1. Year 11 Resistant Materials Seminar June 2015

2. The exam The exam is 1 hour and 30mins long Section A consists of multiple choice questions based on sustainability and design issues. Section B consists of questions based on technical aspects of working with materials, tools and equipment. As well as design questions requiring you to sketch and annotate. The quality of your written communication will be assessed in questions marked with an asterix * You will need to bring with you: sharp pencil, black pen, rubber and a ruler

3. The language used in the exam State, name OR give This requires a specific name of a tool, process, construction technique or material. A one or two word answer is fine. Example: Name a suitable material for the wooden chair THE ANSWER CANNOT BE HARDWOOD OR SOFT WOOD IT MUST BE SPECIFIC i.e. Oak or Beech Describe This requires you to give an idea of how something works. Example: Describe how the Ø60mm hole could be cut in the wooden back. Explain When this is used they require a detailed answer and will always carry at least two marks.

4. Discuss When you are asked to discuss something you need to give well reasoned points adding examples to show the examiner what you are thinking. There are usually six marks for this part of the question and these are split as follows: 3 marks for three relevant points 2 marks for the quality of your explanation 1 mark for a specific example to support your answer EXAMPLE: Discuss the impact that self assembly has had on the design of many household products. (6) The language used in the exam

5. Sustainability Section A You need to show that you know about The 6R’s: Reduce Reuse Recycle Rethink Repair Refuse The 5 issues: Social Issues Moral Issues Cultural Issues Environmental Issues Design Issues

6. Reuse 6 Rs Rethink Repair Refuse Reduce

7. Social, moral and legal issues - Considerations for the designer What does the designer of a new product have to consider? The 5 issues Cultural Moral Ethical Social Environmental

8. Social, moral and legal issues - Considerations for the designer What will it be made from? Where will it be made? Who will make it? Will it have a positive or negative impact on human kind. How long will it last? What will happen to it at the end of its useful life? Will it have fixable/replaceable parts? What methods will be used to produce it? C02 impact? How will it be distributed? Can it be recycled? Globalisation Will it be sold in other countries?

9. Section B There is a lot that could come up in this section but unfortunately we can’t go through everything. Industrial Production Quality Control CAD/CAM Materials Properties Finishes

10. Commercial Production Methods One-off - The production of a single product (prototype) Batch - The production of a series of identical products (usually between 2 and 1000) Mass Production or Repetitive Flow -The production of large quantities of products Continuous Flow - Constant production of products (24/7)

11. One-off Batch Mass Production Continuous Flow Which Production Method?

13. Just in time is a ‘pull’ system of production, so actual orders provide a signal for when a product should be manufactured. Demand-pull enables a firm to produce only what is required, in the correct quantity and at the correct time. Cadburys world is a JIT factory. Just In Time Production (JIT)

14. Quality Quality Control Checks To help with this process companies will check a certain number of the products. This is called inspection, and would generally include checks on; – Accuracy of sizes – Overall appearance, a visual check – Surface finish – The consistency, composition, and structure of the materials Describe what it means when this symbol is found on a product?

15. CAD/CAM CAD (computer aided design) -Use of 2D and 3D design software Example 2D Design, Solid Works CAM (computer aided manufacture) -Outputting jobs from a computer generated drawing to a machine. Example such as CNC lathes, milling machines, routers, and laser cutters

18. The drawings can be changed quickly by using the edit tool The product would be produced to a high degree of accuracy By using CAM each piece would be exactly the same shape and size which will improve consistency and quality.

19. Materials Go into the exam ready to give specific examples of materials and have an understanding of their properties. HardwoodOak Property – Hard, tough, open grained Non ferrous Aluminium Property – Light, soft malleable Thermosetting Melamine-formaldehyde plastic Property – Hard, strong and scratch resistant You need to have 2 or 3 examples of each type of material

20. Task Name 2: Hardwoods Softwoods Manufactured boards Ferrous metals Non Ferrous metals Thermosetting plastics Thermoplastic Could you state their properties too? Can you name two smart materials?

21. Smart Materials Smart materials react to temperature and light and appear to act intelligently Polymorph Thermochromic inks Hydromorphic polymer

22. How they will ask you about materials The exam will either ask you to name a material OR state why a material is suitable. State a suitable hardwood for a child’s toy? Give a reason why ………… is suitable for a child’s toy?

23. Properties OR Working Characteristics Hardness Toughness Brittle Elasticity Flexible Impact resistance Ductility Malleability Elasticity Toughness Flexible Brittle

24. PropertiesProperties continued Performance characteristics of different materials have to be considered when choosing what products should be made of, you need to know the definitions of the following properties; Hardness – resist cutting and indentations Toughness – withstand shocks such as hammering Strength = 4 types include the ability to withstand... Being pulled apart or stretched Crushed or compressed Twisted Sheared as a result of sideways force like scissors Elasticity – can be stretched and then return to original length Flexibility – bend but not break and return to original shape Ductility – can be stretched into wire Durable – can withstand bad weather conditions Malleability – can be hammered, pressed into a shape

25. Metals We think that this could be a big part of the exam

26. Plastic dip-coating Polythene is a common thermoplastic powder which is used for dip coating. Air is blown through the powder which makes it act like a liquid. Before dipping, the metal is pre heated to 180 degrees and it is then dipped in the fluidised powder and returned to the oven where it melts to form a smooth finish. It is used commercially for products such as dishwasher racks. Galvanising Galvanising involves dipping metal into a bath of molten zinc. The zinc provides a good corrosion resistant finish although it does not look that appealing. Anodising Anodising is a process used on aluminium to provide a hard- wearing corrosion-resistant finish. The anodising process involves electrolysis and uses acids and electric currents. Colour can be added to the anodising process to tint the aluminium. Anodising is the most common finishing process used on aluminium.

27. Wood Finish Details Example Product PaintsWater-based paints are not durable. Oil-based paints are tough, hard wearing and weatherproof. Acrylic paints are quick drying. VarnishesPolyurethane varnishes give clear, tough and hard-wearing finish = plastic coating that doesn’t go into wood. Can get them in quick-drying. ‘Yacht’ varnish provides waterproofing. StainsDo not protect wood. Used to enhance the look of wood by showing off grain or colouring it to look like different, more expensive wood or bright colour. Not easy to apply and can look patchy. WaxBeeswax is sustainable, natural finish for wood that leaves dull gloss shine. It is applied straight on bare wood after it has been sanded and sealed with oil. PolishingBuild up layers of clear polish, sanding between each coat, which enhances look of grain. Also used to seal wood before waxing.

28. Plastic Finishes Plastic is self finished. It just needs polishing.

29. Exam tips Read all of the questions first before you fill in the answers Underline key words in the questions Fill in all answers. If you are not sure then guess! Look at how many marks are available for each question Keep an eye on the time Always annotate your designs Do your best