Fig. 1 shows a product. It is made to last. The parts fit well. It is safe to use. The shape is good. It does its job well. All the bits are smooth. It can ...

(a)

1. Name the process: The process shown is press forming (also known as stamping or die cutting). A sheet of metal is placed between a punch and a die, and the press forces the punch down to cut or shape the metal into the required profile. [1]
2. One advantage in a factory: It is fast for large quantities; once the die is made, each pressing takes only seconds. Components are identical and accurate, reducing waste compared with hand cutting and making it cost-effective for mass production. [1]

(b)

1. Scale of production for a single 3D-printed prototype: One-off production. A single, unique item is made, typically at higher unit cost but without the expense of moulds or tooling. [1]
2. Two advantages of 3D printing a prototype rather than making by hand:
   • Complex shapes (internal cavities, thin walls, organic curves) can be produced that would be difficult or impossible to achieve by hand, since the printer builds layer by layer. [1]
   • The prototype is made directly from a CAD file with high dimensional accuracy; design changes can be implemented quickly by modifying the digital model and reprinting. [1]
3. Why 3D printing is unsuitable for 100 000 identical phone cases: 3D printing is slow (each case is built layer by layer over minutes to hours), making very high volumes impractical in terms of time. The unit cost remains constant regardless of quantity, whereas injection moulding has a high initial tooling cost but very low per-unit cost at scale, making it far more economical for mass production.

(c)

1. CNC stands for: Computer Numerical Control. A computer reads coded instructions (G-code) to control the machine tool's movements with high precision and repeatability. [1]
2. Software for creating digital CNC instructions: CAM (Computer Aided Manufacture) software. CAM converts a CAD model into machine-readable tool paths, specifying cutting strategies, feed rates, and depths of cut. [1]

(d)

1. Purpose of a jig: A jig holds and locates the workpiece while guiding the cutting tool, ensuring every component is manufactured identically without the need for individual marking out. [1]
2. Advantage of using a jig for batch quantities: It ensures accuracy and consistency, with all features produced in exactly the same position on every component. It also speeds up production because less time is spent measuring and marking out each piece, and less skilled operators can produce accurate work. [1]
3. Part labelled 'stop' and its function: The stop (end stop / location stop) positions each workpiece against a fixed edge so it is placed in exactly the same position before the operation begins, guaranteeing identical positioning across the batch. [1]

(e)

1. Process shown: Injection moulding. Granules of thermoplastic are heated until molten, then injected under high pressure into a steel mould cavity. The plastic cools and solidifies into the shape of the mould. [1]
2. One product made using this process: Plastic bucket, bottle cap, toy, phone case, comb, ruler, or plastic chair (any suitable mass-produced thermoplastic product). [1]

(f)

1. Scale of production: Mass production (also called continuous production). This is the manufacture of very large quantities of identical products on a continuous or near-continuous basis. [1]
2. Two advantages of mass production compared with one-off production:
   • Lower unit cost: The high initial investment in tooling, moulds, and automated machinery is spread across a very large number of units, drastically reducing the cost per item. In one-off production, all setup costs apply to just one item. [1]
   • Consistency and quality: Automated processes and fixed tooling produce identical products with minimal variation. Every chair meets the same specification, reducing waste and rework. One-off production relies more on individual skill, leading to potential variation. [1]
   • Speed: Automated production lines operate continuously at high speed. 50 000 chairs per week would be impossible to achieve with one-off methods.
   • Less skilled labour: Automated systems require operators rather than highly skilled craftspeople, reducing labour costs.