Design & Technology (9-1) 0979 | Paper 3 Mock 01 | Materials
Question 1 Report
Fig. 4 shows a wood joint. The joining method has been selected for its strength and suitability for the materials being used. The joint must be strong enough to withstand the forces applied during use. Different joining methods are suitable for different materials and applications.
It is made in a shop. It stays cool in the heat.
The wood is easy to cut and shape. It must last a long time. The mild steel does not rust or rot.
This type of copper is chosen because of its electrical conductivity. The finished product is expected to have a working life of several years.
Name the joint shown in Fig. 4.
Name the joint shown in Fig. 4
Dovetail joint [1]. The dovetail joint consists of interlocking fan-shaped projections (tails) on one piece that fit into corresponding wedge-shaped sockets (pins) on the other. The angled shape of the tails and pins creates a mechanical interlock that resists pulling forces along the joint line, making it very strong even without adhesive. It is commonly used for drawer construction, box corners, and fine furniture where both strength and visual appeal are important.
Answer Details
Name the joint shown in Fig. 4
Dovetail joint [1]. The dovetail joint consists of interlocking fan-shaped projections (tails) on one piece that fit into corresponding wedge-shaped sockets (pins) on the other. The angled shape of the tails and pins creates a mechanical interlock that resists pulling forces along the joint line, making it very strong even without adhesive. It is commonly used for drawer construction, box corners, and fine furniture where both strength and visual appeal are important.
Question 2 Report
Fig. 3 shows a freehand sketch of a desk lamp. The sketch uses thick and thin lines. The product is manufactured in large quantities using industrial processes. The choice of material is important for the function and appearance of the product.
The sides are smooth. The lid lifts up and down. It looks clean and neat.
(a) State the purpose of using thick lines on the outer shape of the sketch. [1]
(b) State the purpose of using thin lines for the dimension lines and the detail of the bulb. [1]
(c) Give one reason why freehand sketching is used in the early stages of a design process. [1]
[Total: 3 marks]
(a) Thick lines on the outer shape of the sketch are used to show the outline and visible edges of the product, making the overall shape stand out clearly [1]. By drawing the silhouette and main edges in a heavier line weight, the designer ensures that the form of the desk lamp is immediately recognisable and visually dominant on the page, separating it from the background and from lighter detail lines.
(b) Thin lines are used for the dimension lines and the detail of the bulb so that they do not compete visually with the main outline of the product [1]. Dimension lines, annotations, and internal details are secondary information. If they were drawn at the same weight as the outline, the sketch would appear cluttered and the overall shape would be harder to read. The contrast between thick and thin lines creates a clear visual hierarchy: form first, detail second.
(c) One reason why freehand sketching is used in the early stages of a design process is that it is quick and allows ideas to be recorded rapidly without the need for drawing equipment such as rulers, set squares, or a CAD workstation [1]. The designer can explore many different concepts in a short time, capturing initial thoughts before they are lost and communicating them to others for early feedback. Speed is more important than precision at this stage, because most ideas will be refined or discarded before detailed drawing begins.
Answer Details
(a) Thick lines on the outer shape of the sketch are used to show the outline and visible edges of the product, making the overall shape stand out clearly [1]. By drawing the silhouette and main edges in a heavier line weight, the designer ensures that the form of the desk lamp is immediately recognisable and visually dominant on the page, separating it from the background and from lighter detail lines.
(b) Thin lines are used for the dimension lines and the detail of the bulb so that they do not compete visually with the main outline of the product [1]. Dimension lines, annotations, and internal details are secondary information. If they were drawn at the same weight as the outline, the sketch would appear cluttered and the overall shape would be harder to read. The contrast between thick and thin lines creates a clear visual hierarchy: form first, detail second.
(c) One reason why freehand sketching is used in the early stages of a design process is that it is quick and allows ideas to be recorded rapidly without the need for drawing equipment such as rulers, set squares, or a CAD workstation [1]. The designer can explore many different concepts in a short time, capturing initial thoughts before they are lost and communicating them to others for early feedback. Speed is more important than precision at this stage, because most ideas will be refined or discarded before detailed drawing begins.
Question 3 Report
Fig. 1 shows a kitchen saucepan.
It is made to last. The base keeps it still. It is used a lot.
The MDF was picked for its look and feel. The metal has a smooth finish. It is cheap to make in large numbers. It is light but strong. The handle is shaped to fit the hand. The sides are straight and even.
The copper can be shaped using turning or filing. The finished product is expected to have a working life of several years.
(a) Name a suitable metal for the body of the saucepan. [1]
(b) State one property of this metal that makes it suitable for a saucepan. [1]
(a) A suitable metal for the body of the saucepan is stainless steel. [1] Aluminium is also an acceptable choice.
(b) One property that makes this metal suitable for a saucepan:
Stainless steel is a good thermal conductor, allowing heat to transfer efficiently from the hob through the base and walls of the pan to the food inside. [1] It is also resistant to corrosion, meaning it will not rust or react with acidic foods, making it safe for cooking and easy to clean. If aluminium is chosen, its key advantage is being lightweight while still conducting heat effectively.
