Money Mac £15 Ciaran £10 Chan £6 Alex £8 Will £3 Toby £12 David - £12 Logan £10 Evie £8 Stevie – paid Luke morton - £6 Luke Murray - £10 Ben - £5 Connor £15 Jack £ 12 Charlie £14 Corey - £8

EXAM CONDITIONS – 30 minutes In the space below develop a design for product for children aged between 3 and 6 based on one of the natural structures images you can see here. You should show enough detail for somebody else to be able to make it. The marks are for: (15 marks) How well your design reflects nature. Originality of ideas. Materials and construction techniques. How well you communicate your design. Include 2 different views or a magnified view of a smaller part of your idea. Annotate to explain your idea in as much detail as possible.

Which material is your product made from? How was it made? Prohibited words Wood plastic metal

Colours of common hardwoods: Design & Technology GCSE Product Design Wood Timber is the general name for wood materials. There are main types of timber, Hardwoods, Softwoods. These are not descriptions of the woods, they just describe the type of tree it comes from. Hardwoods – deciduous or broad-leafed trees Most hardwood trees are broadleaved and deciduous, meaning they shed their leaves annually. They tend to grow in warmer climates and are generally slower growing which tends to make them harder. They can take around a hundred year to mature making them more expensive than softwoods. Colours of common hardwoods: Mahogany - reddish brown Elm - light reddish brown Beech - creamy Oak - rich light brown Softwoods – evergreen trees Most softwood trees are coniferous. They typically have thin needle like leaves and are evergreen. They grow in colder climates and are fast growing, mostly reaching maturity in around 30 years. This makes them easier to replace with new trees , so they are usually cheaper than hardwoods. They are normally softer and easier to machine than hardwoods. There are several types of softwood commonly used, but they are all generally the same colour, pale yellow with brown streaks. Scots pine is fairly strong but knotty and is used for general building work. Parana pine is hard and usually knot free making it harder and more expensive. It is usually used for interior joinery.

Design & Technology GCSE Product Design Plastics Most plastics are produced by industry using water, oil (or coal or gas), are and salt. There are two families of plastics – Thermoplastics and Thermosetting Plastics. Thermoplastics – recyclable and bendy Thermoplastics are recyclable. They don’t resist heat very well and thus can be melted down and re-used. Thermoplastics are easily formed into shapes under moderate heat. A moulded shape can be reheated and softened without changing it’s properties. They can return to their original shape on reheating, this is known as plastic memory. Some examples of thermoplastics are Acrylic, Polystyrene, polythene, polypropylene and ABS. Thermosetting plastics – Non-recyclable and usually rigid These types of plastic are non-recyclable. When formed they undergo a change in chemical properties, this creates strong links or cross chains in their structure. This chemical change means that once set they are permanently formed and cannot be reshaped on heating. Because they do not soften on heating they can be used in situations where temperatures reach in excess of 400 degrees. Some examples of thermosetting plastics are, melamine-formaldehyde, polyester resin, epoxy resin and urea formaldehyde. Plastics come in a lot of different forms Plastics can be bought in many different forms – from powder, granules, pellets and liquids for processing into finished products, through to films, sheets, rods, tubes and extruded mouldings. Plastics do not need any protective finishes due to high resistance to corrosion and decay. Plastics can be painted or polished for an alternative finish, but this is purely for aesthetic reasons.

Ferrous metals contain Iron Some metals are pure and others are (alloys) mixtures of different metals. Both can be classified into two basic groups- Ferrous and Non-Ferrous. Metal Properties Uses Mild Steel Quite strong and cheap but rusts easily and can’t be hardened or tempered. Car Bodies, screws, nuts 7 bolts High-Carbon Steel Harder than mild steel and can be hardened and tempered. Difficult to work and rusts. Drills, files, chisels and saws Stainless Steel Hard and won’t rust like most ferrous metals, is more expensive as a result Medical equipment, sinks, cutlery, kitchen appliances Ferrous metals contain Iron Ferrous metals consist mostly of iron and small quantities of other elements and minerals. Ferrous metals are prone to rusting if exposed to moisture and can be picked up by a magnet. Both these properties are due to the iron. Metal Properties Uses Aluminium Lightweight and corrosion resistant. Expensive and not nearly as strong as steel. Aeroplanes, cars, ladders Brass Quite strong, corrosion resistant, malleable, ductile and looks good. Door furniture, electrical parts Copper Relatively soft, malleable and ductile and a very good conductor of electricity. Wires & piping Non-Ferrous metals don’t contain Iron Non-Ferrous metals are metals that do not contain Iron at all. These metals therefore do not rust in the same way when exposed to moisture and are not attracted to magnets.

