FINISHING MATERIALS

IGCSE DESIGN AND TECHNOLOGY

Lesson objectives/aims
• Understand the role of thorough cleaning and preparation in
achieving a high-quality finish.
• Understand the range of finishes available, and the reasons for
selecting a particular one for a given situation.
• Be able to describe how to apply a liquid finish – varnish.
 Learning ladder
By the end of the lesson:

You must:
• be able to specify appropriate finishes for a range of products.

You should:
• be able to explain the finishing process for a timber-framed product that is
to be varnished.

You could:
• be able to justify your choice of finish for a particular product.
 Introduction
• Finishing is the final stage of the manufacturing process.

• A well-made product can be ruined by a poor quality finish.

• Finishing is carried out for the following reasons:

– to protect the surface of the product in order to prolong its life
– to improve the aesthetic appearance of the product.

• There are a wide range of finishes and finishing processes available.

• It is important to select the correct one for a particular material and
situation.
Starter
• What do you understand by the term finishing when working with
resistant materials?

• When does the finishing process start?

 Finishing materials
Timber Metal Plastic
Painting  
Varnishing 
Polishing   
Staining 
Oil  
Lacquering 
Etching 
Anodizing 
Electroplating 
Galvanizing 
Dip coating 
The finishing process
• The finishing process begins as soon as the components required to
make the product have been manufactured.

• As much cleaning up and finishing should be carried out as possible

before assembly.
• Particularly important on internal surfaces that would be difficult to access
after the product has been assembled.
• After the surfaces have been cleaned up they need to be prepared.

• Timber and metal require different methods of preparation prior to the

application of a finish.
• Plastics tend not to require any preparation, or the application of a
decorative/protective surface finish.
 Finishing timber (1)
Step 1: Cleaning up
• Use a smoothing plane to remove pencil marks
and clean the surfaces.

Step 2: Preparation
• Use glasspaper/ sandpaper to create a smooth
surface. This should be done by wrapping the
glasspaper around a cork block. Always rub in the
same direction as the grain.

• Before applying paint/ stain to timber, any knots

must first be sealed to prevent any resin seeping
out, and a coat of primer must be applied.
 Finishing timber (2)
Step 3: Application of the finish
• Liquid finishes should be applied in a warm, dust-free
environment.

• Liquid finishes should be applied in three or more thin

coats, rubbing down lightly between each to build up
a deep smooth surface.
• The thicker the finish, the more moisture-resistant it is.

• When applying a liquid finish with a brush, brush out

well and finish with long brushstrokes in the same
direction as the grain.

• When applying a finish to unassembled components

do not apply any to surfaces that are to be glued.
 Finishes for timber (1)
• Wax polish is made from beeswax dissolved in turpentine to form a
paste.
• Turpentine oil acts as a solvent that dissolves the beeswax and
carries it into the grain of the wood.

• The polish is applied by cloth, and then buffed to give a dull gloss
finish that shows off the natural colour and grain of the timber.

• Wax polish is suitable for indoor furniture. It is not heat resistant.

 Finishes for timber (2)
• French polish is made by dissolving shellac in methylated spirits.

• The first coat is applied using a brush, and subsequent coats are applied
by cloth, to build up a high-gloss finish that shows off the natural colour
and grain of the timber.

• French polish is suitable for indoor furniture. It is not heat resistant.

Finishes for timber (3)
• Varnish is a solution of natural resins in oil or spirit.

• Varnish is applied by brush, spray or cloth and gives a durable,

hard, waterproof, high-gloss finish that shows off the natural
colour and grain of the timber.
• Varnish is used for indoor and outdoor carpentry and furniture.
• It is not heat resistant.
Finishes for timber (4)
• Synthetic varnish is most commonly available as polyurethane. It
is a solution of synthetic resins in oil, spirit or water.
• Synthetic varnish can be applied by brush, spray or cloth, and gives
a very durable, hard, waterproof, high-gloss finish that shows off
the natural colour and grain of the timber.
• Synthetic varnish is suitable for indoor and outdoor carpentry and
furniture.
• It is heat resistant.
 Finishes for timber (5)
• Oil is an especially suitable finish for naturally oily timbers such as
teak and iroko.
• It can be used on indoor and outdoor furniture, but requires regular re-
application in order to maintain protection.
• It is applied using a cloth, by rubbing it well into the grain and
allowing up to a week between coats.
• Olive oil is applied to timber that is to be used with food.
 Finishes for timber (6)
• Stain is used to change the shade or colour of timber.
• It is a decorative finish that does not protect the timber; protection is
provided by the application of clear varnish when the stain has dried.
• Stain can be applied by brush, spray or cloth.
 Finishes for timber (7)
• Paint is used to change the colour and protect timber.
• When it has been applied, the natural colour and grain
pattern are completely obscured.
• Paint can be applied by brush or spray, and gives a very
durable, hard, waterproof, high-gloss finish.
• Paint is suitable for indoor and outdoor carpentry and
furniture. It offers some resistance to heat.

