GCSE Resistant Materials Revision Booklet D&T@BHBS Name: Target grade: Group: After School Revision Sessions: Tuesdays Revision Guide Page Assessment of Understanding March April May Tools, Equipment, Health and Safety PPE and risk assessments Safety signs and symbols Work shop tools and equipment Materials: Woods, Plastics and Metals Woods: Hard, Soft, Manufactured boards, working properties, uses. Metals: Names and types, working properties, uses. Plastics: Names and types, working properties, uses. Smart Materials: Names and types, working properties, uses. Sustainability of Materials Composite Materials Surface preparation and finishes. Construction Techniques Joints Marking out / jigs Fixtures and fittings Adhesives Forming Plastics Forming Metal Forming Wood CAD/CAM Industrial Practice Scale of production (Batch, Mass, One-off, JIT) Manufacturing Processes Systems and Control Basic mechanisms Basic electrical systems Quality control checks / maintenance D&T@BHBS - REVISION GUIDE 2015 - MR RICHARDS

Assessment of Understanding Revision Guide Page Assessment of Understanding March April May Sustainability of Design 6 R’s Ergonomics and anthropometric data Social, Moral, Cultural and Economic considerations when making and designing products Product Analysis Design specification Needs of the client/user (target market) in design “Market-pull” and “Technology-push” Drawing Techniques Isometric Drawing Orthographic Drawing Exploded views Where to start…?! Make a plan for revision: Set days and times at the side of each topic so you know you can fit it all in. Assess where you are in your understanding so you can focus your revision and track your progress Get organised; Treat yourself to new pens, note book, pencils, colours, post-it notes and flash cards – fail to prepare = prepare to fail! Attend your focus group after school revision sessions for personalised help and support.

How to Revise…??? Doodle it ! Sing it ! DO it! Visual learner: Make your revision more visual by using notes with colours and sketches to help you remember key bits of information: Use symbols next to key process or materials to help jog your memory.   Recopy notes in colours Use mind maps or spider diagrams on key topics.. Write facts and notes on index cards and stick every where! On the wall, fridge TV or even you bed. Use colour-coded markers or highlighters to pick out key bits of information. Use You tube, and Podcasts Doodle it ! This App has lots of good videos linked to all areas of Resistant Materials. Auditory learner: You may find it useful to listen to information rather than writing it down, or putting on some background music whilst revising. Try some of these techniques to help: Put facts to your favourite tuuunes and change the lyrics of songs to things you need to remember. Discuss information a with friend immediately after new learning to help it sink in – ring a friend or chat after class. Study/do homework with friend(s) via telephone or get together in a group. Repeat key phrases or thing you want to remember out loud lots of times to help it stick. Record your self reading your revision guide and listen to the recording on your phone/ipod. Use of different voices to study (like creating a script, or acting out a play) Use videos and pod casts. Sing it ! Kinesthetic Learner: You will find it easier to be doing something whist revising, weather that is moving about, taking notes or even exercising. You will find it easier if your notes are neat and organised with out crossed out bits or mistakes: Copy out key information over and over to make them neat and help you remember it. Make notes during lesson as an aid to concentration. Walk and talk – link in revision with exercising. Move hands or feet for rhythm emphasis while studying Make charts, grids, timelines, diagrams similar to visual learner strategies Trace key words with finger, marker or you hand whilst reading Re-enact situations while studying. Practice exam questions. Practice drawing skills. Physical activities linked to theory learning. DO it!

Exam Talk You need to talk the talk if your going to walk the walk! It is vital that you understand the language used in the exam so you can fully understand what it is you are being asked to do in each question. Below is a list of frequently used key terms. Fill in the table to show you understand what each one means and how they may be used in the exam: Key Word / Phrase Meaning How it might be used in the exam Criteria Develop Manufacture Requirement Design Brief Creativity Construction Design Features Dimension Jig / former Maintenance

Environmental Impact Source of Material Product life cycle Prototype Properties CAD CAM Techniques/ Processes Quality Control Ergonomics Anthropometric Tolerance Evaluate Describe Sustainability

Tools, Equipment and Health and Safety Pg 14-16, 26-31 What you need to know… PPE and risk assessments Safety signs and symbols Work shop tools and equipment PPE (Personal Protection Equipment) – Complete the table below to test you understanding of some different PPE Picture Name of safety equipment Why needed Process when it would be used 17.

