Design & Technology (9-1) 0979 | Paper 3 Mock 01 | Materials
Question 1 Report
Fig. 20 shows a pillar drill with a safety guard. 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.
It looks clean and neat. It works in rain and sun. It is held in place.
It is used in many homes and schools.
The aluminium used gives the product good hardness and impact resistance. Consideration has been given to the environmental impact of the materials and processes used.
Give two safety rules that must be followed when using the pillar drill shown in Fig. 20.
Two safety rules that must be followed when using the pillar drill:
- Keep the safety guard in place [1] - The guard, visible in Fig. 20 around the drill bit area, prevents the user's hands, hair, or clothing from coming into contact with the rotating chuck and drill bit. It also contains any debris thrown up during drilling.
- Clamp the workpiece securely to the drill table [1] - If the material is held by hand, the rotating drill bit can catch and spin the workpiece violently, causing injury to the user. A clamp or machine vice holds the material firmly in position.
Other valid safety rules include: tie back long hair to prevent it being caught in the rotating parts; do not wear loose clothing, jewellery, or ties; wear safety goggles to protect eyes from flying chips; and ensure the correct drill bit is fitted and tightened in the chuck before starting.
Answer Details
Two safety rules that must be followed when using the pillar drill:
- Keep the safety guard in place [1] - The guard, visible in Fig. 20 around the drill bit area, prevents the user's hands, hair, or clothing from coming into contact with the rotating chuck and drill bit. It also contains any debris thrown up during drilling.
- Clamp the workpiece securely to the drill table [1] - If the material is held by hand, the rotating drill bit can catch and spin the workpiece violently, causing injury to the user. A clamp or machine vice holds the material firmly in position.
Other valid safety rules include: tie back long hair to prevent it being caught in the rotating parts; do not wear loose clothing, jewellery, or ties; wear safety goggles to protect eyes from flying chips; and ensure the correct drill bit is fitted and tightened in the chuck before starting.
Question 2 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 3 Report
Fig. 4 shows a wood chisel being used to cut a housing joint in a piece of timber. The tool is used to shape and remove material in a controlled manner. It requires careful handling and correct technique to produce accurate results. The blade must be kept sharp and the workpiece securely held during use.
The handle is round. The parts fit well. It can be used on its own.
The mild steel was picked for its look and feel.
(a) Name the type of chisel most suitable for cutting this housing joint. [1]
(b) Describe how the chisel is used to remove the waste material from the housing. [3]
[Total: 4 marks]
(a) Name the type of chisel most suitable for cutting this housing joint [1]
A bevel-edged chisel (a firmer chisel is also accepted) [1]. The bevelled edges allow the chisel to reach into corners of the housing, and the flat back lets it pare the base to a smooth, even depth.
(b) Describe how the chisel is used to remove the waste material from the housing [3]
- The chisel is held with the bevel facing down against the timber [1]. This orientation gives the user control over the depth of each cut and prevents the blade from digging too deeply into the wood.
- A series of cuts are made across the grain, working progressively from one end of the housing to the other. Each cut removes a thin layer of waste material [1]. The chisel is struck lightly with a mallet for each cut.
- Once the bulk of the waste has been removed, the chisel is used flat (bevel up) to pare the base of the housing to the required depth, producing a smooth, level surface for the mating piece to sit in [1].
Answer Details
(a) Name the type of chisel most suitable for cutting this housing joint [1]
A bevel-edged chisel (a firmer chisel is also accepted) [1]. The bevelled edges allow the chisel to reach into corners of the housing, and the flat back lets it pare the base to a smooth, even depth.
(b) Describe how the chisel is used to remove the waste material from the housing [3]
- The chisel is held with the bevel facing down against the timber [1]. This orientation gives the user control over the depth of each cut and prevents the blade from digging too deeply into the wood.
- A series of cuts are made across the grain, working progressively from one end of the housing to the other. Each cut removes a thin layer of waste material [1]. The chisel is struck lightly with a mallet for each cut.
- Once the bulk of the waste has been removed, the chisel is used flat (bevel up) to pare the base of the housing to the required depth, producing a smooth, level surface for the mating piece to sit in [1].