Answer Details
(a) A suitable metal for the body of the saucepan is stainless steel. [1] Aluminium is also an acceptable choice.
(b) One property that makes this metal suitable for a saucepan:
Stainless steel is a good thermal conductor, allowing heat to transfer efficiently from the hob through the base and walls of the pan to the food inside. [1] It is also resistant to corrosion, meaning it will not rust or react with acidic foods, making it safe for cooking and easy to clean. If aluminium is chosen, its key advantage is being lightweight while still conducting heat effectively.
Question 4 Report
Fig. 19 shows a piece of personal protective equipment (PPE). The item shown is commonly used in design and technology projects. It has been designed and manufactured to meet specific requirements. The choice of materials and construction methods affects the quality of the finished product.
The blade is thin and sharp. It can be fixed if it breaks.
Pine is a popular choice for this application due to its corrosion resistance and ease of bending. Consideration has been given to the environmental impact of the materials and processes used.
(a) Name the item of PPE shown in Fig. 19. [1]
(b) State one workshop activity where this item must be worn. [1]
(a) The item of PPE shown in Fig. 19 is safety goggles (eye protection) [1]. The diagram shows two circular lenses connected by a bridge and fitted with side arms, which is the characteristic shape of protective goggles used in a workshop.
(b) Safety goggles must be worn during activities such as drilling, grinding, soldering, sawing, or using a lathe [1]. These are any workshop operations that produce chips, sparks, flying debris, or fine particles that could enter the eyes and cause injury.
Answer Details
(a) The item of PPE shown in Fig. 19 is safety goggles (eye protection) [1]. The diagram shows two circular lenses connected by a bridge and fitted with side arms, which is the characteristic shape of protective goggles used in a workshop.
(b) Safety goggles must be worn during activities such as drilling, grinding, soldering, sawing, or using a lathe [1]. These are any workshop operations that produce chips, sparks, flying debris, or fine particles that could enter the eyes and cause injury.
Question 5 Report
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 be used a lot. The base keeps it still. It can hold a lot of weight.
(a) State a suitable operation for the box labelled A . Explain the purpose of the decision box in the flow chart. State one quality check that could be carried out after the frame is assembled. [3]
(b) Explain the purpose of the foam insert inside the packaging. State two items of printed information that should appear on the outside of the packaging. Explain why the manufacturer uses a barcode label on the packaging. [3]
(c) State the purpose of a work order. State one additional piece of information that could be included in this work order. [2]
(d) The cast iron can be shaped using sanding or welding. Quality control checks are carried out at various stages of manufacture. Name Item X . State one workshop activity where Item Y should be worn. [13]
[Total: 21 marks]
(a)
- Suitable operation for box A: Glue and assemble the mitre joints (apply PVA adhesive, clamp the frame in a picture-frame clamp, and allow to set). This is the logical next step after the joints have been cut and checked for accuracy. [1]
- Purpose of the decision box: The decision box is a quality check point where the accuracy of the mitre joints is inspected. If they fit accurately, the process moves forward; if not, the flow loops back to re-cut the joints. This feedback loop prevents poorly fitting joints from progressing to permanent assembly. [1]
- One quality check after assembly: Check that the frame is square by using a try square at each corner or by measuring the two diagonals (equal diagonals confirm a square frame). Other valid checks: verify overall dimensions match the specification; visually inspect for gaps in joints or surface defects; check the frame lies flat on a known flat surface. [1]
(b)
- Purpose of the foam insert: The foam insert protects the product from damage during transit by absorbing shocks and vibrations. It is shaped to hold the product securely, preventing movement inside the box. [1]
- Two items of printed information on the packaging:
- Product name and brand name, for retail identification and display. [1]
- Handling instructions such as "Fragile" or "This way up", to inform handlers how to treat the package. [1]
- Why a barcode label is used: A barcode allows electronic scanning for stock control and tracking through the supply chain (monitoring inventory, reordering). At the point of sale it speeds up checkout and reduces human error in pricing.
(c)
- Purpose of a work order: A work order sets out the sequence of operations, tools, materials, and timings needed to manufacture a product. [1] It acts as a planning document that ensures every worker follows the same process, contributing to consistency and efficiency in production.
- One additional piece of information: Any one of: quantity to be produced; quality control checkpoints; specific machine settings; materials and sizes required; estimated completion time; name of the operator responsible. [1]
(d)
- Name of Item X: Safety goggles (eye protection). They protect the eyes from flying debris, chips, sparks, and dust generated during workshop operations. [1]
- Workshop activity where Item Y (ear defenders) should be worn: Using a pillar drill, lathe, planer/thicknesser, circular saw, belt sander, or any machinery generating sustained high noise levels that could cause hearing damage. [1]
Item Y is ear defenders (hearing protection). The two padded cups seal around the ears and are connected by a headband, reducing noise to a safe level during loud workshop operations.
