GCSE Resistant Material Theory Examination 2010 Past Paper Questions and Answers

Question 1 Section A. 20% Marked out of minutes Question 1. This question is about Product Analysis. It is worth 15 marks. The photograph shows a self assembly computer desk. Cost: £70 Material: laminated chipboard – Beech finish. Assembly: self assembly – Knock down fittings. Made in China (a) Before starting to design the computer desk a Design Specification was written. State with as much detail as you can, what you think was the most important design specification point for each of the following aspects. (i) The function or purpose of the computer desk. [2] (ii) The target market for the computer desk. [2] (iii) The safety considerations for the user of the computer desk. [2] (b) The computer desk is made from laminated chipboard. State two properties that make it the most suitable material for the computer desk. Property 1: ………………………………………………………………………………………………………………………………………….[1] Property 2: ………………………………………………………………………………………………………………………………………... [1] The purpose is to allow the user to efficiently use and store a home computer system. The computer desk would be for a user who has little space and needs to make efficient use of the space he/she has. 1. No sharp edges / corners / surfaces. 2. Strength of unit – to safely support weight of computer system. 3. Ergonomics – so product can be used safely over period of time. 4. Can't catch fingers in runners / drawers 5. Stable – can support weight of user resting on edges. 1. No sharp edges / corners / surfaces. 2. Strength of unit – to safely support weight of computer system. 3. Ergonomics – so product can be used safely over period of time. 4. Can't catch fingers in runners / drawers 5. Stable – can support weight of user resting on edges. 1. Available in range of finishes. 2. Easily cleaned. 3. Safe finish for use with children. 4. Is cheap to manufacture. 5. Can be mass produced. 6. Suitable for flat packing. 7. Renewable material. 1. Available in range of finishes. 2. Easily cleaned. 3. Safe finish for use with children. 4. Is cheap to manufacture. 5. Can be mass produced. 6. Suitable for flat packing. 7. Renewable material.

Question 1 (c) The computer desk was made using large scale production. Explain why this is the most suitable scale of production. [2] (d) The computer desk has to appeal to potential customers. (i) Describe the appeal of the product in terms of one of the following :[2] Fashions trends styles Circle your chosen criteria above and write your description below. (e) The bar chart below shows the sales of the computer desk. (i) State in which month exactly 7000 were sold. [1] (ii) The total number of sales in the first three months (Jan - March 07) was 6,000 (1, , ,000) and the average sales per month in this period was 2,000. Calculate the total number of sales in this next four months (April – July 07) and the average sales per month in this period. Show your calculations. [2] 1. Can produce a lot of products cheaply in big quantities, all identical. 2. Automated process; needs relatively few people to make. 3. Suitability for making flat packed 1. Can produce a lot of products cheaply in big quantities, all identical. 2. Automated process; needs relatively few people to make. 3. Suitability for making flat packed The product follows the current trends of designs that are simplistic, functional and available at low cost this would appeal to potential customers. May 07 5,000+7,000+9,000+10,000 = 31,000. Correct Total (31,000) 5,000+7,000+9,000+10,000 = 31,000. Correct Total (31,000) 31,000 / 4 = 7,750 Correct Average (7,750). 31,000 / 4 = 7,750 Correct Average (7,750).

Question 2 Question 2. This question is about the general issues of D&T. It is worth 10 marks. (a) (i) Name a resistant material technology (RMT) product that makes use of recycling. (ii) Describe how the product you named above makes use of recycling. [2] (iii) State one advantage of using recycling in a (RMT) product. [1] (b) (i) Designers of new products think about the SIX Rs. Underline the correct SIX Rs in the list that follows. Two have been done for you. [1] REMAKE RETHINK REUSE RECYCLE REDESIGN REPAIR REDUCE REFUSE (ii) Sustainable design is more than making the product from recycled materials or making it recyclable. Describe one other way in which sustainable products can be designed. [2] (c) Mass Production of products like the one shown below produces winners and losers. (i) State one of the winners of mass production of the product and give details of one reason for this. The winner : Reason : Office chair SEAT = Foam cover made from recycled textile material. CHAIR FRAME = Steel frame reclaimed from scrap steel. CHAIR WHEELS = Reclaimed rubber (from old car tyres) instead of plastic which is made from oil. SEAT = Foam cover made from recycled textile material. CHAIR FRAME = Steel frame reclaimed from scrap steel. CHAIR WHEELS = Reclaimed rubber (from old car tyres) instead of plastic which is made from oil. Slows 1. Recycling helps to limit the amount of metal, glass, paper and plastic that must be produced. This will end with less rubbish in landfills because it's being reused. 2. Slows the consuming of natural resources. high standard materialssaved 1. Products should be made to a high standard (quality) so they will last twice as long. In this way there will not be a need to replace it in the near future and materials will be saved. 2. Reducing energytype of energy 2. Reducing energy used to produce product. 3. Consider the type of energy used to produce the product. SOLAR, WIND, HYDROELECTRIC, TIDAL ENERGY RESOURCES. high standard materialssaved 1. Products should be made to a high standard (quality) so they will last twice as long. In this way there will not be a need to replace it in the near future and materials will be saved. 2. Reducing energytype of energy 2. Reducing energy used to produce product. 3. Consider the type of energy used to produce the product. SOLAR, WIND, HYDROELECTRIC, TIDAL ENERGY RESOURCES. The customer 1. Cheaper products as they are cheaper for manufacturers to produce. 2. More choice 1. Cheaper products as they are cheaper for manufacturers to produce. 2. More choice