Question 4 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 5 Report
Fig. 12 shows a cross-section of a piece of plywood. The timber has been selected for its working properties and appearance. Different types of timber have different characteristics that affect their suitability. The grain direction and moisture content affect how the timber can be worked.
The base is wide. The sides are smooth. It works in rain and sun. The parts fit well. The grip stops it from slipping.
The surface of the PVC can be improved by applying a varnish. The product is intended for use in a school workshop environment.
(a) State why plywood is classified as a composite material. [1]
(b) Explain why the grain direction of each layer alternates. [1]
(a) Plywood is classified as a composite material because it is made from two or more materials bonded together to create improved properties [1]. Specifically, it consists of thin layers (veneers) of wood glued together with adhesive. The wood veneers and the adhesive are different materials that, when combined, produce a board with greater strength, stability, and resistance to splitting than a single piece of solid timber of the same thickness.
(b) The grain direction of each layer alternates (each veneer is laid at 90 degrees to the one above and below it) so that the plywood has equal strength in both directions [1]. In solid timber, the wood is strong along the grain but weak and prone to splitting across it. By alternating the grain, each layer reinforces the weakness of its neighbours. This also prevents the board from warping, twisting, or shrinking unevenly when exposed to changes in moisture, because the opposing grain directions counteract each other's tendency to move.
Answer Details
(a) Plywood is classified as a composite material because it is made from two or more materials bonded together to create improved properties [1]. Specifically, it consists of thin layers (veneers) of wood glued together with adhesive. The wood veneers and the adhesive are different materials that, when combined, produce a board with greater strength, stability, and resistance to splitting than a single piece of solid timber of the same thickness.
(b) The grain direction of each layer alternates (each veneer is laid at 90 degrees to the one above and below it) so that the plywood has equal strength in both directions [1]. In solid timber, the wood is strong along the grain but weak and prone to splitting across it. By alternating the grain, each layer reinforces the weakness of its neighbours. This also prevents the board from warping, twisting, or shrinking unevenly when exposed to changes in moisture, because the opposing grain directions counteract each other's tendency to move.
Question 6 Report
Fig. 8 shows three polymer products labelled X, Y and Z.
All the bits are smooth. It is made in a shop.
The table below lists three polymers and their properties.
| Polymer | Type | Key properties |
|---|---|---|
| HDPE | Thermoplastic | Tough, stiff, good chemical resistance |
| Polypropylene | Thermoplastic | Flexible, lightweight, good fatigue resistance |
| Urea formaldehyde | Thermosetting | Hard, brittle, good electrical insulator, heat resistant |
(a) Using the information in the table, select the most suitable polymer for each product X, Y and Z. For each, give a reason linked to its properties. [6]
(b) Explain the difference between a thermoplastic and a thermosetting polymer. [2]
(c) Describe one environmental consideration when disposing of thermoplastic products. [2]
(a) Selecting the most suitable polymer for each product using the table of properties:
Product X (shampoo bottle):
- The most suitable polymer is HDPE (high-density polyethylene). [1]
- HDPE has good chemical resistance, so it will not react with or be degraded by the shampoo or other toiletry chemicals inside. It is also tough and stiff, meaning the bottle holds its shape and resists splitting when squeezed. [1]
Product Y (garden planter):
- The most suitable polymer is polypropylene. [1]
- Polypropylene is lightweight, making the planter easy to move around the garden, and it has good fatigue resistance, so the planter can withstand repeated stresses from being moved, filled with soil, and exposed to outdoor temperature changes without cracking. [1]
Product Z (plug casing):
- The most suitable polymer is urea formaldehyde. [1]
- Urea formaldehyde is a good electrical insulator, which is essential for safety in an electrical plug, and it is heat resistant, so the casing will not soften or deform from the heat generated during electrical use. [1]
(b) The difference between thermoplastic and thermosetting polymers relates to their molecular structure and behaviour when heated:
- A thermoplastic can be repeatedly heated and reshaped because it softens when heated. [1] Its polymer chains are held together by weak intermolecular forces that break on heating and re-form on cooling, allowing the material to be recycled and remoulded multiple times.