Answer Details
(a)
- Suitable operation for box A: Glue and assemble the mitre joints (apply PVA adhesive, clamp the frame in a picture-frame clamp, and allow to set). This is the logical next step after the joints have been cut and checked for accuracy. [1]
- Purpose of the decision box: The decision box is a quality check point where the accuracy of the mitre joints is inspected. If they fit accurately, the process moves forward; if not, the flow loops back to re-cut the joints. This feedback loop prevents poorly fitting joints from progressing to permanent assembly. [1]
- One quality check after assembly: Check that the frame is square by using a try square at each corner or by measuring the two diagonals (equal diagonals confirm a square frame). Other valid checks: verify overall dimensions match the specification; visually inspect for gaps in joints or surface defects; check the frame lies flat on a known flat surface. [1]
(b)
- Purpose of the foam insert: The foam insert protects the product from damage during transit by absorbing shocks and vibrations. It is shaped to hold the product securely, preventing movement inside the box. [1]
- Two items of printed information on the packaging:
- Product name and brand name, for retail identification and display. [1]
- Handling instructions such as "Fragile" or "This way up", to inform handlers how to treat the package. [1]
- Why a barcode label is used: A barcode allows electronic scanning for stock control and tracking through the supply chain (monitoring inventory, reordering). At the point of sale it speeds up checkout and reduces human error in pricing.
(c)
- Purpose of a work order: A work order sets out the sequence of operations, tools, materials, and timings needed to manufacture a product. [1] It acts as a planning document that ensures every worker follows the same process, contributing to consistency and efficiency in production.
- One additional piece of information: Any one of: quantity to be produced; quality control checkpoints; specific machine settings; materials and sizes required; estimated completion time; name of the operator responsible. [1]
(d)
- Name of Item X: Safety goggles (eye protection). They protect the eyes from flying debris, chips, sparks, and dust generated during workshop operations. [1]
- Workshop activity where Item Y (ear defenders) should be worn: Using a pillar drill, lathe, planer/thicknesser, circular saw, belt sander, or any machinery generating sustained high noise levels that could cause hearing damage. [1]
Item Y is ear defenders (hearing protection). The two padded cups seal around the ears and are connected by a headband, reducing noise to a safe level during loud workshop operations.
Question 6 Report
Fig. 6 shows a CNC milling machine being used to cut a component from aluminium. The metal has been selected for its specific properties that make it suitable for this application. Different metals have different properties that affect how they can be worked and used. The choice of metal depends on the functional requirements of the product.
It works in rain and sun. It is made to last. The top is flat. It does its job well.
The brass can be shaped using sanding or sanding.
(a) State what the letters CNC stand for. [1]
(b) Name the type of software used to create the digital instructions for the CNC machine. [1]
(a) CNC stands for Computer Numerical Control. [1]
In a CNC system, a computer reads a set of coded numerical instructions (the CNC program, written in G-code) that control the movement of the machine tool. The program specifies exact coordinates, feed rates, spindle speeds, and tool paths. This allows the machine to cut, drill, or shape materials with very high precision and repeatability, without the operator needing to guide the tool manually for each operation.
(b) The software used to create the digital instructions (tool paths) for the CNC machine is CAM (Computer Aided Manufacture) software. [1]
CAM software takes a digital 3D model (usually created in CAD - Computer Aided Design software) and converts it into a set of machine-readable instructions. The CAM software allows the user to specify cutting strategies, tool selection, feed rates, and depth of cut. It can simulate the machining process on screen before the program is sent to the CNC machine, helping to identify potential collisions or errors before any material is cut.
Answer Details
(a) CNC stands for Computer Numerical Control. [1]
In a CNC system, a computer reads a set of coded numerical instructions (the CNC program, written in G-code) that control the movement of the machine tool. The program specifies exact coordinates, feed rates, spindle speeds, and tool paths. This allows the machine to cut, drill, or shape materials with very high precision and repeatability, without the operator needing to guide the tool manually for each operation.
(b) The software used to create the digital instructions (tool paths) for the CNC machine is CAM (Computer Aided Manufacture) software. [1]
CAM software takes a digital 3D model (usually created in CAD - Computer Aided Design software) and converts it into a set of machine-readable instructions. The CAM software allows the user to specify cutting strategies, tool selection, feed rates, and depth of cut. It can simulate the machining process on screen before the program is sent to the CNC machine, helping to identify potential collisions or errors before any material is cut.
Question 7 Report
Fig. 8 shows a logic circuit used in a greenhouse ventilation system. The fan turns on when the temperature is high AND the light level is high.
The paint keeps out the damp. It is made to last. It can be fixed if it breaks.
The surface of the cast iron can be improved by applying a powder coating.
(a) Name the type of logic gate at position P. [1]
(b) Name the type of logic gate at position Q. [1]
(c) Complete the truth table for the circuit.
| Thermistor input | LDR input | Output of gate P | Output Z |
|---|---|---|---|
| 0 | 0 | ||
| 0 | 1 | ||
| 1 | 0 | ||
| 1 | 1 |
[2]
[Total: 3 marks]
(a) The type of logic gate at position P is an AND gate [1]. The AND gate symbol is recognisable by its D-shape (flat back with a curved front) and the "&" symbol inside. An AND gate produces a HIGH (1) output only when ALL of its inputs are HIGH (1). If either input or both inputs are LOW (0), the output is LOW (0).
