Fig 4 shows
a metal can and a plastic bottle. Both are used to contain soft drinks.
a suitable material for the production of the metal can.
in detail, with the aid of diagrams, the process by which the can would
(b)(i) Name a suitable material for the production of the body of the
in detail, with the aid of diagrams, the process by which the body of
the bottle would be produced.
(c) Assess the suitability of these materials in meeting the requirements
(i) the manufacturer,
(ii) the retailer,
product currently mass produced from a plastics material which was previously
manufactured from metal.
why you think the change in use of materials has taken place.
how the product was manufactured from the two separate materials. How
influential is the use of modern technology ?
Fig. 5 shows
a brake-lever assembly from a mountain bike.
(a) List eight
design requirements of this type of brake-lever assembly.
(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.
(c) Describe how the metal part of the brake lever assembly could be manufactured.
(d) Explain, with reference to two components, why designers of cycles
are making greater use of plastics materials.
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
(i) sketch the product and identify the materials used; 
(ii) list four important design requirements of the product; 
(iii) explain how the specific qualities of the two materials used combine
to give a product with superior qualities.
(b) Select one of the products and describe how it could be volume produced
of volume-produced furniture are increasingly using manufactured boards.
with the aid of diagrams, four types of manufactured board used in the
production of furniture.
(b) State three advantages and three disadvantages of manufactured board
compared with solid timber.
(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.
(d) Modern, fitted kitchen-units are increasingly using combinations of
solid timber and manufactured boards in their construction.
to specific examples, show how manufacturers make use of the particular
properties of each material.
Fig. 3 shows
a hair dryer.
(i) a suitable thermosetting plastic that could be used to produce the
(ii) a suitable thermoplastic that could be used to produce the body.
(b) Explain how one property of each of the materials selected in part
(a) contributes to the success of the product.
(c) Describe, with the aid of diagrams, the process used to produce:
(i) the switch in a thermosetting material;
(ii) the body in a thermoplastic material.
(d) Discuss four important features in the design of one of the moulds
used in the above.
Fig. 4 shows
a chair made of wood with an upholstered seat.
using appropriate sketches a suitable process by which the curved wooden
part of the back could be produced in a school workshop.
(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.
(c) A surface finish is to be applied to the wooden frame.
(i) Name a suitable finish for this particular situation and justify your
(ii) Describe in detail the application of your chosen surface finish.
used in the manufacture of products are periodically changed.
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;
(ii) describe two changes which have been made to the product to enable
it to be manufactured in plastic.
(b) With reference to examples, discuss two advantages and two limitations
of using plastic materials instead of metals in the manufacture of an
(c) Some manufactured products combine the best properties of plastics
(i) Sketch and describe such a product.
(ii) Explain how the properties of each material have been combined to
produce a successful product.
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);
(ii) With the aid of diagrams, describe a suitable process for joining
the handle to the tankard in fig. 5(ii).
(b) Assess the effectiveness of the joining techniques for each example
in terms of their strength, ease of use and quality of finish.