Lesson video

Hello there.

My name is Mrs. Dhami.

Thank you for joining me for your design and technology lesson today.

Now the big question for today is how can we reform timbers? So we're going to explore a few different methods.

Some you might be familiar with, and some you might not be.

So hard hats on.

Let's get cracking.

Our outcome for today is we will be able to explain and compare small-scale and industrial reforming processes.

We have four keywords today.

Reform, which means reshaping a material into a new form without changing its basic chemical structure.

We then have recycle, which is when we convert waste into reusable materials.

We also have upcycle, which is when we turn old or unwanted materials or products into something useful.

And lastly, we have fibers.

Fibers are thin strands that are the building blocks of a material.

Our lesson is going to follow three learning cycles today.

Firstly, small-scale reforming processes, then industrial reforming processes, and ending with conserving resources.

So let's get started with small-scale reforming processes.

Reforming processes change the shape or structure of a material without changing its chemical structure.

So for example, without completely breaking it down.

For timbers, reforming involves combining wood materials to create new products, often enhancing properties, or extending timber life.

Time for our first check-in.

Which of the following best describes a reforming process in timber? A, cutting timber into smaller pieces, B, burning timber to create charcoal, C, painting timber to protect it, or D, combining wood materials to make new products.

Have a think.

Come back to me when you've made your decision.

Well done if you got D.

The statement "combining wood materials to make new products" describes reforming processes in timber.

Examples of reforming timber include combining timber fibers with another material.

Now a fiber is a thin thread-like structure.

The plant cells that make up timber fibers have two key components, cellulose and lignin.

Now if you take a little look at the picture, it shows timber fibers look like really thin threads.

Almost looks hairy, doesn't it? Let's take a closer look.

So a natural piece of timber has a grain.

Take a little look at the arrow on the diagram.

That shows the grain direction.

Now the grain shows how its fibers are aligned.

The fibers run parallel to the length of the wood.

Let's zoom in a bit further.

These are the fiber cell walls, and they are made of cellulose.

Now, cellulose provides the strength along the grain.

Let's zoom in to the ends of those.

This is lignin.

Now lignin is inside the cell wall, and it helps to bind the fibers together.

Time for a quick check-in.

Which is true about cellulose and lignin in timber? A, cellulose gives rigidity, lignin gives flexibility, B, lignin binds fibers, cellulose gives strength, C, both make wood soft, or D, they don't affect timber strength.

Have a think.

Come back to me when you've got an answer.

Well done if you got B.

This is true about cellulose and lignin in timber.

Lignin binds the fibers, cellulose gives the strength.

Hopefully lots of you will be familiar with 3D printing.

Now 3D printing is a process of making three-dimensional objects by adding material layer by layer based on a digital design.

So how does it work? First of all, we create a CAD, a computer-aided design drawing.

Then we download it as an STL file.

And then we use slicer software to generate what we call a G-code.

Now the G-code is basically the print instructions, the method of how to print.

Fused filament fabrication is often abbreviated to FFF.

Now, FFF is a type of 3D printing process where layers of material are melted and deposited to build objects.

So once the file is prepared, it can then be sent to print.

So let's carry on along the 3D-printing journey.

The filament then is extruded through the heated nozzle, and the material is laid down a layer at a time onto the build plate.

The layers are repeated and repeated until, finally, the object is complete.

3D printing using fused filament fabrication, FFF, is a type of reforming process, which can also be used with timbers.

And you might not have considered this, 'cause you might have always linked it to polymers.

So timber filament is a mix of wood fibers and a polymer allowing complex shapes to have a timber-like finish, which would be difficult to achieve using traditional methods.

And as you can see in the picture on the right, it's a really complex shape that has been produced, which would be really hard to produce by hand otherwise.

And it also means there is hardly any waste.

As prints take a considerable amount of time to complete, this method is better suited for small-scale manufacture.

Time for a quick check-in.

What happens when filament is extruded in 3D printing? Is it A, it cools inside the nozzle, B, it turns into powder, C, it melts and forms layers, or D, it gets cut and glued? Have a think.

Come back to me when you've made your decision.

Well done if you got C.

When filament is extruded in 3D printing, it melts and forms layers.

Damaged or waste timber can be combined with resin to form new products.

Resin acts as the binding agent, strengthening the timber, and filling gaps or cracks.

This method helps reduce timber waste by reforming scraps into usable materials.

However, because it's combined with the resin, it then makes it difficult to recycle.

Take a little look at this beautiful tabletop.

This is some damaged teak.

Now teak is a hard wood, as we know, and it's been combined with resin to make this beautiful tabletop.

So let's take a closer look at how this process works.

First of all, if we are going to do resin casting, we prepare the mold.

What kind of shape do we want the outcome to be? We then mix the resin, which is usually in two parts, a resin and a hardener.

And you have to get that spot-on, otherwise it won't set or cure properly.

You then pour the resin into the mold, you leave it to set, leave it to cure, and then you it out of the mold and you polish it.

We actually do this in my jewelry club, but on a much, much smaller scale.