(b) The type of logic gate at position Q is a NOT gate (inverter) [1]. A NOT gate takes a single input and produces the opposite output: if the input is 1, the output is 0, and if the input is 0, the output is 1. It inverts whatever signal it receives.
(c) The completed truth table for the circuit:
| Thermistor input | LDR input | Output of gate P (AND) | Output Z (NOT) |
|---|---|---|---|
| 0 | 0 | 0 | 1 |
| 0 | 1 | 0 | 1 |
| 1 | 0 | 0 | 1 |
| 1 | 1 | 1 | 0 |
[1 mark per fully correct column, maximum 2]
The AND gate (P) produces a 1 only when both inputs are 1 (thermistor HIGH and LDR HIGH). In all other input combinations, at least one input is 0, so the AND gate outputs 0. The NOT gate (Q) then inverts each of these values: the three 0 outputs from gate P become 1 at output Z, and the single 1 output from gate P becomes 0 at output Z. The result is that Z is LOW (0) only when both the temperature and light level are high simultaneously.
Answer Details
(a) The type of logic gate at position P is an AND gate [1]. The AND gate symbol is recognisable by its D-shape (flat back with a curved front) and the "&" symbol inside. An AND gate produces a HIGH (1) output only when ALL of its inputs are HIGH (1). If either input or both inputs are LOW (0), the output is LOW (0).
(b) The type of logic gate at position Q is a NOT gate (inverter) [1]. A NOT gate takes a single input and produces the opposite output: if the input is 1, the output is 0, and if the input is 0, the output is 1. It inverts whatever signal it receives.
(c) The completed truth table for the circuit:
| Thermistor input | LDR input | Output of gate P (AND) | Output Z (NOT) |
|---|---|---|---|
| 0 | 0 | 0 | 1 |
| 0 | 1 | 0 | 1 |
| 1 | 0 | 0 | 1 |
| 1 | 1 | 1 | 0 |
[1 mark per fully correct column, maximum 2]
The AND gate (P) produces a 1 only when both inputs are 1 (thermistor HIGH and LDR HIGH). In all other input combinations, at least one input is 0, so the AND gate outputs 0. The NOT gate (Q) then inverts each of these values: the three 0 outputs from gate P become 1 at output Z, and the single 1 output from gate P becomes 0 at output Z. The result is that Z is LOW (0) only when both the temperature and light level are high simultaneously.
Question 8 Report
Fig. 1 shows a worker using a bench-mounted pillar drill to make a hole in a piece of acrylic. The machine is commonly found in school and industrial workshops. It is used to produce accurate holes in a range of materials including metals, plastics and timbers. Safety precautions must be followed when operating this machine.
The grip stops it from slipping. It is made to last. It looks clean and neat.
It keeps its shape well over time.
(a) Name one item of personal protective equipment (PPE) the worker should wear when using the pillar drill. [1]
(b) State one reason why the acrylic should be clamped to the drill table. [1]
(a) One item of PPE the worker should wear: safety goggles (eye protection). [1]
When drilling acrylic on a pillar drill, small chips and shards of material are thrown upward and outward by the rotating drill bit. These sharp fragments can cause serious eye injury. Safety goggles form a seal around the eyes, preventing debris from entering from any direction. Other acceptable PPE includes a dust mask (acrylic dust can be an irritant) or an apron (to protect clothing).
(b) One reason why the acrylic should be clamped to the drill table: [1]
Clamping prevents the workpiece from spinning or being pulled upward by the drill bit, which could cause serious injury to the operator. When the drill bit catches in the material, the rotational force (torque) can wrench the workpiece out of the operator's hands if it is only being held manually. A clamp or machine vice holds the acrylic securely against the table, keeping the operator's hands away from the rotating drill bit and ensuring the hole is drilled accurately in the correct position.
Answer Details
(a) One item of PPE the worker should wear: safety goggles (eye protection). [1]
When drilling acrylic on a pillar drill, small chips and shards of material are thrown upward and outward by the rotating drill bit. These sharp fragments can cause serious eye injury. Safety goggles form a seal around the eyes, preventing debris from entering from any direction. Other acceptable PPE includes a dust mask (acrylic dust can be an irritant) or an apron (to protect clothing).
(b) One reason why the acrylic should be clamped to the drill table: [1]
Clamping prevents the workpiece from spinning or being pulled upward by the drill bit, which could cause serious injury to the operator. When the drill bit catches in the material, the rotational force (torque) can wrench the workpiece out of the operator's hands if it is only being held manually. A clamp or machine vice holds the acrylic securely against the table, keeping the operator's hands away from the rotating drill bit and ensuring the hole is drilled accurately in the correct position.
Question 9 Report
Fig. 21 shows a net for a box made from card. The product has been designed to be both functional and aesthetically pleasing. It is constructed from a combination of materials chosen for their properties and suitability. The designer has considered the needs of the user and the environment in which it will be used.
It can be moved to a new spot. It is made to last.
(a) Name the feature labelled A on the net. [1]
(b) Explain why the fold lines are shown as dashed lines. [1]
(c) State one reason why corrugated card would be more suitable than cartridge paper for making a large packaging box. [1]
[Total: 3 marks]
(a) The feature labelled A on the net is a glue tab (tab or flap) [1]. It is a narrow strip of card that extends beyond the edge of one face of the net. When the net is folded into a box, this tab is folded inward and glued to the inside of an adjacent face, holding the box together.