- A thermosetting polymer undergoes a permanent chemical change (cross-linking) when first heated and moulded. [1] Once set, the strong covalent cross-links between polymer chains cannot be broken by reheating, so the material cannot be reshaped or recycled by melting.
(c) One environmental consideration when disposing of thermoplastic products:
Thermoplastics can be recycled by collecting, sorting, melting, and re-moulding them into new products. [1] This reduces the volume of plastic waste sent to landfill and conserves the crude oil from which the polymers are originally derived, lowering the demand for raw materials and reducing the environmental impact of extraction. [1]
Alternatively, if thermoplastics are sent to landfill rather than recycled, they are not biodegradable and persist in the environment for hundreds of years, occupying landfill space and potentially breaking into microplastics that harm wildlife and ecosystems.
Answer Details
(a) Selecting the most suitable polymer for each product using the table of properties:
Product X (shampoo bottle):
- The most suitable polymer is HDPE (high-density polyethylene). [1]
- HDPE has good chemical resistance, so it will not react with or be degraded by the shampoo or other toiletry chemicals inside. It is also tough and stiff, meaning the bottle holds its shape and resists splitting when squeezed. [1]
Product Y (garden planter):
- The most suitable polymer is polypropylene. [1]
- Polypropylene is lightweight, making the planter easy to move around the garden, and it has good fatigue resistance, so the planter can withstand repeated stresses from being moved, filled with soil, and exposed to outdoor temperature changes without cracking. [1]
Product Z (plug casing):
- The most suitable polymer is urea formaldehyde. [1]
- Urea formaldehyde is a good electrical insulator, which is essential for safety in an electrical plug, and it is heat resistant, so the casing will not soften or deform from the heat generated during electrical use. [1]
(b) The difference between thermoplastic and thermosetting polymers relates to their molecular structure and behaviour when heated:
- A thermoplastic can be repeatedly heated and reshaped because it softens when heated. [1] Its polymer chains are held together by weak intermolecular forces that break on heating and re-form on cooling, allowing the material to be recycled and remoulded multiple times.
- A thermosetting polymer undergoes a permanent chemical change (cross-linking) when first heated and moulded. [1] Once set, the strong covalent cross-links between polymer chains cannot be broken by reheating, so the material cannot be reshaped or recycled by melting.
(c) One environmental consideration when disposing of thermoplastic products:
Thermoplastics can be recycled by collecting, sorting, melting, and re-moulding them into new products. [1] This reduces the volume of plastic waste sent to landfill and conserves the crude oil from which the polymers are originally derived, lowering the demand for raw materials and reducing the environmental impact of extraction. [1]
Alternatively, if thermoplastics are sent to landfill rather than recycled, they are not biodegradable and persist in the environment for hundreds of years, occupying landfill space and potentially breaking into microplastics that harm wildlife and ecosystems.
Question 7 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 8 Report
Fig. 7 shows an injection moulding machine used to produce polymer components in large quantities. The polymer has been chosen for its specific properties including its ability to be formed into shape. Modern manufacturing processes allow polymers to be produced in large quantities efficiently. The choice of polymer depends on the required properties of the finished product.
It is held in place. The sides are smooth.
(a) Name the part labelled A in Fig. 7. [1]
(b) Describe the function of the heated barrel and Archimedean screw in the injection moulding process. [2]
(c) Give two advantages of injection moulding for manufacturing polymer products in large quantities. [2]
[Total: 3 marks]
(a) The part labelled A is the hopper. [1] The hopper is a funnel-shaped container mounted at one end of the injection moulding machine. Its purpose is to hold and feed the raw polymer granules (or pellets) into the heated barrel by gravity. Without the hopper, there would be no controlled supply of material entering the system.
(b) The heated barrel and Archimedean screw perform two essential functions in injection moulding:
- The heated barrel surrounds the polymer granules with heat as they travel along its length, melting them from a solid granular form into a viscous molten state. [1] The barrel contains heating elements (electric band heaters) that raise the temperature sufficiently to soften the specific thermoplastic being processed.