Health and safety

Always work in a well-ventilated room when applying finishes, because of
the fumes given off. Water-based paints are much safer to use and are more
environmentally friendly.
 Finishing metal (1)
Step 1: Cleaning up
• On completion of the shaping processes
use drawfiling to remove any marks left.
• This is done with a smooth file. Hold the
file in both hands, with the hands close to
the work, and move the file backwards
and forwards.
• Use progressively finer grades of emery
cloth or wet and dry paper to remove any
marks left by drawfiling.
• Wrap the abrasive sheet around the file to
achieve a flat finish.
Filing Techniques
Draw Filing Cross Filing
Used to remove file marks and for finishing Used for efficient removal of maximum amount
operations of material in shortest possible time

For this, a fine cut file with a flat face should be Can also be used for finishing and shaping
used.

https://www.youtube.com/watch?v=FQY1Q9lBLy4&ab_channel=MarkCroghan
(Draw filing vs Cross filing )
© Folens 2009
Wet and Dry Paper
Dry Sanding Wet Sanding

Removes more material.

Removes less material.
Dry is going to be more aggressive, especially with
Uses high grit sandpaper.
lower grit sandpaper.

No lubricant required. Uses lubricant (usually water)

Used in a later stage of the process to bring out a

shine on the object or to prep for buffing and
This allows you to shape your work piece or polishing.
significantly grind down uneven surfaces to level
them out. Wet sanding allows you to remove any scratches
that dry sandpaper may have caused without
removing too much of the underlying material.

• https://www.youtube.com/watch?v=K2vVnVurfOQ&ab_channel=deyidt (Wet and Dry Paper)

© Folens 2009
Finishing metal (2)

Function
Preparation Technique

Use wire brush and emery cloth To remove loose scale caused by hot working

To clean and degrease the metal

Use methylated spirit or degreaser
(Degreaser for badly affected parts)

Use solution of caustic soda or detergent To remove light oil and dirt

Dipping in a weak acid pickle (one part sulphuric For cleaning and degreasing non-ferrous metals
acid to ten parts water)

*Always use brass tongs to dip work in a pickle

bath because steel will contaminate the
solution.
 Finishing metal (3)
Step 3: Applying the finish
• Liquid
finishes should be applied in a
warm, dust-free environment.

• Liquid finishes should be applied in three

or more thin coats, rubbing down lightly
between each to build up a deep,
smooth surface.

• When applying a liquid finish with a

brush, brush out well, and finish with
long brush strokes along the length of
the metal.
Finishes for metal (1)
• Polishing can done by hand or machine. It is done after all the
manufacturing processes have been completed, and before a
protective finish is applied.
• Polishes contain a very fine abrasive that cuts away the top surface
of the metal to create a bright sheen.
• Hand polishing is done with a soft cloth and a liquid polish such as
Brasso.
• Machine polishing is done with a buffing machine. A polishing
compound is applied to a soft mop that revolves at speed; the work
is then gently pushed against the mop to polish it.
 Finishes for metal (2)
• Oilcan be burnt into the surface of steel
to produce an attractive dark blue finish.
• Thework is heated to a dull red and
quenched in oil.
•A darker finish can be achieved by using
old sump oil.

• Toprotect steel from corrosion, and

maintain its bright colour,
• apply a thin smear of grease over a finished
piece of work.
 Finishes for metal (3)
• Lacquer is usually applied to
non-ferrous metals after the final polishing and
degreasing has been completed.

• Lacquer is similar to varnish, and can be applied

by spraying or brush.

• The protective coat prevents the metal from

coming into contact with air and oxidizing,
thereby preserving its polished finish.
 Finishes for metal (4)
• Paint is usually applied to non-ferrous metals after final cleaning up
and degreasing, in order to change the colour and protect the metal
from oxidization.
• Paint is suitable for indoor and outdoor use.
• For maximum protection a red oxide paint should be applied, followed
by a primer and undercoat before applying the top coat.
• Paint can be applied by brush or spray in thin coats to give a very
durable, hard, waterproof, high-gloss finish.