(b) The fold lines are shown as dashed lines to distinguish them from the cut lines, which are shown as solid lines [1]. The dashed lines indicate where the card is scored (compressed along a straight line to create a hinge) and then folded. Using a different line type makes the net unambiguous: a worker or cutting machine can see immediately which lines to cut through and which lines to fold along.
(c) Corrugated card would be more suitable than cartridge paper for making a large packaging box because corrugated card has a fluted (wavy) inner layer sandwiched between two flat liners, which gives it significantly greater rigidity and compressive strength [1]. This structure allows it to support heavier contents without collapsing or crushing, whereas cartridge paper is thin, flexible, and would buckle under the weight. The fluted core also provides some cushioning to protect the contents during transport.
Answer Details
(a) The feature labelled A on the net is a glue tab (tab or flap) [1]. It is a narrow strip of card that extends beyond the edge of one face of the net. When the net is folded into a box, this tab is folded inward and glued to the inside of an adjacent face, holding the box together.
(b) The fold lines are shown as dashed lines to distinguish them from the cut lines, which are shown as solid lines [1]. The dashed lines indicate where the card is scored (compressed along a straight line to create a hinge) and then folded. Using a different line type makes the net unambiguous: a worker or cutting machine can see immediately which lines to cut through and which lines to fold along.
(c) Corrugated card would be more suitable than cartridge paper for making a large packaging box because corrugated card has a fluted (wavy) inner layer sandwiched between two flat liners, which gives it significantly greater rigidity and compressive strength [1]. This structure allows it to support heavier contents without collapsing or crushing, whereas cartridge paper is thin, flexible, and would buckle under the weight. The fluted core also provides some cushioning to protect the contents during transport.
Question 10 Report
A manufacturer is planning to produce a new outdoor portable speaker. The speaker must be waterproof, durable, and appeal to young adults aged 18 to 30.
It can be fixed if it breaks. It cuts in a line. It is used a lot.
The surface of the nylon can be improved by applying a anodising.
Fig. 15 shows the initial concept sketch.
Use sketches and notes to develop the design of the outdoor portable speaker. In your answer you should consider:
- the overall shape and form
- the choice of suitable materials, giving reasons
- ergonomic and aesthetic features
- how the speaker could be made waterproof
- the target market
- sustainability of the design
[25]
This extended-response question is assessed using a levels-based mark scheme. A strong answer develops the outdoor speaker design with detailed, well-annotated sketches addressing all six bullet points. The following indicative content outlines the key knowledge expected at the highest level.
Overall shape and form:
A rounded, pebble-like or cylindrical shape is appropriate for an outdoor speaker. Rounded forms resist impact better than sharp-cornered designs because forces are distributed across the curved surface rather than concentrating at edges. The shape should be compact enough to fit comfortably in one hand or clip onto a bag, with a flat base so the speaker can stand upright on uneven surfaces. The carry loop shown in the concept sketch allows attachment to a rucksack or belt loop via a carabiner clip.
Choice of suitable materials with reasons:
- ABS or polycarbonate outer shell: Tough, impact-resistant, and lightweight. Polycarbonate has particularly high impact strength, important for a product that may be dropped outdoors. Both can be injection moulded in a range of colours.
- TPU / silicone rubber overmould: Applied over the outer shell to provide grip, shock absorption, and a soft-touch feel. Silicone is waterproof and UV-resistant, making it suitable for outdoor use.
- Stainless steel or aluminium speaker grille: Corrosion-resistant, durable, and acoustically transparent. Stainless steel withstands outdoor exposure without rusting.
- Aluminium internal frame: Lightweight yet rigid, providing structural support for the electronic components without adding excessive weight.
Ergonomic and aesthetic features:
- Ergonomic: Size that fits comfortably in one hand; tactile buttons (power and volume) that can be located and operated by touch without looking; weight under 400 g for portability; carry loop or carabiner attachment point.
- Aesthetic: Bold colour options (e.g. matte black, vibrant orange, electric blue) to appeal to the 18-30 age group; textured surface finish that looks and feels premium; minimal visible fixings for a clean, modern appearance; subtle LED indicator light for power/pairing status.
How the speaker could be made waterproof:
- Sealed USB-C charging port with a tight-fitting rubber cap that compresses against an O-ring gasket when closed.
- Ultrasonic welding of the two casing halves to create a seamless, watertight joint without screws or adhesive.
- IP67-rated gasket seals (silicone or EPDM rubber) on all joints and component interfaces.
- Waterproof acoustic membrane over the speaker grille that allows sound to pass through while blocking water ingress.
- Sealed button mechanisms using elastomeric (rubber) domes that deform under finger pressure without allowing water to enter.
Target market considerations:
The target market is young adults aged 18-30 who use the speaker outdoors for activities such as hiking, camping, beach trips, and garden parties. The price point should be in the range of $40-60 to suit the budget of this age group. Bluetooth 5.0 connectivity for wireless pairing with smartphones is essential. Battery life of 8-12 hours suits a full day of outdoor use. The compact size and carry loop support an active, mobile lifestyle.