Question 3 Question 3. This question is about the designers that you have studied. It is worth 10 marks. During your course you have studied the work of James Dyson and Ross Lovegrove. Select one of these designers and write a short essay in the space below to :- [10] Describe the designer’s work identifying its main features. Discuss the influence your chosen designer has had on other designers. Marks will be awarded for the content of the answer and the quality of written communication. James Dyson Started off as an Art teacher. Known for his Vacuum Cleaner designs, Wheelbarrow and Sea Truck. One of the first designers to use the ball as a form of wheel. Unique products in the market place today; bright coloured plastic a trade mark of his work. The cyclonic action leads to the bag less vacuum cleaner. Not afraid to develop an existing/traditional idea or product and look at it from a different angle. Took on the big corporate companies and won. Started in the U.K., set up his own business to start off.( Self-belief) The idea is as important as the technology. The concept of the ball as an idea used in the vacuum cleaner Dyson Ball. Still a designer today the Airblade his latest concept. James Dyson Started off as an Art teacher. Known for his Vacuum Cleaner designs, Wheelbarrow and Sea Truck. One of the first designers to use the ball as a form of wheel. Unique products in the market place today; bright coloured plastic a trade mark of his work. The cyclonic action leads to the bag less vacuum cleaner. Not afraid to develop an existing/traditional idea or product and look at it from a different angle. Took on the big corporate companies and won. Started in the U.K., set up his own business to start off.( Self-belief) The idea is as important as the technology. The concept of the ball as an idea used in the vacuum cleaner Dyson Ball. Still a designer today the Airblade his latest concept. Ross Lovegrove Industrial Design degree. Worked for Frog Design a company in West Germany; on products like Walkman’s and Apple Computers. Designs a range of product from chairs to domestic sinks. Objects have clean lines with interesting forms and shapes. Likes to experiment with materials. Worked with well known designers Stark, Nouvel, Dupont etc. Likes to use the shape and forms in nature as inspiration. Works as a freelance designer for companies such as Peugeot, Olympus major corporate companies.

Question 4 Question 4. This question is about the Design Process and how it is used. It is worth a total of 25 marks. PART A (a) (i) The design process uses a number of steps in a specific order. Select from the list below the correct activity to complete the table of the steps in the design process. [3] GENERATE IDEAS DEVELOP AND MODEL A SOLUTION RESEARCH THE TASK GIVE DETAILS OF THE FINAL SOLUTION LOOK AT EXISTING PRODUCTS APPLY A GOOD FINISH (b) (i) State one design aspect that a Design Specification in Resistant Materials will have statements about. [1] Aspect : (ii) A Plan for Making is more than a list of the making process. State one other consideration included in a plan and describe why it is important. [3] Consideration: GENERATE IDEAS DEVELOP AND MODEL A SOLUTION GIVE DETAILS OF THE FINAL SOLUTION Function, safety, aesthetics 1.Time to carry out aspects of making. 2. Time to complete task. 3. The order necessary to manufacture. 4. Availability of materials when required. 1.Time to carry out aspects of making. 2. Time to complete task. 3. The order necessary to manufacture. 4. Availability of materials when required.

Question 4 PART B (a) The music department in your school has asked you to design a portable tabletop stand to hold sheet music for use when playing instruments. Specification The design must: be portable, stable and suitable for tabletop use; hold an A4 music booklet; enable the music to be easily read when playing an instrument; be able to be stored in a small space. Draw one idea for the portable stand. Use notes to explain your idea. Sketch your solution on the opposite page. (i)Generate one idea so satisfy a specification. 8(ii) Specify suitable materials. 3 (iii) Specify details needed to satisfy specification. 3(iv) Quality of communication 4[18]

Question 4 Specification The design must: stored be portable, stable and suitable for tabletop use; hold an A4 music booklet; enable the music to be easily read when playing an instrument; be able to be stored in a small space.