Pillar Drill Fret Saw Belt Sander Vacuum Former & Strip Heater Health and safety investigation – Work in pairs to investigate each of the workshop machines below. For each you must fill in the table with potential hazards and precautions which could stop the hazards occurring. Pillar Drill Fret Saw Hazard Precaution/Safeguard Small pieces of material could ‘fly’ off towards the user. Position the guard and wear goggles. The chuck key could be left in the chuck. Hazard Precaution/Safeguard Belt Sander Vacuum Former & Strip Heater Hazard Precaution/Safeguard Hazard Precaution/Safeguard

Exam Style Question You are advised to spend about 5 minutes on this question. Name each of the following tools. Give details of a specific process where you would use each tool. Name……………………………………… (1 mark) Process………………………………………………………………… (1 mark) Name……………………………………… (1 mark) Process………………………………………………………………… (1 mark) Name……………………………………… (1 mark) Process………………………………………………………………… (1 mark) Name……………………………………… (1 mark) Process………………………………………………………………… (1 mark) Name……………………………………… (1 mark) Process………………………………………………………………… (1 mark) Name……………………………………… (1 mark) Process………………………………………………………………… (1 mark) 12

Dust mask ear defenders gauntlets apron goggles safety boots Exam Style Question You are advised to spend about 10 minutes on this question. Complete the sentences below by adding the key words from the following list Dust mask ear defenders gauntlets apron goggles safety boots When using a pillar drill to drill wood you should ensure you are wearing ……………………………………to protect your feet. ……………………………………to protect your eyes. ……………………………………to protect your breathing. ……………………………………to protect your hearing. (4 marks) Complete the table below by giving the meaning of each sign. State an example of a situation where you would see these signs. (6 x 1 mark) Sign Meaning Example …………………………………………………………… ……… ……………………………………………………………………… 10

10. Picture No. Name of tool Material Process Picture No. Name of tool Types of saw – Using the pictures below, put a number next to all of the saws (1-4) – complete the table below using information about each type of saw (20 Minutes) Picture No. Name of tool Material Process Tools for shaping materials – Using the pictures below, put a number next to all of the tools used for shaping materials (5-8) – complete the table below using information about each type of tool (20 Minutes) Picture No. Name of tool Material Process 10.

PALM SANDER JIGSAW ROUTER DRILL Types of power tool – On each desk is a different power tool – sketch a diagram of each in the first box with its name and complete the table below with specific and detailed information. (5 Minutes each) Sketch and Name Materials Process PALM SANDER JIGSAW ROUTER DRILL Machine presentation – Your task is to use PowerPoint to produce a presentation about workshop machines you must have the following information on each (60 Minutes) Name of machine Picture of machine Materials you can use with it Specific processes where the machine might be used Health and safety precautions required with the machine. The machines you should research are in red below – you MUST use your own words to describe each. 1) BELT SANDER 2) PILLAR DRILL 3) FRET SAW 4) WOOD LATHE 5) BUFFING MACHINE 6) MORTICER 7) POWER HACKSAW 8) MILLING MACHINE

Materials: Woods, Plastics and Metals Pg 34, 50, 68 What you need to know… Woods: Hard, Soft, Manufactured boards, working properties, uses. Metals: Names and types, working properties, uses. Plastics: Names and types, working properties, uses. Smart Materials: Names and types, working properties, uses. Sustainability of Materials Composite Materials Surface preparation and finishes. Types of Woods Types of Plastics

Composite Materials Types of Metals Smart Materials

Test yourself: Where does plastic come from and explain how it is made? …………………………………………………………………………………...……………..………………………………………………………………………………………….……… Explain what a thermoplastic is …………………………………………………………………………………..…………...... …………………………………………………………………………………...……………..……… ………………………………………………………………………………….……… Give 3 examples of thermoplastics and their typical use ………………………………………………………………………………..…………........ …………………………………………………………………………………...……………..……… ………………………………………………………………………………….…....… Explain what a thermosetting plastic is …………………………………………………………………………………..…………...... Give 3 examples of thermosetting plastics and their typical use Explain what a composite material is …………………………………………………………………………………..…………...... Give 3 examples of composite materials and their typical use

Finishing Materials Pg 47, 64, 76 You will be expected to know about how to finish different types of materials. Have a look at the relevant page in you revision guide and try to complete the task below:

Food storage containers Exam Style Question You are advised to spend about 15 minutes on this question. Study the products shown below. Name one suitable, specific material which has been used to make each product. Give one reason for each choice. Give the original source of the material. Kitchen Stool Material…………………………………… (2 marks) Reason……………………………………………………………………………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Toy Digger Material…………………………………… (2 marks) Reason……………………………………………………………………………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Food storage containers Material…………………………………… (2 marks) Reason……………………………………………………………………………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Tennis Racket Material…………………………………… (2 marks) Reason……………………………………………………………………………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) 16