Sustainability of the design:
- ABS and polycarbonate casing can be recycled at end of life if clearly marked with polymer identification codes.
- Rechargeable lithium-ion battery eliminates the need for disposable batteries.
- The product should be designed for disassembly (DfD) using snap-fit joints rather than adhesives, so components can be separated for recycling or repair.
- Minimal packaging using recycled cardboard and soy-based inks, avoiding polystyrene foam inserts.
- LED indicator and efficient Class D amplifier reduce power consumption, extending battery life and reducing overall energy use.
Levels-based assessment:
| Level | Marks | Descriptor |
|---|---|---|
| 5 | 21-25 | Excellent: detailed development with well-drawn, fully annotated sketches; all six bullet points addressed thoroughly; materials named and justified with specific properties; ergonomic and aesthetic features clearly identified and explained; waterproofing described with technical detail; sustainability addressed with specific strategies; design clearly targeted at the specified user group. |
| 4 | 16-20 | Good: clear sketches and notes covering most bullet points in detail; materials named with some justification; ergonomic and aesthetic features identified; waterproofing addressed; some consideration of sustainability and target market; sketches show development from the initial concept. |
| 3 | 11-15 | Adequate: recognisable sketches and notes covering at least four bullet points; some materials named; basic ergonomic or aesthetic features mentioned; some attempt at addressing waterproofing; limited consideration of sustainability or target market. |
| 2 | 6-10 | Basic: simple sketches with limited notes; two or three bullet points addressed at a superficial level; materials may be named without justification; limited evidence of design development. |
| 1 | 1-5 | Minimal: very basic or unclear sketches; one or two bullet points addressed briefly; little or no evidence of design thinking or development. |
Answer Details
This extended-response question is assessed using a levels-based mark scheme. A strong answer develops the outdoor speaker design with detailed, well-annotated sketches addressing all six bullet points. The following indicative content outlines the key knowledge expected at the highest level.
Overall shape and form:
A rounded, pebble-like or cylindrical shape is appropriate for an outdoor speaker. Rounded forms resist impact better than sharp-cornered designs because forces are distributed across the curved surface rather than concentrating at edges. The shape should be compact enough to fit comfortably in one hand or clip onto a bag, with a flat base so the speaker can stand upright on uneven surfaces. The carry loop shown in the concept sketch allows attachment to a rucksack or belt loop via a carabiner clip.
Choice of suitable materials with reasons:
- ABS or polycarbonate outer shell: Tough, impact-resistant, and lightweight. Polycarbonate has particularly high impact strength, important for a product that may be dropped outdoors. Both can be injection moulded in a range of colours.
- TPU / silicone rubber overmould: Applied over the outer shell to provide grip, shock absorption, and a soft-touch feel. Silicone is waterproof and UV-resistant, making it suitable for outdoor use.
- Stainless steel or aluminium speaker grille: Corrosion-resistant, durable, and acoustically transparent. Stainless steel withstands outdoor exposure without rusting.
- Aluminium internal frame: Lightweight yet rigid, providing structural support for the electronic components without adding excessive weight.
Ergonomic and aesthetic features:
- Ergonomic: Size that fits comfortably in one hand; tactile buttons (power and volume) that can be located and operated by touch without looking; weight under 400 g for portability; carry loop or carabiner attachment point.
- Aesthetic: Bold colour options (e.g. matte black, vibrant orange, electric blue) to appeal to the 18-30 age group; textured surface finish that looks and feels premium; minimal visible fixings for a clean, modern appearance; subtle LED indicator light for power/pairing status.
How the speaker could be made waterproof:
- Sealed USB-C charging port with a tight-fitting rubber cap that compresses against an O-ring gasket when closed.
- Ultrasonic welding of the two casing halves to create a seamless, watertight joint without screws or adhesive.
- IP67-rated gasket seals (silicone or EPDM rubber) on all joints and component interfaces.
- Waterproof acoustic membrane over the speaker grille that allows sound to pass through while blocking water ingress.
- Sealed button mechanisms using elastomeric (rubber) domes that deform under finger pressure without allowing water to enter.
Target market considerations:
The target market is young adults aged 18-30 who use the speaker outdoors for activities such as hiking, camping, beach trips, and garden parties. The price point should be in the range of $40-60 to suit the budget of this age group. Bluetooth 5.0 connectivity for wireless pairing with smartphones is essential. Battery life of 8-12 hours suits a full day of outdoor use. The compact size and carry loop support an active, mobile lifestyle.
Sustainability of the design:
- ABS and polycarbonate casing can be recycled at end of life if clearly marked with polymer identification codes.
- Rechargeable lithium-ion battery eliminates the need for disposable batteries.
- The product should be designed for disassembly (DfD) using snap-fit joints rather than adhesives, so components can be separated for recycling or repair.
- Minimal packaging using recycled cardboard and soy-based inks, avoiding polystyrene foam inserts.
- LED indicator and efficient Class D amplifier reduce power consumption, extending battery life and reducing overall energy use.
