Prototyping Tools & Processes – Lecture Review

A comprehensive set of 42 Q&A flashcards covering hand and machine tools, processes, components, advantages, limitations and safety practices taught in the lecture.

What defines a hand tool?

A manually operated tool used for cutting, shaping, assembling and measuring materials.

Which hand tool is specifically designed to drive and remove nails?

The claw hammer.

What is the safest way to choose a screwdriver?

Match the tip type and size to the screw head to avoid damage.

Which hand tool tightens or loosens nuts and bolts?

A wrench (spanner).

Name the hand tool that holds, bends and cuts wires.

Pliers.

Which hand tool is used to carve and shape wood or metal?

A chisel.

State one key safety rule when using cutting tools.

Always cut away from your body and from your other hand.

Why should workpieces be clamped or secured when using tools?

To prevent movement and reduce the risk of accidents.

What basic operation on a lathe reduces the diameter of a workpiece?

Turning.

Which lathe operation produces a smooth end surface at the workpiece’s face?

Facing.

Name three parts of a conventional manual lathe.

Headstock, tailstock and chuck (other acceptable parts: ram, cross-slide, gears).

What manual mill operation produces a flat surface on the top of a part?

Face milling.

What component of a milling machine rotates the cutting tool?

The spindle.

In milling, what is the purpose of a vice?

To secure the workpiece firmly on the table.

Give one essential safety tip for manual milling or turning.

Wear protective eyewear and avoid loose clothing.

Define laser cutting.

A process that uses a high-powered laser beam to cut or engrave materials with a typical kerf of ~0.3 mm.

Which type of laser cutter is most commonly used to cut wood and acrylic?

A CO₂ laser.

What function does assist gas (O₂, N₂ or air) serve in laser cutting?

It improves cutting precision and reduces oxidation of the cut edge.

List one major advantage of laser cutting.

High precision and speed with smooth, clean edges and minimal waste.

Why must PVC not be laser-cut?

It emits toxic fumes (chlorine) when cut with a laser.

What is 3D printing?

An additive manufacturing process that builds objects layer by layer from digital models.

Describe Fused Deposition Modelling (FDM).

A 3D-printing method that extrudes heated plastic filament through a nozzle.

Name two common FDM slicing parameters.

Layer height and infill density (others: nozzle diameter, supports, shells, infill pattern).

Which 3D-printing material is biodegradable and often used for prototypes?

PLA filament.

Give one limitation of 3D printing for large parts.

Prints can be slow and may have limited strength depending on material.

What precaution should be taken when printing with ABS or resin?

Ensure proper ventilation to avoid inhaling fumes.

Identify three main parts of an FDM 3D printer.

Build plate, hot end/nozzle, and filament feed motor.

Explain vacuum forming.

Heating a plastic sheet until soft, then drawing it over a mould with vacuum pressure to create a shape.

List in order the first three steps of the vacuum-forming process.

1) Clamp the plastic sheet, 2) heat until soft, 3) raise the mould through the sheet.

Give one common application of vacuum-formed parts.

Product packaging (others: automotive panels, medical trays).

Why should plastics not be overheated during vacuum forming?

To prevent toxic fumes and material degradation.

Name a disadvantage of vacuum forming regarding part geometry.

It is generally limited to shallow-depth shapes.

What is CNC milling/routing?

Automated material removal using programmed (G-code/M-code) machine instructions.

State one key difference between a CNC router and a CNC mill.

Routers run at higher spindle speeds for wood/plastic, whereas mills are slower for hard metals and precision machining.

Which CNC component holds and rotates the cutting tool?

The spindle.

Why is fixture security critical in CNC machining?

To prevent tool crashes and ensure precision and safety.

Mention one advantage of CNC machining.

High precision and repeatability with reduced labour costs.

Provide one limitation of CNC technology.

High initial cost and requirement for skilled programming.

What PPE is essential when operating any cutting or machining equipment?

Protective (safety) eyewear.

Which cutting process features a kerf of about 0.3 mm?

Laser cutting.

What file format is commonly used to export CAD models for FDM 3D printing?

.stl file format.

When using a hacksaw, why is cutting away from your body recommended?

To reduce the risk of injury if the blade slips.