1) Fig. 1 shows a design for a mass-produced A4 paper file holder, manufactured from 3 ply birch faced plywood.
(i) Give three reasons, other than cost, why birch faced plywood is a suitable material for the file holder. 
(ii) Describe, using annotated sketches, how plywood is constructed. 
(iii) Give two surface treatments for birch faced plywood which will retain its natural wood effect. 
(i) The holder is to be assembled without the use of any other components, such as screws or nails.
Name and describe, using annotated sketches, a suitable joint. 
(ii) Explain why Knock Down fittings would not be appropriate for use on the file holder. 
(c) Discuss the implications
of manufacturing the holder in plywood rather than plastic. 
2) Fig. 2(a) shows a design for a paper hole punch made form mild steel.
(i) Give two suitable finishes for the paper hole punch. 
(ii) Name the type of machine that would be used to machine the chamfer for large quantities of the mild steel punches. 
(iii) The punch shown in Fig. 2(b)
is made from mild steel.
(i) Describe, using annotated sketches, how the mild steel base would be manufactured by press forming. 
(ii) The company offers a two year
warranty (guarantee) on the hole punch.
(c) Discuss, in relation to economics the implications of not carrying out Quality Control checks during manufacture. 
3) Fig. 3 shows a design for a clear plastic measuring jug, aimed at the domestic market. It is to be produced by injection moulding.
(i) Give the specific name of two thermoplastics that would be suitable for the measuring jug. 
(ii) Select one of the specific materials and give two properties that make it suitable for this application. 
(iii) Give two reasons why plasticisers are added to plastics prior to moulding. 
(iv) Explain how the 3 mm thickness of the jug is achieved in injection moulding. 
(i) Describe, using annotated sketches, two manufacturing methods of including liquid level markings on the side of the jug. 
(ii) Give two surface features which would indicate that the jug has been produced by injection moulding. 
(c) Discuss the factors that have led to a greater acceptance of mass produced plastic products since their introduction in the 1950's. 
4) Fig. 4 shows a design for a soft drinks carton.
(a) The material for the soft drinks carton is to be made from bonding together thin layers of paperboard, polyethylene and aluminium.
(i) Give the name of this method of combing materials. 
(ii) State the purpose of each of the three layers. 
(iii) State the name of a suitable high quality colour printing process for the cartons, and give one reason for your choice. 
(iv) Explain why it is important that the raw material for the paperboard comes from 'well managed forests'. 
(b) The soft drinks product is to be fully protected from damage by using two forms of packaging. The first is the carton containing the drink and the second is an outer box into which the cartons are packed and transported to the shops.
Explain the difference between the specifications for the drink carton and the outer box. 
(c) Discuss the production implications
to be considered before a company would decide to launch a new soft drink
6) The window frames in many houses are made from timber or plastic.
(a) (i) Give two reasons why hardwood is a suitable material for window frames. 
(ii) Give two reasons why softwood might be chosen in preference to hardwood for window frames. 
(iii) State why it is particularly important that the end grain on timber window frames is treated with a weather resistant finish. 
(i) Describe, using annotated diagrams, a system that could be used for cutting and assembling 1000 identical hardwood window frames as shown in Fig. 1(a). The frames are made from timber of a performed section as shown in Fig.1(b). 
(ii) Identify four key aspects of dimensional accuracy that would need to be considered in manufacturing a batch of window frames. 
(c) Discuss the full implications for the window manufacturer of investing in automated cutting, profiling and assembly equipment. 
7) Fig. 2 shows a design for a chair.
The chair is manufactured from a mild steel tube frame with canvas seating.
(i) Give two advantages of using tubular steel section, rather than solid steel bar, for the manufacture of the chair frame. 
(ii) Give two possible surface treatments for the tubular steel to prevent corrosion. 
(iii) Describe, using annotated sketches, how two side frames would be produced by a small company in preparation for manufacturing 1000 chairs. 
(i) Describe, using annotated sketches, how tubing is produced by extrusion. 
(ii) Identify four pieces of anthropometric data that would be used in designing the chair. 
(c) By making reference to style, materials and construction techniques, discuss how they influence designers of chairs. 
8) Fig. 3(a) shows a design for a plastic container used for fabric conditioner.
(i) Give two reasons why polythene is widely used for containing liquid. 
(ii) State why polythene is not normally used for fizzy liquid containers. 
(i) Describe, using annotated sketches, how the integral handle on the milk container is produced. 
(ii) Draw, using annotated sketches, two surface features which show that a bottle has been blow moulded. 
(iii) Describe, using annotated sketches, how the screw thread on the neck of the container is produced. 
(c) The coding system for plastic identification is shown in Fig. 3(b).
(i) Explain why such an identification system has been developed. 
(ii) Discuss the environmental issues arising from the use of plastics in packaging. 
9) Fig. 4 shows a design for a carton for fresh fruit juice.
(i) Give two reasons why these types of cartons are rectangular in shape. 
(ii) Give two reasons why laminated paperboard is considered a suitable material for the carton. 
(i) Explain why manufacturers go to the expense of including a polythene opening tab with a foil seal, rather than the cheaper method of using a tearable corner. 
(ii) Produce an annotated flow chart which outlines the key stages in the production of large quantities of the completed carton in its flat packed form. 
(c) Discuss the relative merits
of different packaging materials used for fruit juice containers. 
10) Fig. 5 shows a design for a 3D pop-up greetings card.
(i) Give three properties of a suitable material from which to manufacture the greetings card. 
(ii) Give three reasons why the manufacturer may prefer to make the greetings card from a single piece of card. 
(b) Describe, using annotated sketches, how the design of the greetings card could be changed so that it can be cut from a single piece of card. 
All cut and fold lines to be clearly labelled.
No glue flaps to be used.
(c) High volume manufacturers of greetings cards have cut back on producing 3D pop-up cards in recent years.
Discuss the reasons which have led to this decision. 
11) Fig. 1(a) shows a design for a
mass-produced flat packed shelf unit, manufactured from veneered chipboard.