Thermosetting plastic Exam Style Question This question is about materials. Complete the following table by matching each plastic (polymer) with its correct category. The first one has been done for you.     Category Plastic (polymer) Thermoplastic Thermosetting plastic Acrylic (PMMA) ✓ Urea formaldehyde (UF) Polyvinyl chloride (PVC) Polypropylene (PP) Polyethylene terephthalate (PET) Melamine formaldehyde (MF) (Total 5 marks) This question is about materials. Name one suitable, specific material which has been used to make the wooden chair. Give one reason for each choice. Give the original source of the material. Material ....................................................................................................................... (1 mark) Reason ....................................................................................................................... ...................................................................................................................................... Original source of the material

Exam Style Question The figures below show two types of orange juice bottles. Glass bottle     Plastic bottle Discuss the sustainability of each orange juice bottle. Glass bottle ...................................................................................................................................... (4) Plastic bottle (Total 8 marks)

Exam Style Question Material Property Use This question is about smart and modern materials. Complete the table below. The first one has been done for you.   Material Property Use Shape memory alloys (SMA) ‘Nitinol’ This metal will return to its original shape when heat is applied to it. Spectacle frames Thermochromatic plastic ....................................................... (2 marks) (1 mark) Carbon fibre ‘Polymorph’ Motion control gel ‘Smart grease’ (Total 12 marks)

Construction Techniques What you need to know… Joints Marking out / jigs Fixtures and fittings Adhesives Forming Plastics Forming Metal Forming Wood CAD/CAM Use the table below to help you make some notes on adhesives: Pg 46-47 Joining Materials Adhesive Properties / H&S Wood to wood Wood to plastic Plastic to plastic Metal to plastic Metal to Metal Wood to metal

Pg 43 -45

Pg 45 Knock-Down Fittings

Exam Style Question This question is about quality control. Study the drawing shown below. Explain how you would ensure that the three holes are accurately marked out on a piece of mild steel. ...................................................................................................................................... (Total 4 marks) This question is about design patents. Explain why it is important for designers to protect their ideas. ...................................................................................................................................... (Total 4 marks)

Description of Process Forming Plastics Pg 72 - 74 Most plastics are formed using some kind of thermo (heat) forming process. Investigate the ones listed below: Diagram Description of Process Example of Products Press Moulding Vacuum Forming Blow Moulding Die Casting Injection Moulding Extrusion

Advantages Disadvantages CAD/ CAM Pg 10 &11 What does CAD stand for?...................................................................... What does CAM stand for?...................................................................... Think about the advantages and disadvantages of CAD CAM, both for the designer and the client: Advantages Disadvantages

Exam Style Question Use clear notes and sketches to show how you would make a batch of ten in a school workshop. At each stage, name all the tools, equipment or software you would use. Stage 1: Marking out or CAD (Computer aided design) Stage 2: Cutting and shaping or CAM (Computer aided manufacture) 4 Marks 4 Marks Stage 3: Show how the base could be joined to the stem Stage 4: Show how the wires could be secured to the back of the switch 4 Marks 4 Marks

Exam Style Question 4 Marks 4 Marks 4 Marks 4 Marks This question is about making. Study the two designs for a spice jar holder shown below.                   A plastic or metal spice jar holder  A wooden spice jar holder Each of these spice jar holders could be made in a school workshop. Choose one of the spice jar holders and tick the appropriate box. You will be asked to show how you would make a batch of ten of your chosen spice jar holder in a school workshop.                                           Stage 1: Marking out or CAD (Computer aided design) Stage 3: Bending or joining Stage 4: Producing the ‘spice jar’ text Stage 2: Cutting and shaping or CAM (Computer aided manufacture) 4 Marks 4 Marks 4 Marks 4 Marks

Industrial Practice Pg 10, 11, 22-25 What you need to know… Scale of production (Batch, Mass, One-off, JIT) Manufacturing Processes CAD/CAM Mass Production Batch Production Continuous Production

One-off Production JIT Production What is a production line? ................................................................................................. .............................................................................................................................................

Exam Style Question This question is about quality control. Study the wooden block shown below. This wooden block is to be made in a school workshop. Produce a labelled drawing of a simple drilling jig that will allow 100 similar wooden blocks to be drilled. (Total 5 marks) Explain how the use of jigs, moulds and templates affect the manufacture of products. ...................................................................................................................................... (Total 8 marks)

Exam Style Question This question is about Computer-Aided Manufacture (CAM). Quality of Written Communication will be assessed in this question. A local manufacturing company makes ‘one off’ furniture by traditional methods. Write an article explaining the advantages and disadvantages of changing to CAM techniques. ...................................................................................................................................... (Total 10 marks)

Exam Style Question This question is about design and market influences. Quality of Written Communication will be tested in this question. Explain what is meant by the term market pull, technology push. Give examples of products to illustrate your answer. ...................................................................................................................................... (Total 8 marks) This question is about quality control Describe the various methods that a manufacturer would use to ensure that the consumer receives a high quality product. ...................................................................................................................................... (Total 4 marks)

Where would you see this shape used for a quality control check? Systems and Control Pg 23-27 84 -89 What you need to know… Basic mechanisms Basic electrical systems Quality control checks / maintenance Types of Movement: Name of Movement Related Products What is a quality control check? ………………………………………………………………………………………………………………………………………………………….. Why are they important? ……………………………………………………………………………………… ……………………………………………………………………………….. ……………………………………………………………………………..… Where would you see this shape used for a quality control check?