- The Archimedean screw (also called the reciprocating screw) rotates inside the barrel, pushing the molten polymer forward along the barrel and forcing it under high pressure into the mould cavity. [1] The screw action also contributes to mixing and even heating of the polymer, ensuring a uniform melt before injection.
(c) Two advantages of injection moulding for manufacturing polymer products in large quantities:
- High production rate with fast cycle times, making it economical for mass production. [1] Each cycle (injection, cooling, ejection) can take only seconds to minutes, so thousands of identical components can be produced per day.
- Very consistent and identical products with high dimensional accuracy and good surface finish. [1] Because the same precision-machined mould is used repeatedly, every part produced is virtually identical, reducing quality-control costs and rejection rates.
Answer Details
(a) The part labelled A is the hopper. [1] The hopper is a funnel-shaped container mounted at one end of the injection moulding machine. Its purpose is to hold and feed the raw polymer granules (or pellets) into the heated barrel by gravity. Without the hopper, there would be no controlled supply of material entering the system.
(b) The heated barrel and Archimedean screw perform two essential functions in injection moulding:
- The heated barrel surrounds the polymer granules with heat as they travel along its length, melting them from a solid granular form into a viscous molten state. [1] The barrel contains heating elements (electric band heaters) that raise the temperature sufficiently to soften the specific thermoplastic being processed.
- The Archimedean screw (also called the reciprocating screw) rotates inside the barrel, pushing the molten polymer forward along the barrel and forcing it under high pressure into the mould cavity. [1] The screw action also contributes to mixing and even heating of the polymer, ensuring a uniform melt before injection.
(c) Two advantages of injection moulding for manufacturing polymer products in large quantities:
- High production rate with fast cycle times, making it economical for mass production. [1] Each cycle (injection, cooling, ejection) can take only seconds to minutes, so thousands of identical components can be produced per day.
- Very consistent and identical products with high dimensional accuracy and good surface finish. [1] Because the same precision-machined mould is used repeatedly, every part produced is virtually identical, reducing quality-control costs and rejection rates.
Question 9 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 10 Report
Fig. 18 shows a machine used to cut shapes from sheet metal in a factory. 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.
The parts are all the same size. The handle is round.
The plywood can be shaped using vacuum forming or filing. The product must comply with relevant safety standards for its intended market.
(a) Name the process shown in Fig. 18. [1]
(b) Give one advantage of using this process in a factory. [1]
(a) The process shown is press forming (also known as stamping or die cutting). [1]
In this process, a sheet of metal is placed between a punch (upper tool) and a die (lower tool). The press forces the punch downward with great force, cutting or shaping the metal to match the profile of the die cavity. The process is fast and produces clean, accurate shapes with consistent dimensions.
(b) One advantage of using this process in a factory: [1]
It is fast and efficient for producing large quantities of identical components. Once the die is set up, each pressing takes only seconds, making it highly cost-effective for mass production. The shapes produced are identical, accurate, and require little or no finishing, reducing waste compared with hand cutting.
Answer Details
(a) The process shown is press forming (also known as stamping or die cutting). [1]
In this process, a sheet of metal is placed between a punch (upper tool) and a die (lower tool). The press forces the punch downward with great force, cutting or shaping the metal to match the profile of the die cavity. The process is fast and produces clean, accurate shapes with consistent dimensions.
(b) One advantage of using this process in a factory: [1]
It is fast and efficient for producing large quantities of identical components. Once the die is set up, each pressing takes only seconds, making it highly cost-effective for mass production. The shapes produced are identical, accurate, and require little or no finishing, reducing waste compared with hand cutting.
Question 11 Report
Fig. 9 shows a cross-section through a piece of plywood. The timber has been selected for its working properties and appearance. Different types of timber have different characteristics that affect their suitability. The grain direction and moisture content affect how the timber can be worked.
It can hold a lot of weight.
The acrylic provides adequate lightweight nature while keeping the overall weight low. The dimensions of the product have been determined by the needs of the intended user.
