1. GCSE Resistant Materials Revision Booklet Assessment of Understanding MarchAprilMay 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. Heat treatments for Metal 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 CAD/CAM Name: Target grade: Focus Group: After School Revision Sessions ?

2. Assessment of Understanding MarchAprilMay Tech nolog y EPOS, Email, Videconferencing 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 od 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! Exam Date: Monday 8 th June PM

3. How to Revise…??? Doodle it ! Sing it ! Kinesthetic Learner: You will find it easier to be doing something whist revising, whether 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. 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. 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 tunes 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. DO it!

4. You need to talk the talk if your going to walk the walk! Exam Talk 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 MeaningHow it might be used in the exam Criteria Develop Manufacture Requirement Design Brief Creativity Construction Design Features Dimension Jig / former Maintenance

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

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

7. HazardPrecaution/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. HazardPrecaution/Safeguard HazardPrecaution/Safeguard Pillar DrillFret 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. HazardPrecaution/Safeguard

8. 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

9. Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use: Tool Name: Use:

10. 10 You are advised to spend about 10 minutes on this question. (a) 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) (b)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) SignMeaningExample ……………………………… …………………………… ……… ……………………………… ……………………………… ………

11. Picture No. Name of toolMaterialProcess 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) 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 toolMaterialProcess

12. Sketch and NameMaterialsProcess 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) 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

13. Materials: Woods, Plastics and Metals 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 Pg 15 and 23, 24. 79

14. Composite Materials Types of Metals Smart Materials

15. PropertyMeaningImage DUCTILITY MALLEABILITY HARDNESS TOUGHNESS ELASTICITY Strength PropertyMeaningImage TENSION COMPRESSION SHEAR Methods of describing the physical properties of materials. – Define the terms used to describe materials Pg 21 and 25 Describe Plasticity : Plasticity is...... Describe Durability: Physical Properties of Materials

16. 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 ………………………………………………………………………………..…………........ …………………………………………………………………………………...……………..……… ………………………………………………………………………………….…....… Test yourself:

17. 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: Finishing Materials Pg 76, 79

18. 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. 16 Kitchen Stool Toy Digger Material…………………………………… (2 marks) Reason………………………………………………………………… …………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Material…………………………………… (2 marks) Reason………………………………………………………………… …………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Material…………………………………… (2 marks) Reason………………………………………………………………… …………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Material…………………………………… (2 marks) Reason………………………………………………………………… …………………………………………………...…. (1 mark) Original source of the material …………………………………………….. (1 mark) Tennis Racket Food storage containers

19. Category Plastic (polymer)ThermoplasticThermosetting plastic Acrylic (PMMA) ✓ Urea formaldehyde (UF) Polyvinyl chloride (PVC) Polypropylene (PP) Polyethylene terephthalate (PET) Melamine formaldehyde (MF) 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. (Total 5 marks) Material....................................................................................................................... (1 mark) Reason............................................................................................................................................................................................................................................................. (1 mark) Original source of the material...................................................................................................................................... (1 mark) 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.

20. 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...................................................................................................................................... (4) (Total 8 marks)

21. MaterialPropertyUse Shape memory alloys (SMA) ‘Nitinol’ This metal will return to its original shape when heat is applied to it. Spectacle frames Thermochromatic plastic/paint....................................................... (2 marks)....................................................... (1 mark) Carbon fibre....................................................... (2 marks)....................................................... (1 mark) Reactive Glass’....................................................... (2 marks)....................................................... (1 mark) Carbon Nano-tubes....................................................... (2 marks)....................................................... (1 mark) This question is about smart and modern materials. Complete the table below. The first one has been done for you. (Total 12 marks)

22. 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: Joining MaterialsAdhesiveProperties / H&S Wood to wood Wood to plastic Plastic to plastic Metal to plastic Metal to Metal Wood to metal Pg 72 to 75

23. Describe how you would harden steel. ……………………………………………………….. …… ………………………………………………………..…… …………………..…………........................................... Describe how you would temper steel. ……………………………………………………….. …… ………………………………………………………..…… …………………..…………........................................... How is annealing Aluminium different to annealing Copper. ……………………………………………………….. …… ………………………………………………………..…… …………………..…………........................................... Describe how you would case harden steel. ……………………………………………………….. …… ………………………………………………………..…… …………………..…………...........................................

