Safety
What does PPE stand for?
Personal Protective Equipment
This tool is used to "pop-out" dents in plastic parts, using heat
Heat gun
A technician is deciding whether a repair needs shrinking or a different method. Which material in the comparison specifically lists shrinking as a possible repair requirement?
Metal
What are three types of damage a plastic part can have?
Cracks and splits; tears and holes; broken mounting tabs; deformation
A technician finds a plastic identification label before starting a repair. What important repair decision can this information help the technician make?
It helps determine the type of plastic and select an appropriate repair procedure.
Name four types of PPE you should be wearing when repairing plastic?
Safety glasses; coveralls; leather gloves; boots; respirator; dust mask
This is used bond two dissimilar materials together
Two-part adhesive/ two-part epoxy
A student says plastic repair is easier because plastic does not necessarily develop high spots like metal. Why is that not a good reason to assume plastic repair is simple?
Plastic can still crack, tear, deform, or suffer damage from excessive heat.
What product is used to fix any remaining low spots left after using filler rods and fiberflex in plastic repair?
Plastic Body Filler
A technician reheats a plastic component expecting it to melt and flow, but it does not. Which plastic category may this be, and what is the key reason?
Thermosetting plastic. It forms a permanent cross-linked structure during original curing and does not melt or flow again when reheated.
A student leaves the work area cluttered with hot equipment nearby. Identify two hazards this can create.
Trips, burns, or accidental contact with hot equipment
Why might metal mesh be useful in a plastic repair?
Meal mesh adds structure while still allowing flexibility.
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A metal panel has the correct contour after straightening. What additional property must a technician consider when restoring a plastic component?
The plastic repair must restore strength while retaining flexibility
This type of plastic and plastic repair method is known as an adhesive repair
Thermoset-two-part epoxy
This type of plastic and plastic repair method is known as a cohesive repair
Thermoplastic-plastic welding
A student finishes welding a plastic part and walks away while the equipment is still hot, but it is unplugged AND they told others around them that the tool was still hot. A student comes over and touches the metal part of the welder, burning their hand. Who is at fault for the injury?
The student who touched the tool is at fault. Always assume that if a tool is out, it has been used. Be cautious.
This is used to melt plastic filler rods to fix similar materials
Plastic Welder
A student immediately applies adhesive to a deformed plastic part without reshaping it. What steps were missed?
Cleaning, inspection, preparation, repair(using heat gun), abrasive prep, plastic filler
A plastic repair requires additional material at a weak joint. Which material from the may be appropriate, and what must be considered when selecting it?
Plastic filler rods may be used to add compatible material and restore strength at weak joints. Compatibility with the original plastic and the repair procedure matters.
A damaged component is labeled <PP+EPDM>. Which filler rod would you use to fix the damage?
(Bonus 500 points for the proper name of EPDM)
PP-Polypropylene
**Bonus answer: Ethylene Propylene Diene Monomer**
During plastic repair, you notice flammable materials near the work area, the ventilation is inadequate, and the technician plans to leave the hot equipment unattended. Identify three safety problems and the corrective action for each.
Remove flammable materials and ensure suitable fire protection is available; provide proper ventilation; never leave hot equipment unattended, and turn it off and allow it to cool in a safe location. Required PPE must also be worn
This tool is used to join two halves of the damaged plastic back together, using heat, but it indirectly joins the material together (does not melt to combine similar materials, does not use adhesive to bond dissimilar materials)
Plastic Stapler
Two technicians disagree. One says all damaged panels should be straightened with hand tools; the other says all damaged panels should be heated. Explain why neither statement is correct.
The method depends on the material and the damage. Metal can be shaped using hammers and dollies and may need shrinking or straightening. Plastic is generally reshaped using controlled heat when the material allows it, and may need welding or an approved adhesive repair.
A plastic component has several types of damage. Explain why the technician should not assume that repairing every damaged area is automatically the best choice.
Not all damage is worth fixing. The technician should assess the damage, identify the plastic, and determine whether an appropriate approved repair can restore the part.
Where is the plastic ID usually located on a plastic part?
What other number is it usually located under?
Embedded into the backside of the part, under the official part number