Lesson video

Hello, my name is Mrs. Taylor, and thank you for joining me for our lesson today.

Our lesson today is Deforming manufacturing processes for timbers, and this is part of the Technical principles unit.

The outcome: I can explain and compare small-scale and industrial deforming processes.

There are five keywords in today's lesson: deform, which is a change in the shape of materials when they are put under physical pressure or stress.

Force: a push or pull that can affect the movement, direction or shape of an object.

Automation: the use of technology to perform tasks.

Bending jig: a tool used to guide and control the shape of a material as it is bent.

And former: a solid object that a material is manipulated around to create a specific shape.

There are two parts to the lesson today, small-scale deforming processes and industrial deforming processes.

Let's make a start with small-scale deforming processes.

A deforming process changes the shape of a material without removing any parts.

It uses a force to shape timber into a new form.

Deforming timber makes it easier to create curved or angled shapes that would be hard to cut directly.

Here we can see an example.

The body of an acoustic guitar is made from deformed timber.

Here we have a check for understanding.

What is a deforming process in manufacturing? Is it A: cutting material, B: joining material, C: changing shape by force without removing material, or D: adding a coating? Pause the video and have a go.

Fabulous.

Let's check.

That's right, it's C: changing shape by force without removing material.

Well done.

Small-scale deforming processes often use simple manual tools.

Small boxes that are connected to a wallpaper stripper are used to create steam chambers.

These chambers steam timber lengths to make it pliable.

Here we can see a wallpaper stripper and a steam chamber.

Once the timber lengths become pliable, they can be curved along their grain around a bending jig.

A bending jig is a tool used to guide and control the shape of a material as it is bent.

The bending jig often has pegs to control the bend angle or position.

Once the timber is in position, it is clamped and left to cool.

Then it will assume its new form.

Here we can see the adjustable pegs and the bent timber.

Here we have a check for understanding.

What is the main purpose of using a steam box in timber deforming? Is it A: to cut the timber into thin pieces, B: to soften the timber fibres for bending, C: to dry the timber quickly, or D: to paint the timber? Pause the video and have a go.

Wonderful.

Let's check.

That's right, it's B, to soften the timber fibres for bending.

Well done.

Here we can see an image of a former and some strips of veneer.

Veneers are thin slices of timber that can be deformed into a curved shape.

The veneers are layered with adhesive and between a former.

A former is a solid object that a material is manipulated around to create a specific shape.

Once the glue dries, the bonded veneers take the shape of the former.

This process is called laminating, and here we can see the second and third stage of the process with the veneers layered in between two parts of the former in the centre, and then at the bottom shows the former open with the shaped veneer layers bonded and glued together.

Formers can also be made from styrofoam.

Styrofoam is an ideal material to make formers with as they can be shaped easily.

It also retains its shape when subjected to compressive forces.

Here we have an example of a styrofoam former and veneer bent over the former.

Kerfing is a technique where a series of closely-spaced cuts, known as kerfs, are made partially through a piece of timber using a circular saw to allow it to bend or curve more easily.

The kerfs are commonly used in curved furniture, musical instruments or architectural features.

A living hinge is a type of kerfing.

Strategic cuts are made in a material, usually by a laser cutter, to allow the material to bend easily without any additional components.

Living hinges are often used in small-scale manufacture because of the length of time required to laser cut.

Here we can see an example of a living hinge.

Here we have a check for understanding.

What does kerf cutting help with in timber deforming? Is it A: changing the colour of the timber, B: joining two pieces of timber, C: adding strength to timber, or D: allowing timber to bend without breaking? Pause the video and have a go.

Fabulous.

Let's check.

That's right, it's D, allowing timber to bend without breaking.

Well done.

Arborsculpture is the art of shaping living trees into useful or decorative forms as they grow.

This is a very long process that involves forcing branches when they're young and flexible into the desired shape, which will harden over time as the tree gets older.

Arborsculpture is normally done for artistic purposes, but can be functional, such as living chairs.

Here is an example of an aborsculpture, which involves shaping trees as they grow.

With small-scale deforming processes, there are benefits and limitations.

The benefits include: low cost and easy to set up, good for one-off prototype pieces, and can achieve detailed and bespoke shapes.

And the limitations include: time consuming compared to industrial methods, requires skill and patience, and are limited to smaller or thinner timber pieces.

Here we have a check for understanding.

Which of the following is a limitation of small-scale deforming processes? Is it A: time consuming, B: can achieve bespoke shapes, C: low cost, or D: good for prototypes? Pause the video and have a go.

Well done.

Let's check.

That's right.

It's A, time consuming.

Brilliant.

We now move to Task A.

There are four parts.

Part one: Explain what is meant by a deforming process in timber manufacturing.

Part two: Draw a diagram to describe how a small steam box helps in timber deforming.

Part three: What is the purpose of curve cutting in small-scale timber deforming? And part four: Give two benefits and two limitations of small-scale timber deforming processes.

Pause the video.

Wonderful.

Let's have a look at some of the answers you may have come up with.

For part one, you may have said: A deforming process changes the shape of timber without cutting away any material.

It uses force often combined with heat or moisture to bend or shape the timber into a new form.

And for part two, your answer may look something similar to this.

One: A small steam box softens the timber fibres.

This makes the timber flexible.

And number two: The timber is bent around a bending jig.

When it cools and dries, it keeps the new shape.