And the timber looks really good set with the resin, and then you can set it with a few other bits like sequins or little beads.

Looks fab.

Onto Task A, Part One.

I'd like you to explain what a reforming process is, and give two examples related to timber.

Part Two, describe how 3D printing can be used in timber reforming.

And lastly, compare two-small scale timber reforming processes in terms of their benefits.

Good luck.

Use the information in the slide deck to help you, and come back to me when you've got some wonderful answers.

Part one, I asked you to explain what a reforming process is and give two examples related to timber.

You might have said a reforming process changes the shape or structure of timber without altering its chemical structure.

Reforming can also include combining timber fibers with another material.

Examples include fused filament fabrication, 3D printing with timber filaments, and combining resin with damaged timber.

Part Two, I asked you to describe how 3D printing can be used in timber reforming.

You might have said 3D printing with timber filaments involves melting and layering a mix of wood fibers and polymer to create precise complex timber objects.

It reduces waste, and is suitable for small-scale production.

Part Three.

I asked you to compare two small-scale timber reforming processes in terms of their benefits.

You might have said 3D printing timber filament allows for precise and complex shapes with minimal waste, ideal for prototypes.

Combining resin with damaged timber recycles wood waste and strengthens it, which is useful for products like tabletops.

Onto learning cycle two, industrial reforming processes.

Industrial reforming is used to create manufacture boards on a large scale, using automated methods.

These methods ensure speed.

Mass production is generally faster than manual processes.

Accuracy, machines produce consistent precise parts, and then consistency.

Identical parts can be made repeatedly.

Time for a quick check-in.

Which of the following is a key benefit of using automation for industrial timber reforming? Is it A, it requires no adhesives or heat, B, it ensures speed and consistent quality, C, it creates unique one-off products, or D, it uses hand tools for precise cuts? Have a think.

Come back to me when you've made your decision.

Well done if you got B.

A key benefit of using automation for industrial timber reforming is that it ensures speed and consistent quality.

MDF is short for medium-density fiberboard.

Now MDF is made from fine wood fibers mixed with wax and resin, and then it's compressed under high heat and pressure.

The result is a dense uniform sheet material that can be used for flat-pack furniture, as it is easy to machine and paint.

Let's take a little look.

So first of all, we have the wood fibers combined with the wax and resin.

Then this is compressed, and out comes a MDF board.

Plywood is made by gluing and compressing thin layers of wood together.

And we call those thin layers veneers.

The grain direction of each layer is rotated 90 degrees for strength.

So the first layer might go like that, the next layer might go like that, next layer, like that, next layer like so.

And that is repeated.

Plywood is a strong board that is stable in all directions because of that.

Therefore, it's resistant to warping.

Warping is when it bends.

It is commonly used in construction and furniture.

The grain direction, as I've said, alternates, but the top and bottom layers always face the same way.

And again, this stops it from warping.

This means that plywood always has an odd number of layers.

You'll never find an even number of layers in plywood.

Quick check-in.

What makes plywood strong and stable in all directions? Is it A, its use of recycled plastics, B, its use of softwood only, C, the alternating grain direction of glued veneers, or D, its smooth surface? Have a think.

Come back to me when you've made your decision.

Well done if you got C.

The alternating grain direction of glued veneers ensures that plywood is strong and stable in all directions, and does not warp.

Chipboard is another manufactured board.

Chipboard is made from wood particles and sawdust, again, combined with resin.

The mixture is pressed into sheets under heat.

Chipboard is often covered with a polymer laminate for furniture use and kitchen worktops.

And perhaps that might be the case with your school desk that you might be sat at now, or perhaps a home desk.

So what happens, the wood particles and sawdust are mixed with the resin.

They are then compressed, and out comes our beautiful piece of chipboard.

Finger jointing reforms short timber pieces by joining them together to make a longer usable length, like those found in door frames.

Let's take a closer look.

An interlocking pattern, and you can see that in the zoom in there, the interlocking pattern is cut into the ends, and glued together.

The increase in gluing surface area provides a lovely strong joint.

Onto Task B, Part One.

I'd like you to explain how finger jointing helps reduce timber waste.

And I said it right that time.

Part Two.

I'd like you to compare MDF and plywood in terms of how they are made, and one key property.

And lastly, I'd like you to use diagrams to explain the process of making chipboard.

Think back to the previous slides, use that wonderful knowledge, and enjoy writing your answers.

Part One, I asked you to explain how finger jointing helps reduce timber waste.

You might have said finger jointing connects short timber pieces by cutting interlocking shapes at the ends, and gluing them together.

This allows small offcuts to be reused instead of being discarded.

Great for sustainability.

Part Two, compare MDF and plywood in terms of how they are made, and one key property.

You might have said MDF is made from fine wood fibers mixed with wax and resin, then compressed.

Plywood is made from layers of wood veneer glued with alternating grain directions.

Plywood is stronger than MDF due to its layered construction.

Part Three.

I asked you to use diagrams to explain the process of making chipboard.

Perhaps you drew some diagrams a little bit like this, showing that wood particles and sawdust are combined with resin.