• Hammerite is a metal paint that does not require the same level of
surface preparation, because it can be painted directly onto the metal.
It is used mainly on wrought iron work and workshop machinery.
Red Oxide Coating

© Folens 2009
 Finishes for metal (5)
• Etching is a decorative finish that produces patterns
or designs on the surface of the metal.
• The work is first coated with an acid-resist material
such as paraffin wax; then the design is created by
removing parts of the wax coating to reveal the
metal beneath.
• The work is then put into an acid bath that etches
away the exposed metal: the longer it is in the acid,
the deeper the etching.
• Finally the acid-resist material is removed to leave a
contrasting polished and etched finish.
• The work can be lacquered to protect it against
oxidization.
 Finishes for metal (6)
• Anodizing is the most common finishing process used
on aluminium.
• It is used to produce a durable, corrosion-resistant
finish, to provide a key for painting and for decoration.
• Anodizing is an electrolytic process that thickens the
oxide film present on the surface of the metal.
• The metal is immersed in a lead-lined bath of chlorine-
free electrolyte (sulphuric, chromic and oxalic acids are
the most commonly used), and an electric current is
passed through. The longer the material is in the bath,
the thicker the coating.
• Colour can be added to the bath to tint the aluminium.
 Finishes for metal (7)
• Electroplating is used to produce an
attractive, durable, corrosion-resistant finish.
• Chrome, silver and nickel are some of the
most commonly used plating metals.
• Electroplating is the depositing of one metal
onto another by means of an electric current.

• The object to be plated (cathode) is placed in a

bath of metallic salts through which an electric
current is passed, causing the salts to dissolve
and precipitate onto the object.
Electrolysis Basics

© Folens 2009
 Steps

A hot alkali solution, mild Acid pickling removes the to prepare surfaces for
acidic bath, or biological iron oxides or scales from the metallurgical phase
cleaning bath removes the steels surface to by applying a saline layer
contaminants from the expose a bare area and that facilitates Iron-Zinc
steel such as dirt, grease permit a galvanized bonding.
and oil. coating to form upon
immersion in a molten zinc © Folens 2009
bath
 Finishes for metal (8)
• Galvanizing is used to produce
a durable, corrosion-resistant
finish on steel products that are
to be used outside.
• Galvanizing is carried out by
dipping the finished product
into a bath of molten zinc.
 Finishes for metal (9)
• Plastic dip coating is used to produce a durable,
corrosion-resistant finish on steel products.
• The finished product can be black, white or brightly
coloured, depending on the tint added to the powder
being used.
• Polythene is the most commonly used plastic because of
its low cost; nylon and PVC can also be used.
• The work is heated to 180°C in an oven.
• It is then dipped into a fluidizing tank containing the
plastic powder.
• It is then returned to the oven to fuse the powder coating
into a smooth shiny finish.
• If it is left in the oven too long, the plastic will burn.
Finishes for plastic
• Because plastics do not corrode or decay, there is no need to apply a
protective surface coating.
• The quality of the moulds used in injection moulding, for instance, mean
that there is no further finishing other than the trimming off of any flash or
runners and risers.

Finishing acrylic
• The cut edges need to be finished by first filing, then drawfiling, followed
by wet and dry paper.
• Once all of the scratches have been removed, the edges can be polished
either by hand, using a cloth and acrylic polish, or on a buffing machine
mop to which a suitable acrylic polishing compound has been applied.
Tasks
• Task 1: Complete the table in Worksheet 1 by adding which finishes
are appropriate for use with which materials.
• Task 2: Describe with appropriate quality checks the processes that
will need to be carried out in order to finish a timber frame project.
Use Worksheet 2
Plenary
• Why do we apply finishes to some materials and not to others?
• What is the secret of achieving a highly polished finish when using varnish
or lacquer?
Extension
• Why do we apply finishes to some materials and not to others?
• Carry out individual research into finishing. Use the Internet or
books.
• Write up your conclusions.
• You may wish to include images of examples of finishing.
Homework
• What finish would you recommend for a range of products?
• Give reasons for your choice. Use Worksheet 3

Wire kitchen draining rack MDF internal door

Steel shelf bracket Pine dining table

Teak garden table Wrought iron garden gate

Mahogany jewellery box Wooden chopping board

Die-cast bathroom tap
Hardwood external door

Engineer’s sliding bevel Brass wall light