Question 5 Section B 20% Marked out of minutes Question 5. This question is about commercial manufacturing processes. This question is worth a total of 10 marks. (a) Select the most appropriate process for each of the following products from the list below. [4] Vacuum forming Injection moulding Compression moulding Blow moulding (b) The diagram shows a bookcase manufactured from veneered chipboard (i) The bookcase is bought flat packed. Explain what you understand by this term. [2] (ii) Give three advantages to the furniture company of selling furniture flat packed. [3] Advantages: (c) The design for a table lamp is shown below. The designer has chosen to make the body of the lamp from layers of wood veneer. (i) Underline the correct manufacturing process used to make the body of the lamp out of wood veneer. [1] Blow moulding Laminating Strip heating Commercial process of producing products that are prepared ready to be assembled by the customer. 1.Reduced manufacturing costs / cheaper to produce. 2.Requires less workers. 3.Easy transportation. 4.Ease of storage in factory / store. 5.Automated manufacturing process. 6.Easier to manufacture and ship from abroad. 1.Reduced manufacturing costs / cheaper to produce. 2.Requires less workers. 3.Easy transportation. 4.Ease of storage in factory / store. 5.Automated manufacturing process. 6.Easier to manufacture and ship from abroad. Injection mouldingBlow moulding Vacuum formingCompression moulding

Question 6 Question 6. This question is about Materials and Components. It is worth a total of 15marks. (a) Complete the resistant materials table using the materials provided.[6] Urea formaldehyde Oak Steel AcrylicPine Aluminium (b) Complete the following sentence using the words provided: Ferrous Aluminium Stainless steel Alloy Brass Non Ferrous Use one word only once An ………… is a mixture of two or more metals. An example is ………. A …………………… metal is a metal that does not contain iron. An example is …………[4] (c) Complete the exact name for each of the holding devices shown below. [3] (d) Write the correct material alongside its description below. OakPineSteelAluminiumAcrylic Urea formaldehyde AlloyBrass Non Ferrous Aluminium GSash Machine Polystyrene Urea formaldehyde

Question 7 Question 7. This is about Tools, Equipment and Making. It is worth a total of 20 marks. (a)Select the correct machine from the list below to make each of the products shown. Woodworking lathe Metalworking lathe Strip heater Milling machine Vacuum former (b) Study the list of adhesives below and select the most appropriate for joining the following materials : PVA Pritt Stick Epoxy resin Tensol (i) Acrylic to Acrylic. (ii) Acrylic to Aluminium. (iii) Wood to Wood.[3] (c) The diagram shows a 5mm thick piece of steel marked out for drilling and shaping. (i) Name the tool used to mark the centre of the 50mm radius. [1] (ii) Name a tool used to mark out the 50mm radius curve. [1] (iii) Using notes and sketches, explain how you would remove the waste material and finish the radius. [4] Woodworking lathe Metalworking latheMilling machine Strip heater Tensol Epoxy resin PVA Centre punch. Dividers, scriber and template. 2.Use hacksaw a cut out the shape. 1. Secure the metal to a workbench using a vice. 3. Use a hand file to remove roughest edges. 4. Use a emery cloth to finish

Question 7 (d) Explain how you would accurately and safely drill the 10mm hole in the steel.[3] (e) The diagram shows a foot rail for a kitchen stool made from square section steel tube. [4] Use notes and sketches to show the main stages needed to make a permanent joint between these two pieces of square steel tube. 1.Centre punching hole. 2.Clamping metal in hand vice / with G Cramp. 3.Drilling a pilot hole. 4.Drill safely ; use goggles, guards, tie hair back, tuck in loose clothing etc Brazing The steel must first be cleaned using wire wool or emery cloth. A borax flux (powder) is brushed along the joint. Flux prevents oxidation taking place as this would prevent brazing being successful. The flame is slowly moved backwards and forwards along it. The joint will eventually become so hot that it becomes red in colour. A brazing rod (copper-zinc alloy) is then pushed gently against the joint and if the temperature is right the end of the rod will melt and begin to run along the joint. The rod is fed into the joint until a brazed joint is complete. The steel is allowed to cool slowly. If cooled quickly, such as quenching in water, the joint can crack or become distorted 12 34

Question 8 Question 8. This question is about ICT, CAD/CAM, Systems and Processes. It is worth a total of 15 marks. (a) The diagram for a ‘post-it’ note holder is shown below. The design is to be made from five separate pieces of 5mm Acrylic glued together. The five separate pieces must be produced from one sheet of Acrylic using CAD/CAM. Draw the pieces on the grid below, the dots are 10mm apart on the screen. (two have been done for you) [6]

Question 8 (b) The diagram shows a design for a computer disk holder made from one piece of 3mm Acrylic. (c) The diagram shows two pieces of steel that are held together using a countersunk machine screw. Use CAD to draw out the design. Use CAM to cut out the plastic. Wet and Dry the edges of the plastic. Bend the Acrylic on strip heater Clamp together and drill a tapping size hole. Drill a clearance hole in part A. Countersink part A. Tap the thread in part B. Screw parts A and B together.