CAMS Pulleys Gears

Maintenance Operation Exam Style Question This question is about sustainability and maintenance. You are advised to spend about 15 minutes on this question. Study the mountain bike shown below. Identify three components found on the mountain bike that require maintenance. For each component, describe the maintenance operation that should be carried out. Explain why a designer should consider the importance of maintenance when designing products. ………………………………………………………………………………… …………………………………………………………………………………(8 marks) Component Maintenance Operation ………………………………… (1 mark) …………………………………………………………………………………………..………… (2 marks) (2 marks) (2 marks) 17

Exam Style Question (i) Name a mechanism that is used on a buggy. ............................................................................................................................. (1 mark) (ii)     Draw a labelled diagram of the mechanism you named in part (i) above. (4 marks) (iii)    Explain the function of your chosen mechanism. ............................................................................................................................. (Total 9 marks)

Exam Style Question This question is about electrical systems. Complete the table shown below. The first one has been done for you.                                                              (Total 7 marks) Component Schematic symbol Function Battery       It provides power to the circuit Switch ……………………… (1 mark) ............................................................ ............................................................................................................................. Lamp ........................................................................................................................................................................................... Motor .............................................................................................................................. ............................................ It converts electrical energy into sound (Total 4 marks) LED ……………………..

Ergonomics and anthropometric data Sustainability in Design Pg 18, 20 & 32 What you need to know… 6 R’s Ergonomics and anthropometric data Social, Moral, Cultural and Economic considerations when making and designing products Join up each of the 6 R’s to their definitions. In the blank boxes find an image example of each of them and write a sentence to explain hoe it links to the 6 R’s ____________________________________ Ask whether we can sustain our current way of life and the way we design and make Reduce When a product breaks down or doesn’t function properly, try to fix it ____________________________________ Reuse Take an existing product that’s become waste, and use the material or parts for another purpose, without reprocessing it ____________________________________ Recycle ____________________________________ Refuse Minimise the amount of material and energy you use Take an existing product that has become waste and reprocess the material to use in a new product ____________________________________ Repair ____________________________________ Don’t use a material or buy a product if you think you don’t need it or its unsuitable Rethink

Social Issues Moral Issues Cultural issues

Exam Style Question Discuss the environmental impact of using wood to manufacture products. ...................................................................................................................................... (Total 6 marks) Discuss the possible environmental impact of using metal to manufacture products. ...................................................................................................................................... (Total 7 marks) Discuss the possible environmental impact of using plastic to manufacture products. ...................................................................................................................................... (Total 7 marks)

Exam Style Question 24. This question is about sustainability. You are advised to spend about 10 minutes on this question. Quality of Written Communication will be assessed in your answer. Explain what is meant by the term ‘sustainability’. Give examples of products where sustainability has been considered during their design, manufacture or use. ………………………………………………………………………………… (10 marks) 10 24.

Exam Style Question Above there are four different designs of Razors, choose what you think is the most sustainable and give a reason to explain why? ………………………………………………………………………………… (2 marks) 2 The photograph shows a rechargeable razor. What are the advantages of having a rechargeable product of this type? ………………………………………………………………………………… (2 marks) The photograph shows a rechargeable razor. What are the disadvantages of having a rechargeable product of this type? ………………………………………………………………………………… (2 marks) 4

Orthographic Projection Drawing Techniques Pg 6-8 What you need to know… Isometric Drawing Orthographic Drawing Exploded views Rendering Orthographic Projection Orthographic projection or working drawings give clear information about a design showing it from different angles. Advantages: Everyone can understand the drawings. Measurements can be taken from the drawings. Views are accurate without any distortions.

Task: Have a go at completing these 2 tutorials. Isometric Drawing Task: Have a go at completing these 2 tutorials. Rules Always make sure you can see vertical lines when using the underlay. Only draw lines that are on top of underlay lines. Use a ruler. 300 300

You should use this type of drawing to explain your ideas especially for showing how you would join materials or how parts fit together… The examiner expects you to be able to explain how you designs will work and drawings like these are good way to do it. Exploded View Drawing

You must sketch the hand torch shown above in each of the drawing techniques below, use your revision guide to help you with each technique – 45 Minutes. Orthographic View (Front view, side view and plan view with dimensions) 6.

Isometric view Rendered view Exploded View