24. Nails Screws Pg 64 to 68 Nuts and Bolts

25. Pg 69

26. Knock-Down Fittings Pg 68

27. 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)

28. DiagramDescription of ProcessExample of Products Press Moulding Vacuum Forming Blow Moulding Die Casting Injection Moulding Extrusion Forming Plastics Most plastics are formed using some kind of thermo (heat) forming process. Investigate the ones listed below: Pg 56 - 62

29. CAD/ CAM 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: Pg 106 to 109

30. 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) 4 Marks Stage 3: Show how the base could be joined to the stem 4 Marks Stage 2: Cutting and shaping or CAM (Computer aided manufacture) 4 Marks Stage 4: Show how the wires could be secured to the back of the switch 4 Marks

31. 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 joiningStage 4: Producing the ‘spice jar’ text Stage 2: Cutting and shaping or CAM (Computer aided manufacture) 4 Marks

32. Industrial Practice What you need to know… Scale of production (Batch, Mass, One-off, Continuous flow) Manufacturing Processes CAD/CAM Mass Production Batch Production Continuous Production Pg 46 to 49

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

34. 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)

35. 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)

36. 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)

37. 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) 17 ComponentMaintenance Operation ………………………………… (1 mark) ………………………………… ………………………………… ……………………..………… ………………………………… (1 mark) ………………………………… ………………………………… ……………………..………… ………………………………… (1 mark) ………………………………… ………………………………… ……………………..………… (2 marks)

38. Type of ICTApplication, advantages/disadvantages Email Email for marketing and sales EPOS EPOS in manufacturing Bluetooth Videconferencing Pg 103 to 105

39. Sustainability in Design What you need to know… 4 R’s Ergonomics and anthropometric data Social, Moral, Cultural and Economic considerations when making and designing products Join up each of the 4 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 4 R’s Ask whether we can sustain our current way of life and the way we design and make Take an existing product that’s become waste, and use the material or parts for another purpose, without reprocessing it When a product breaks down or doesn’t function properly, try to fix it Recover energy from waste through burning or recharging Reduce Reuse Recycle Recover Pg 112, 113 ____________ ____________ ____________

40. Social Issues Moral Issues Cultural issues

41. Pg 114 to 117 Evaluate the benefits of Wind Energy against Fossil fuels....................................................................................................................................... (Total 6 marks) Compare the advantages and disadvantages of Solar energy and energy produced through biomass....................................................................................................................................... (Total 6 marks) Define Global warming and how the Kyoto Protocol aimed to address the issue....................................................................................................................................... (Total 4 marks)

42. 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)

43. Evaluate the benefits of built in obsolescence to the manufacturer?...................................................................................................................................... (Total 6 marks) What are the impacts of offshore manufacturing on the UK?...................................................................................................................................... (Total 4 marks) What challenges exist for the designer when trying to respect different cultures?...................................................................................................................................... (Total 4 marks) Pg 120 to 121

44. 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.

45. 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) 4 The photograph shows a rechargeable razor. What are the disadvantages of having a rechargeable product of this type? ………………………………………………………………………………… (2 marks)

46. 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. What you need to know… Isometric Drawing Orthographic Drawing Exploded views Rendering Drawing Techniques Orthographic Projection Pg 138 to 143

47. 30 0 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. Isometric Drawing Task: Have a go at completing these 2 tutorials.

48. You should use this type of drawing to explain you 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

49. 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.

50. Isometric view Rendered view Exploded View