1. GCSE Resistant Materials
Revision Booklet
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
- REVISION GUIDE MR RICHARDS

2. 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.

3. 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!

4. 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

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
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.

7. 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

8. 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

9. 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. 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.

11. 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 ) MILLING MACHINE

12. 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

13. Composite Materials
Types of Metals
Smart Materials

14. 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

15. 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:

16. 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

17. 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

18. 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)

19. 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)

20. 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

21. Pg

22. Pg 45
Knock-Down Fittings

23. 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)

24. Description of Process
Forming Plastics Pg
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

25. 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

26. 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

27. 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

28. 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

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

30. 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)

31. 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)

32. 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)

33. 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?

34. CAMS
Pulleys
Gears

35. 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

36. 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)

37. 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
……………………..

38. 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

39. Social Issues
Moral Issues
Cultural issues

40. 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)

41. 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.

42. 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

43. 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.

44. 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

45. 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

46. 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.

47. Isometric view
Rendered view
Exploded View