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Two melts flow together perfectly and still peel apart. Solubility parameter, tie layers, the four process variables that set bond strength, and how to write a peel spec.
Acrylic bends beautifully at 150 to 180 C and shatters at the wrong temperature. Heating times, minimum radii, bending tube without collapse, and the anneal that stops late cracks.
A silicone line looks like a plastics line and works in reverse: cold barrel, hot tunnel. Cure systems, die swell, post-cure drift and what tolerance is realistic.
Draft is not a tolerance allowance, it is what makes ejection force achievable. Minimum angles by material and depth, texture multipliers, and the ejector layout that stops pin marks.
Five independent errors, and the largest one is the sheet you started with. Practical tolerance bands by dimension type, and how to write a drawing that can be inspected.
Ring stiffness goes with the cube of wall thickness and impact goes down as temperature falls. Why a pipe can pass one test and fail the other, and how to specify both.
A burn mark is compression ignition, not a hot barrel. Where cavity air gets trapped, how deep a vent land should be, and how to read the burn to find the trap.
A CO2 laser is the only common process that leaves acrylic polished straight off the machine. What the beam does, why cast and extruded differ, and the design rules.
Two clear tubes that fail in completely different ways. The choice is usually made by one number, notched impact, and it is rarely light transmission.
Liquid silicone and high-consistency rubber are different materials with different tooling. Five processes, what each is for, and where platinum cure beats peroxide.
Most start-up scrap is made in the first hour, and most of it is avoidable. Heat soak, purge, string-up, steady state, and why shutdown matters just as much.
Surface energy decides whether anything will stick. Choosing between adhesive, solvent, welding and fasteners, and the joint designs that stop a formed part from cracking.
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