in wood with router bits
○ Jigsaw​: for cutting and shaping, ideal for plywood and mdf
○ Circular saw​: for cutting manmade board, slabs
and other thick materials (30mm), very
powerful