Levels-based assessment:
| Level | Marks | Descriptor |
|---|---|---|
| 5 | 21-25 | Excellent: detailed development with well-drawn, fully annotated sketches; all six bullet points addressed thoroughly; materials named and justified with specific properties; ergonomic and aesthetic features clearly identified and explained; waterproofing described with technical detail; sustainability addressed with specific strategies; design clearly targeted at the specified user group. |
| 4 | 16-20 | Good: clear sketches and notes covering most bullet points in detail; materials named with some justification; ergonomic and aesthetic features identified; waterproofing addressed; some consideration of sustainability and target market; sketches show development from the initial concept. |
| 3 | 11-15 | Adequate: recognisable sketches and notes covering at least four bullet points; some materials named; basic ergonomic or aesthetic features mentioned; some attempt at addressing waterproofing; limited consideration of sustainability or target market. |
| 2 | 6-10 | Basic: simple sketches with limited notes; two or three bullet points addressed at a superficial level; materials may be named without justification; limited evidence of design development. |
| 1 | 1-5 | Minimal: very basic or unclear sketches; one or two bullet points addressed briefly; little or no evidence of design thinking or development. |
Question 11 Report
Fig. 11 shows a hot drinks mug. The surface of the mug changes colour when a hot liquid is poured into it. The product is manufactured in large quantities using industrial processes. The choice of material is important for the function and appearance of the product. The designer has considered the target market and the product's intended use.
It can be used on its own. It works in rain and sun.
(a) Name the type of smart material used on the surface of the mug. [1]
(b) Explain how this smart material works. [2]
(c) Name one other smart material and state a product it is used in. [2]
[Total: 3 marks]
(a) The type of smart material used on the surface of the mug is thermochromic pigment (thermochromic ink) [1]. This is a smart material because it changes its properties in response to an external stimulus (temperature) and reverses when the stimulus is removed.
(b) Thermochromic pigment changes colour in response to a change in temperature [1]. When a hot liquid such as tea or coffee is poured into the mug, the heat transfers through the mug wall and raises the temperature of the pigment. This causes a reversible chemical or physical change in the pigment's molecular structure, making it appear a different colour. When the liquid cools and the mug returns to room temperature, the pigment reverts to its original colour [1]. This reversibility distinguishes it from a permanent colour change.
(c) One other smart material and a product it is used in:
- Shape memory alloy (SMA), such as Nitinol - used in dental braces [1+1]. The wire is deformed at room temperature to fit over the patient's teeth. Body heat causes the alloy to return to its pre-set shape, applying a gentle, constant force that gradually straightens the teeth. Other valid products include spectacle frames and medical stents.
Other acceptable answers include photochromic pigment (used in sunglasses that darken in UV light) or quantum tunnelling composite (QTC), used in pressure sensors and membrane switches.
Answer Details
(a) The type of smart material used on the surface of the mug is thermochromic pigment (thermochromic ink) [1]. This is a smart material because it changes its properties in response to an external stimulus (temperature) and reverses when the stimulus is removed.
(b) Thermochromic pigment changes colour in response to a change in temperature [1]. When a hot liquid such as tea or coffee is poured into the mug, the heat transfers through the mug wall and raises the temperature of the pigment. This causes a reversible chemical or physical change in the pigment's molecular structure, making it appear a different colour. When the liquid cools and the mug returns to room temperature, the pigment reverts to its original colour [1]. This reversibility distinguishes it from a permanent colour change.
(c) One other smart material and a product it is used in:
- Shape memory alloy (SMA), such as Nitinol - used in dental braces [1+1]. The wire is deformed at room temperature to fit over the patient's teeth. Body heat causes the alloy to return to its pre-set shape, applying a gentle, constant force that gradually straightens the teeth. Other valid products include spectacle frames and medical stents.
Other acceptable answers include photochromic pigment (used in sunglasses that darken in UV light) or quantum tunnelling composite (QTC), used in pressure sensors and membrane switches.
Question 12 Report
Fig. 4 shows a stainless steel travel mug used to carry hot drinks. The product is manufactured in large quantities using industrial processes. The choice of material is important for the function and appearance of the product. The designer has considered the target market and the product's intended use.
It is made in a shop. The shape is good. It does not tip over.
A designer used ACCESS FM to evaluate this product.
(a) State one functional feature of the travel mug. [1]
(b) State one safety feature that should be included in the design. [1]
(c) Name one aesthetic feature that could make the mug appeal to customers. [1]
[Total: 3 marks]
ACCESS FM is a framework used to analyse and evaluate products. Each letter represents a different aspect: Aesthetics, Cost, Customer, Environment, Size, Safety, Function, Material.
(a) One functional feature of the travel mug is the double-wall construction, which insulates the drink and keeps it hot for a longer period [1]. Other valid functional features include: the sealed lid that prevents spills during travel, and the drinking hole that allows the user to drink without removing the lid.
(b) One safety feature that should be included is a secure sealed lid that locks in place, preventing hot liquid from spilling and causing scalding burns to the user [1]. Other valid safety features include: a heat-resistant silicone grip sleeve so the mug can be held without burning the hand, and the use of BPA-free, food-safe materials that do not leach harmful chemicals into the drink.
