1. 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

2. 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.

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

4. 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.

5. 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.

6. 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.

7. 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.

8. 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

9. 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

10. 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

11. 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

12. Name a product where you would use each of these wood joints.
Task 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.

13. Task 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.

14. 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

15. 1 2 3 4 5 6 7 8 9 10 11 12

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

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

24. 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

25. 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

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

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