The increased amount of Carbon will result in; Remember Iron Iron (Ferrite) is converted from its Ore by heating. The resulting impurities (Slag) are removed from the furnace leaving a soft greyish metal once it has cooled. Iron is rarely used without combining it with carbon, thus giving it a greater strength. The result in this combination is steel. Steel A mixture of Iron and Carbon. The amount of Carbon present in the material determines the materials initial strength. Alloying with other Metals enables specific properties to be enhanced. I.e. Toughness and resistance to corrosion. Carbon Carbon is an element found in a range of materials. Organic Materials such as Coal and diamond are made up purely of Carbon. The amount of carbon in Steel has the effect of increasing strength and hardness, however added carbon can also cause brittleness to the material. Iron & Carbon Iron is generally soft and ductile, which does not make it very commercially useful. When Carbon is added (a very hard, brittle element) and mixed with Iron the characteristics (properties) change and therefore the resulting material can be used for specific properties. The increased amount of Carbon will result in; The material becomes harder Toughness reduces, can become brittle High Carbon Steel & Medium Carbon Steel can be heat treated to increase strength & Hardness.

Complete the tables on these slides. An example is given for you. Finishing techniques you could use are: Self finish applied in mould Hand painted Wax coating applied Glazed Varnish dip coated Transfer image applied Embossed Zinc plated Piped spray painted Stain resistance coating applied Oiled Browned using high temperature Screen printed Product Material Source of material Renewable or non-renewable Finish applied Aluminium Bauxite Ore Non-Renewable Screen printed

Complete the tables on these slides. An example is given for you. Finishing techniques you could use are: Self finish applied in mould Hand painted Wax coating applied Glazed Transfer image applied Embossed Zinc plated Piped Stain resistance coating applied Oiled Browned using high temperature Screen printed Product Material Source of material Renewable or non-renewable Finish applied

Complete the tables on these slides. An example is given for you. Finishing techniques you could use are: Self finish applied in mould Hand painted Wax coating applied Glazed etched Transfer image applied Embossed Zinc plated Piped Offset lithography Stain resistance coating applied Oiled Browned using high temperature Screen printed Product Material Source of material Renewable or non-renewable Finish applied

Complete the tables on these slides. An example is given for you. Finishing techniques you could use are: Self finish applied in mould Hand painted Wax coating applied Glazed etched Transfer image applied Embossed Zinc plated Piped Offset lithography Stain resistance coating applied Oiled Browned using high temperature Screen printed Product Material Source of material Renewable or non-renewable Finish applied

Name a product where you would use each of these wood joints. Task 1. 25 minutes From Core Programs Open CD ROM player and focus on wood joints. Make sketches and notes of the following joints: Rebate Lap Dowell Mitre Finger Through and stopped Mortise and tenon Corner Bridle Name a product where you would use each of these wood joints.

Task 2. 25 minutes From Core Programs Open CD ROM player and focus on plastics. Make sketches and notes of the following : Injection moulding Blow moulding Vacuum forming Rotational moulding Extrusion Name a product that would be manufactured using each of these processes.

Thermoplastic so can be moulded hygienic Polypropylene flexible Thermoplastic so can be moulded hygienic Available in a range of colours. It can be recycled Injection moulding PET ,PP, HIPS Hopper, granules Heated screw thread Nozzle 2 part mould Cool Ejector pins

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Are the following materials renewable or non renewable? Question Are the following materials renewable or non renewable? Mild steel, polyester, porcelain Answer Non – renewable. They all come from finite sources return

What is the name given to plastic materials which soften with heat? Question What is the name given to plastic materials which soften with heat? Answer Thermoplastics return

Name the two materials this famous chair is made from Question Name the two materials this famous chair is made from Answer Polypropylene seat, mild steel legs (which have been powder coated) return

What do the following materials have in common? Question What do the following materials have in common? Cartridge paper, MDF Answer All made from wood pulp return

Which of these materials is the odd one out and why? Question Which of these materials is the odd one out and why? Brass, pewter, copper. Answer Copper, the other two are alloys return

Why is mahogany regarded as environmentally unfriendly? Question Why is mahogany regarded as environmentally unfriendly? Answer Taken from rain forests which are destroyed in the process. return

What do the following materials have in common? Question What do the following materials have in common? Plywood, MDF, blockboard, chipboard Answer All manufactured timber boards return

Where do renewable materials come from? Question Where do renewable materials come from? Answer Plants or animals (can be grown) return

Where do non-renewable materials come from? Question Where do non-renewable materials come from? Answer They are dug out of the earth – oil, ores, clays etc. or come from resources which are being destroyed such as rainforests. return

Why are standard components often used on products? Question Why are standard components often used on products? Answer Cheaper to purchase from specialist manufacturer, easier to maintain return

Name three common hardwoods Question Name three common hardwoods Answer Ash, Beech, Birch, Mahogany, Oak, Teak, Jelutong……. return

Name three natural fibres Question Name three natural fibres Answer Wool, cotton, silk, linen, mohair, cashmere…. return