Fig. 1 shows a product in which a metal insert is moulded inside a polymer body. Give one reason for combining the two materials in this way.

Explain, using an example, how a designer decides which functions of a product should be automatic and which should remain under the user's control. [9]

A manufacturer builds a small number of products on the intended production line to prove the process before full manufacture. Name this type of run.

A manufacturer is deciding whether to make a product from a virgin polymer or from recycled polymer. Explain the factors the manufacturer must weigh in makin...

A designer uses a gear train in which a 20-tooth gear drives a 60-tooth gear. Calculate the gear ratio and state the effect on the output speed. [2]

Fig. 1 shows wear patterns recorded on a returned product after a year of use. Describe what this evidence tells the designer and give one change it suggests...

Fig. 1 shows a surface coating that repels water and dirt, based on the structure of a leaf. Name the field of design that copies solutions found in nature.

Explain what is meant by a tolerance, and explain how a designer decides the tolerance to place on a dimension, referring to function, cost and assembly. [10]

A company is introducing robots to its assembly line. Explain three effects this change will have on the workforce. [3]