QUESTION 1

Fig.4

Fig 4 shows a metal can and a plastic bottle. Both are used to contain soft drinks.

(a)(i) Name a suitable material for the production of the metal can.

(ii) Describe in detail, with the aid of diagrams, the process by which the can would be produced.
[6]
(b)(i) Name a suitable material for the production of the body of the plastics bottle.

(ii) Describe in detail, with the aid of diagrams, the process by which the body of the bottle would be produced.
[6]
(c) Assess the suitability of these materials in meeting the requirements of:

(i) the manufacturer,

(ii) the retailer,

(iii) the consumer.
[8]

QUESTION 2

Choose a product currently mass produced from a plastics material which was previously manufactured from metal.

(a) Discuss why you think the change in use of materials has taken place.
[8]

(b) Describe how the product was manufactured from the two separate materials. How influential is the use of modern technology ?
[12]

QUESTION 3

Fig. 5

Fig. 5 shows a brake-lever assembly from a mountain bike.

(a) List eight design requirements of this type of brake-lever assembly.
[4]
(b) The components of the brake-lever assembly shown are made either from metal or plastics.
Discuss how the properties of each material contribute to the success of the product.
[6]
(c) Describe how the metal part of the brake lever assembly could be manufactured.
[4]
(d) Explain, with reference to two components, why designers of cycles are making greater use of plastics materials.
[6]

QUESTION 4

Select two products:

one in which two different materials are combined to improve durability
one in which two different materials are combined to improve strength

(a) For each product:
(i) sketch the product and identify the materials used; [6]
(ii) list four important design requirements of the product; [4]
(iii) explain how the specific qualities of the two materials used combine to give a product with superior qualities.
[4]
(b) Select one of the products and describe how it could be volume produced
[6]

QUESTION 5

Manufacturers of volume-produced furniture are increasingly using manufactured boards.

(a) Describe, with the aid of diagrams, four types of manufactured board used in the production of furniture.
[4]
(b) State three advantages and three disadvantages of manufactured board compared with solid timber.
[6]
(c) Select an example of a piece of furniture made, predominantly, of solid timber and show, by means of annotated drawings, how the designer has overcome the problems associated with shrinkage.
[4]
(d) Modern, fitted kitchen-units are increasingly using combinations of solid timber and manufactured boards in their construction.

With reference to specific examples, show how manufacturers make use of the particular properties of each material.
[6]

QUESTION 6

Fig. 3 shows a hair dryer.

Fig. 3
(a) identify:
(i) a suitable thermosetting plastic that could be used to produce the switch;
(ii) a suitable thermoplastic that could be used to produce the body.
[2]
(b) Explain how one property of each of the materials selected in part (a) contributes to the success of the product.
[4]
(c) Describe, with the aid of diagrams, the process used to produce:
(i) the switch in a thermosetting material;
[5]
(ii) the body in a thermoplastic material.
[5]
(d) Discuss four important features in the design of one of the moulds used in the above.
[4]

QUESTION 7

Fig. 4 shows a chair made of wood with an upholstered seat.

(a) Describe, using appropriate sketches a suitable process by which the curved wooden part of the back could be produced in a school workshop.
[8]
(b) If the curved wooden back was commercially manufactured, explain three aspects of quality control that would be important for identical parts to be produced.
[6]
(c) A surface finish is to be applied to the wooden frame.
(i) Name a suitable finish for this particular situation and justify your choice.
[3]
(ii) Describe in detail the application of your chosen surface finish.
[3]

QUESTION 8

The materials used in the manufacture of products are periodically changed.

(a) Select a Household Appliance which was previously made in metal but is now manufactured in plastic and:
(i) sketch your choice of product and identify the specific plastics used in its manufacture;
[4]
(ii) describe two changes which have been made to the product to enable it to be manufactured in plastic.
[4]
(b) With reference to examples, discuss two advantages and two limitations of using plastic materials instead of metals in the manufacture of an object.
[6]
(c) Some manufactured products combine the best properties of plastics and metals.
(i) Sketch and describe such a product.
[2]
(ii) Explain how the properties of each material have been combined to produce a successful product.
[4]

QUESTION 9

Fig. 5(i) shows a computer trolley with a square tubular steel frame and fig. 5(ii) shows a tankard made from gilding metal and brass.


(a) The examples in fig. 5(i) and fig. 5(ii) use thermal joining techniques in their manufacture.
(i) With the aid of diagrams, describe a suitable process for joining the metal parts of the frame in fig. 5(i);
[7]
(ii) With the aid of diagrams, describe a suitable process for joining the handle to the tankard in fig. 5(ii).
[7]
(b) Assess the effectiveness of the joining techniques for each example in terms of their strength, ease of use and quality of finish.
[6]


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