(a) State what is meant by a manufactured board. [1]
(b) Explain why the grain direction of alternate layers (labelled A and B) runs at right angles to each other. [1]
(a) A manufactured board is a sheet material made by processing natural timber into thin veneers, fibres, or particles, which are then bonded together with adhesive under heat and pressure. [1] Unlike solid timber, manufactured boards are engineered products that combine natural wood in a processed form to achieve large, flat, dimensionally stable sheets.
(b) The grain direction of alternate layers (A and B) runs at right angles to each other to make the board equally strong in both directions. [1] In solid timber, the material is much stronger along the grain than across it. By alternating the grain direction of each veneer layer in plywood, the strength is balanced in both the length and width of the board. This cross-lamination also prevents the board from warping or splitting along one grain direction, because the tendency of one layer to shrink or expand is counteracted by the layer above and below it running perpendicular.
Answer Details
(a) A manufactured board is a sheet material made by processing natural timber into thin veneers, fibres, or particles, which are then bonded together with adhesive under heat and pressure. [1] Unlike solid timber, manufactured boards are engineered products that combine natural wood in a processed form to achieve large, flat, dimensionally stable sheets.
(b) The grain direction of alternate layers (A and B) runs at right angles to each other to make the board equally strong in both directions. [1] In solid timber, the material is much stronger along the grain than across it. By alternating the grain direction of each veneer layer in plywood, the strength is balanced in both the length and width of the board. This cross-lamination also prevents the board from warping or splitting along one grain direction, because the tendency of one layer to shrink or expand is counteracted by the layer above and below it running perpendicular.
Question 12 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 13 Report
Fig. 10 shows two methods of converting a log into usable timber planks. The timber has been selected for its working properties and appearance. Different types of timber have different characteristics that affect their suitability. The grain direction and moisture content affect how the timber can be worked.
The lid lifts up and down. The shape is good. The grip stops it from slipping.
The cast iron used gives the product good toughness and electrical conductivity. The designer considered sustainability and cost of materials when selecting materials.
(a) Name Method 1 and Method 2 of timber conversion shown in Fig. 10. [2]
(b) State one advantage of Method 2 over Method 1. [1]
(a) Naming the two methods of timber conversion:
- Method 1 is through-and-through sawing (also called plain sawing or slab sawing). [1] In this method, the log is cut into parallel planks with a series of straight cuts all running in the same direction across the full width of the log. This is the simplest and most economical method because it produces the least waste and the fastest cutting rate.
- Method 2 is quarter sawing. [1] In this method, the log is first divided into quarters, and each quarter is then sawn so that the cuts are roughly perpendicular to the annual growth rings. The radiating pattern of cuts shown in the diagram is characteristic of this approach.
(b) One advantage of Method 2 (quarter sawing) over Method 1 (through-and-through sawing):
Quarter-sawn timber is less likely to warp or distort during seasoning and in use. [1] Because the annual rings run more nearly perpendicular to the face of each board, the timber shrinks and expands more evenly, resulting in greater dimensional stability. Quarter sawing also produces a more attractive, even grain pattern on the face of the board.
Answer Details
(a) Naming the two methods of timber conversion:
- Method 1 is through-and-through sawing (also called plain sawing or slab sawing). [1] In this method, the log is cut into parallel planks with a series of straight cuts all running in the same direction across the full width of the log. This is the simplest and most economical method because it produces the least waste and the fastest cutting rate.
- Method 2 is quarter sawing. [1] In this method, the log is first divided into quarters, and each quarter is then sawn so that the cuts are roughly perpendicular to the annual growth rings. The radiating pattern of cuts shown in the diagram is characteristic of this approach.
(b) One advantage of Method 2 (quarter sawing) over Method 1 (through-and-through sawing):
Quarter-sawn timber is less likely to warp or distort during seasoning and in use. [1] Because the annual rings run more nearly perpendicular to the face of each board, the timber shrinks and expands more evenly, resulting in greater dimensional stability. Quarter sawing also produces a more attractive, even grain pattern on the face of the board.