(c) One aesthetic feature that could make the mug appeal to customers is a smooth brushed or polished finish on the stainless steel surface, which gives it a modern, premium appearance [1]. Other valid answers include offering a range of colour options for the silicone sleeve to suit different tastes, or a sleek, streamlined shape that looks contemporary and stylish.
Answer Details
ACCESS FM is a framework used to analyse and evaluate products. Each letter represents a different aspect: Aesthetics, Cost, Customer, Environment, Size, Safety, Function, Material.
(a) One functional feature of the travel mug is the double-wall construction, which insulates the drink and keeps it hot for a longer period [1]. Other valid functional features include: the sealed lid that prevents spills during travel, and the drinking hole that allows the user to drink without removing the lid.
(b) One safety feature that should be included is a secure sealed lid that locks in place, preventing hot liquid from spilling and causing scalding burns to the user [1]. Other valid safety features include: a heat-resistant silicone grip sleeve so the mug can be held without burning the hand, and the use of BPA-free, food-safe materials that do not leach harmful chemicals into the drink.
(c) One aesthetic feature that could make the mug appeal to customers is a smooth brushed or polished finish on the stainless steel surface, which gives it a modern, premium appearance [1]. Other valid answers include offering a range of colour options for the silicone sleeve to suit different tastes, or a sleek, streamlined shape that looks contemporary and stylish.
Question 13 Report
Fig. 2 shows a cold chisel being used to cut a piece of metal on an anvil.
It is made in a shop. All the bits are smooth. It can be fixed if it breaks.
It can be cut to size with a plane.
(a) Name the type of metal used for the cutting edge of a cold chisel. [1]
(b) Describe the process of case hardening and explain why it would be suitable for the cold chisel. [3]
(c) State one disadvantage of case hardening compared with through hardening. [1]
(d) Name the heat treatment process that would be carried out after hardening the chisel to prevent it from being too brittle. [1]
(a) The type of metal used for the cutting edge of a cold chisel is high carbon steel (tool steel). [1] High carbon steel can be hardened by heat treatment, giving it the hardness needed for a cutting tool that must maintain a sharp edge when struck against other metals.
(b) The process of case hardening:
- The chisel is packed in a carbon-rich material such as charcoal, carbon powder, or a proprietary case-hardening compound, inside a sealed metal container. [1]
- The container is heated to a high temperature (around 900-950 degrees Celsius) and held at this temperature for several hours to allow carbon atoms to absorb (diffuse) into the outer surface layer of the steel. [1] The longer the soaking time, the deeper the carbon penetration.
- The component is then quenched in water or oil to harden the carbon-enriched outer layer. [1]
Case hardening is suitable for the cold chisel because the chisel needs a hard, wear-resistant outer surface at the cutting edge to maintain sharpness and resist abrasion, while the core must remain tough and ductile to absorb the repeated impact of hammer blows without fracturing. Case hardening achieves exactly this combination: a hard case surrounding a tough core.
(c) One disadvantage of case hardening compared with through hardening:
Only the outer surface layer is hardened, so with heavy or prolonged use the hard layer can wear through, exposing the softer core beneath. [1] The depth of the hardened case is relatively thin and difficult to control precisely, so the protection may not last as long as a component that is hardened uniformly throughout its full cross-section (through hardening).
(d) The heat treatment process carried out after hardening the chisel to prevent it from being too brittle is tempering. [1] Tempering involves reheating the hardened steel to a controlled lower temperature and quenching it again, which relieves internal stresses and reduces brittleness while retaining most of the hardness.
Answer Details
(a) The type of metal used for the cutting edge of a cold chisel is high carbon steel (tool steel). [1] High carbon steel can be hardened by heat treatment, giving it the hardness needed for a cutting tool that must maintain a sharp edge when struck against other metals.
(b) The process of case hardening:
- The chisel is packed in a carbon-rich material such as charcoal, carbon powder, or a proprietary case-hardening compound, inside a sealed metal container. [1]
- The container is heated to a high temperature (around 900-950 degrees Celsius) and held at this temperature for several hours to allow carbon atoms to absorb (diffuse) into the outer surface layer of the steel. [1] The longer the soaking time, the deeper the carbon penetration.
- The component is then quenched in water or oil to harden the carbon-enriched outer layer. [1]
Case hardening is suitable for the cold chisel because the chisel needs a hard, wear-resistant outer surface at the cutting edge to maintain sharpness and resist abrasion, while the core must remain tough and ductile to absorb the repeated impact of hammer blows without fracturing. Case hardening achieves exactly this combination: a hard case surrounding a tough core.
(c) One disadvantage of case hardening compared with through hardening:
Only the outer surface layer is hardened, so with heavy or prolonged use the hard layer can wear through, exposing the softer core beneath. [1] The depth of the hardened case is relatively thin and difficult to control precisely, so the protection may not last as long as a component that is hardened uniformly throughout its full cross-section (through hardening).
(d) The heat treatment process carried out after hardening the chisel to prevent it from being too brittle is tempering. [1] Tempering involves reheating the hardened steel to a controlled lower temperature and quenching it again, which relieves internal stresses and reduces brittleness while retaining most of the hardness.
