Polymers — Functional & Aesthetic (AQA GCSE Design & Technology): Revision Note

Functionality of polymers

• The functionality of polymers is to provide lightweight, versatile and durable materials that can be moulded into many shapes

• Polymers offering properties such as:

  • Flexibility

  • Strength

  • Insulation

  • Resistance to chemicals or moisture

• Examples of applications of polymers are

  • Packaging

    • PET bottles, HIPS packaging

  • Construction

    • PVC pipes and window frames

  • Household products

    • HDPE bins and buckets

  • Food containers

    • Polypropylene

  • Electrical components

    • Urea-formaldehyde plugs

    • Phenol-formaldehyde pan handles

• Thermoforming polymers, e.g. acrylic, HDPE, are:

  • Easy to shape when heated

  • Can be reheated

• Thermoset polymers, e.g., epoxy resin, are harder and once set permanently they are:

  • More difficult to reshape

  • Ideal for durable applications

Aesthetics of polymers: surface finish, texture & colour

• The aesthetics of polymers are how they look and feel, including their:

  • Surface finish

  • Texture

  • Colour

• These can be easily controlled during manufacturing

Surface finish

• Polymers can have smooth, glossy or matte finishes, for example:

  • Acrylic has a clear, glass-like finish

  • Melamine provides a smooth laminate surface

Texture

• Polymers can be manufactured with different textures, from very smooth, e.g. PET bottles, to textured for grip or design purposes

Colour

• Polymers can be produced in a wide range of colours or be transparent/translucent, e.g. clear acrylic or PET

  • This makes them highly suitable for product design and branding

Availability of polymers: ease of sourcing & purchase

• The availability of polymers refers to how easily they can be obtained for manufacturing.

• Polymers are widely available due to mass production

  • They are one of the most commonly used materials in industry

• Polymers can be purchased in different forms, such as:

  • Sheets (for cutting, forming and folding)

  • Granules/pellets (for machines like injection moulding and extrusion)

  • Moulded components (extruded lengths)

• This makes them suitable for a wide range of processes

Cost of polymers: bulk buying

• The cost of polymers is generally low, especially for mass-produced thermoforming polymers, where the cost of granules for many processes is extremely low

• Buying polymers in bulk significantly reduces cost, making them ideal for large-scale manufacturing, although some specialised polymers may be more expensive