1. Design and Manufacture

2. Exam The paper will have 60 marks allocated.
The paper will have two Sections.
Section 1 will represent approximately 40% of the total marks for the question paper. It will consist of a single question, based on a product, and will require extended and reasoned responses. The question will focus on the manufacturing issues associated with a product, namely materials, tools and processes.
Section 2 will represent approximately 60% of the total marks for the question paper. It will consist of five questions, based on a number of different products, and will require integration of knowledge and understanding from across the Course . The questions will mainly focus on design and issues relating to the design of products.

3. Section 1 – Topics which could be included are:
Materials – Name different types and advantages of using them.
Woods – Softwood, Hardwood and Man Made Boards
Metals – Ferrous and Non-Ferrous
Plastics – Thermoplastic and Thermosetting
Joining Materials – recognise joint and explain processes.
Wood – Mortise and Tenon, Housing, Halving, dowel etc.
Metal – Welding, riveting, nuts and bolts etc.
Plastic – Gluing
Shaping/Forming Materials
Wood – Wood Lathe; Preparation for turning, tools used etc.
- Wood Joints; Names of different types and how to mark out and cut
Metal – Metal Lathe; different process of lathe (e.g. facing, parallel turning, knurling)
- Metal processes; sand casting, die casting, thread cutting
Plastic – Vacuum forming, strip heater etc
Finishing Materials
Wood – Varnishing, painting, wax, staining etc.
Metal – Lacquer, Paint (gloss), plastic dip coat etc.
Plastic – Four stages in producing an edge on acrylic
Environmental Considerations
Reasons for choosing materials

4. Section 2 – Topics which could be included are:
Design – Explain in relation to products
Design Factors – Ergonomics, Aesthetics, Durability, Materials, Function, Cost, Safety etc.
Ergonomics – split into three areas of anthropometrics, psychology and physiology.
Product Evaluation – Evaluation techniques; user trials, questionnaire, observation, product comparison, market research etc.
Idea generation techniques
Modelling – different types and advantages.
Manual Modelling – Card, clay, foam, polystyrene, foam board etc.
Computer Aided Modelling – 3D Computer modelling, Rapid Prototyping
Flat pack furniture – knock down fittings
Materials and Processes
Choosing materials for products and giving reasons for the choice.
Naming suitable industrial manufacturing processes for products and explaining your choice.
Computer Aided Manufacture (CAM)
Advantages of computer CAM