For part three, you may have said: Kerf cutting involves making a series of thin cuts across the timber's thickness to reduce resistance.

This allows the timber to bend more easily without cracking or breaking.

And for part four, you may have said: The benefits include: low cost and easy to set up, and good for creating custom or prototype pieces.

And the limitations include time consuming and requires skill, limited to smaller or thinner timber pieces.

Well done.

We now move to the second part of our lesson today, industrial deforming processes.

Industrial timber deforming processes are used in large-scale manufacturing to increase: speed; the machines can work continuously and quickly with minimal downtime.

Accuracy; CNC, computer numerical control machine systems produce highly consistent shapes.

And consistency; every product matches the design exactly, ideal for higher volume production.

Here we have a check for understanding.

What is one key benefit of using industrial deforming processes over small-scale ones? Is it A: they require more human input, B: they provide faster and more consistent results, C: they use less electricity, or D: they are more random in shape? Pause the video and have a go.

Wonderful.

Let's check.

That's right, it's B, they provide faster and more consistent results.

Well done.

Industrial steam bending is a scaled-up version of the small-scale technique.

Here is an example of a grand piano.

Timber is placed inside a large steam chamber, which can heat multiple lengths at once.

This part can be automated where time, temperature and humidity are controlled.

The softened timber is transferred to a bending jig.

This is manually clamped in place and left to cool and dry in the new shape.

Laminating veneers can also be done on an industrial scale.

Vacuum pressing is a process that is used to precisely curve veneer.

Part one: Veneers are glued together and placed over a former.

Part two: This is placed in a sealed vacuum bag that is attached to a pump.

And part three: The pump is switched on and the air is sucked out, forcing the timber against the former.

It is left until the glue dries.

Here we have a check for understanding.

What is the purpose of a vacuum bag in timber deforming? Is it A: to clean the surface of timber, B: to keep the timber warm, C: to hold glue in place, or D: to apply even pressure during shaping? Pause the video and have a go.

Fabulous.

Let's check.

That's right, it's D, to apply even pressure during shaping.

Well done.

When bending or laminating timber, both a former or a bending jig are used, but they serve different purposes.

A former shapes the timber.

A bending jig supports the bending process.

Here we have a summary of both formers and bending jig.

So the tool, former, the purpose is a solid shape that timber is bent around, and its key role is defines the final curve.

A bending jig, purpose is to hold the former and timber in place, and the key role is to ensure accuracy, control and repeatability.

Here we have a check for understanding.

Which statement best describes the difference between a bending jig and a former when bending and/or laminating timber? Is it A: a former guides cutting tools while a jig holds glue? Or B: a bending jig shapes the timber and a former holds it in place? Or C: a jig and a former are the same thing, used for cutting timber? Or D: a former defines the curve of the timber while a bending jig holds everything in position? Pause the video and have a go.

Great.

Let's check.

That's right, it's D, a former defines the curve of the timber while a bending jig holds everything in position.

Well done.

In industrial settings, formers and bending jigs are often made from metal, aluminium, or steel because they are: strong, ideal for repeated use, highly accurate, formers are usually CNC machined, durable, can withstand heat, pressure and moisture.

Here we have a check for understanding.

Why are bending jigs and formers used in industry made from metal? Is it A: they provide strength and precision for repeat shaping? Or B: they are easier to shape? Or C: they are flexible? Or D: they are recyclable? Pause the video and have a go.

Wonderful.

Let's check.

That's right, it's A, they provide strength and precision for repeat shaping.

Well done.

Timber can also be deformed in an industrial setting using an automated hydraulic or pneumatic press.

One: timber is clamped against the former using hydraulic or pneumatic systems. Two: machines supply controlled force to shape the timber.

And three: the entire process is often automated, requiring only supervision.

Here we can see a hydraulic press for laminating acoustic guitar bodies.

Kerf cutting on a larger scale is often automated with CNC machinery.

A CNC router can cut precise kerfs at programmed intervals.

This allows the timber to bend at calculated angles or into curves without cracking.

We now move to Task B.

There are four parts.

Part one: Explain why industrial deforming processes are more suitable than small-scale methods for higher volume production.

Part two: Use diagrams to explain how vacuum bagging is used to deform timber.

Part three: What is the role of a former in an industrial deforming process? And part four: Compare kef cutting in small-scale and industrial deforming processes.

Pause the video and have a go.

Wonderful.

Let's have a look at some of the answers you may have come up with.

For part one, you may have said: The use of machines and automation help to produce complex shapes quickly and consistently.

This ensures every product is identical, which is essential for higher volume production.

And for part two, your answer may look something similar to this.

Number one: Veneers are glued together and placed over a former.

Part two: This is placed in a sealed vacuum bag that is attached to a pump.

And part three: The pump is switched on and air is sucked out, forcing the timber against the former.

It is left until the glue dries.

For part three, you may have said: A former provides the shape that the timber will be bent around.

In industrial settings, formers are usually made from metal, which are strong and precise because they keep their shape.

They ensure that each piece of timber is shaped consistently and accurately during the deforming process.

And part four, you may have said: In small-scale deforming, kerf cutting is done manually with a circular saw to allow timber to bend.

In industrial settings, kerf cutting is controlled by a CNC router for more precision and speed.

Well done.

We now have a summary of our learning today.

Deforming involves using force to change the shape of a material.

Small-scale production methods can be used to deform materials.

And deforming materials on a larger scale require different techniques.

Thank you for joining me today and well done.