They are then compressed, and they usually use heat as well, and out comes the piece of chipboard ready to be used and made into a product.

Well done with all your hard work on these answers.

Onto learning cycle three, conserving resources.

Timber is a renewable resource, but it still takes time, energy, and land to grow.

We can conserve timber resources by recycling, which is when we process used timber into new materials, such as manufactured boards, just like MDF.

We can also do something called upcycling.

Now upcycling is when we creatively reuse timber without major processing.

So let's take a look at a few examples.

Recycling is the process of converting waste into reusable materials.

Recycling timber reduces the effects of deforestation, and saves on the energy required to process raw timber.

It also prevents wood waste from going to landfill or incineration, which is when it is burnt.

Waste timber can be reformed into manufactured boards, or shredded into something called mulch.

Now you might have heard of mulch before.

Mulch is a layer of material spread over soil to retain moisture, suppress the weeds, and improve soil health.

Time for a quick check-in.

Which of the following is a benefit of recycling timber? A, it increases landfill waste, B, it adds strength to a material, C, it reduces tree felling, or D, it saves energy.

Have a think, consider those answers, come back to me when you've made a decision.

Well done if you've got C and D.

Reducing tree felling and saving energy are definitely benefits of recycling timber.

Manufactured boards are a type of reformed timber, because waste wood is broken down and reformed into a new material.

There are three main categories of manufactured boards.

We have fiber base, so for example, MDF, like the image on the left.

MDF, as we know, stands for medium-density fiberboard.

And then we also have hardboard, which is the picture on the right.

We then have particle-based boards.

So for example, chipboard, picture on the left, just above.

And then we also have OSB, which stands for oriented strand board.

And that's the picture on the right.

We then have laminate-based.

Okay, so for example, plywood and block wood.

The image on the left is plywood, and the image on the right is blockboard, sorry.

They're all types of reformed timber.

So let's take a little look at the recycling process for timber.

So first of all, we collect the wood waste.

We then remove any extra components, so things like screws, nuts and bolts, panel pins, you name it, anything like that.

We then shred.

So this time we might shred into fibers, to make something like MDF, we might shred into particles, to make things like chipboard, or we might shred into chips, to make boards such as OSB.

Depends on the outcome we need.

Time for a check-in.

Which of the following correctly categorizes manufactured boards? Is it A, fiber-based, particle-based, and laminate, B, natural, synthetic, and engineered, C, plywood, MDF, and chipboard, D, softwoods, hardwoods, and composites? Have a think.

Come back to me when you've made your decision.

Well done if you got A.

The following categorizes manufactured boards, we have fiber-based, particle-based, and laminate.

Upcycling is the process of taking discarded or unwanted materials and creatively transforming them into something useful or attractive.

I bet you have all upcycled something throughout your life.

So, unlike recycling, upcycling does not require breaking the material down.

It usually preserves its current form.

Take a little look at this.

Yep, you got it, it is a skateboard.

But look carefully at what it has been upcycled into.

It has been upcycled into a musical instrument.

What a great idea.

Construction timber can also be reclaimed for use in new projects.

And this is a form of upcycling.

Take a little look at the pictures.

You can see a beautiful bench, and you can see some beautiful planters.

They have been made from construction timber and transportation pallets.

They've been upcycled.

Perhaps you might have something like this in your own school gardens, or perhaps your home gardens, or perhaps a local park.

Keep your eyes open.

Have a little look for some upcycling.

So what are the benefits of upcycling? It reduces waste and landfill, it saves energy, so no processing is required, and it gives old materials a new purpose and a longer life.

It's gotta be a positive there.

Onto task C, Part One.

I'd like you to describe two environmental benefits of recycling timber.

Part Two, explain the difference between recycling and upcycling timber using an example of each.

And finally, Part Three, draw a diagram that explains the process of recycling timber to create a manufactured board.

Good luck.

Come back to me when you've got some wonderful answers.

Part One, I asked you to describe two environmental benefits of recycling timber.

You might have said recycling timber reduces the number of trees that need to be felled and cuts down the amount of waste sent to landfill.

It also uses less energy than producing new timber products.

Part Two, I asked you to explain the difference between recycling and upcycling timber, sorry, using an example of each.

You might have said recycling involves breaking timber into fibers or particles to make new materials like MDF or chipboard.

Upcycling reuses timber in its current form, such as turning an old pallet into a table.

And lastly, I asked you to draw a diagram that explains the process of recycling timber to create a manufactured board.

You might have said, collect the wood waste, remove extra components, such as screws and nails.

You then might have said shred into fibers for MDF, particles for chipboard, and chips for OSB.

Well done with all of your hard work on Task C.

This brings us to the end of our lesson today.

Let's summarize what we have found out.

Reforming involves reshaping a material into a new form without changing its basic chemical structure.

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

Reforming materials on a larger scale require different techniques.

And recycling and upcycling save resources, reduce waste, and give new life to old materials.

Well done with all of your hard work today.

I hope you've enjoyed the lesson, and I look forward to seeing you in another one soon.

Take good care.

Bye-bye-bye.