Forming and Fabrication
Name the materials-processing category that reshapes a material without adding or removing material.
Forming (or forming technology).
What is the term for properties you can observe without changing the material (examples include color, density, hardness)?
What is the main difference between manufacturing and processing according to the slides?
Manufacturing converts raw materials into a finished product; processing modifies or finishes the product after initial manufacture (machining, coating, etc.).
What family of materials are plastics a part of?
Polymers.
What is the student project described in the slides?
Design and manufacture a functional acrylic phone stand by heating and bending an acrylic sheet.
Give two examples of metal forming processes listed in the lesson slides.
Name two mechanical properties mentioned in the text.
List the three ways raw materials can be converted (the three processing methods).
Chemical processing, thermal processing, mechanical processing
Name the three categories of plastics listed and one key trait of each.
Thermoplastic (can be remelted and reshaped), Thermoset (set once, cannot remelt), Elastomer (stretchy).
Name the two phone stand designs students can pick from.
Duo and Easel.
Explain why forming is a good choice when you want a one-piece design with few seams
What is a chemical property? Give one example from the document.
Define “primary manufacturing process” in one sentence.
Converts raw material into a basic primary shaped and sized product.
List two benefits of polymers mentioned in the material.
Resistant to chemicals, lightweight, good insulators, varied processing options, strong for weight. (Any two.)
For the “Easel” prep diagram: what are the three measured section names shown (A, B, C) and one dimension provided?
Sections labeled A, B, C; example dimension: 2 1/4", 2", or 3/4" (depending on diagram).
Identify one safety or manufacturing consideration you must plan for when bending acrylic for a phone stand.
Consideration: avoid sharp edges (safe edge finishing), ensure consistent bend radii to prevent cracking, and heat/acrylic safety (ventilation, gloves).
Contrast organic and inorganic materials with one example of each from the slides.
What are the four main types of materials processing technologies used in secondary manufacturing?
Forming, Cutting, Joining, Finishing.
Explain how thermoplastics differ from thermosets in how they are processed (one to two sentences).
Thermoplastics can be reheated and reshaped multiple times; thermosets cure once via heat/chemistry and cannot be reshaped.
List three functional features the phone stand should have according to the project brief.
Adjustable viewing angle; stability base; phone grip/lip; works vertical/horizontal; one-piece bent design (any three)
Describe how an advanced manufacturing process like 3D printing differs from primary + secondary processes (include one advantage).
Advanced manufacturing (e.g., 3D printing) can create final shape in one step, eliminating separate primary and secondary steps; advantage: reduces time and material waste.
Explain why electrical and thermal properties matter when selecting a material for an electronic device (two-sentence answer).
Give an example from the slides of a product stage that would typically need both machining (processing) and a protective coating (processing step + reason).
Example: A cast steel part (manufactured) would be machined to remove defects and drill holes, then coated with paint or a protective plating to prevent corrosion.
The slides show plastic pellets used as raw material. Describe the next manufacturing step that would turn pellets into a molded part (mention one common process).
Example: Injection molding — pellets are melted and injected into a mold to form the part.
Describe a simple testing method students could use to check whether their acrylic phone stand is stable and meets the “works with or without a phone case” requirement (two steps).
Place a phone (with and without case) on the stand and gently tap or nudge it to check tipping; measure tilt angle and verify the phone stays in place for a timed period (e.g., 30 seconds) — PASS if no tipping and phone doesn’t slide.