1. Year 11 Resistant Materials Seminar 7 th June 2013

2. The exam The exam is 1 hour and 15mins long Section A consists of three questions based on the technical aspects of working with materials, tools and equipment Section B consists of two questions on the design of products reflecting the wider aspects of sustainability and human use (ergonomics). At least one question will require you to design You will need to bring with you: sharp pencil, pen, rubber and 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. Industrial Production Pupils should understand: Basic commercial production methods The impact of new technologies including: –The application of CAD/CAM –Rapid prototyping and rapid manufacturing Globalisation

6. 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)

7. Which Production Method? One-off Batch Mass Production (repetitive flow) Continuous Flow

8. Rapid Prototyping From sketch to prototype in seconds 3D Printers The Spider Web Theory 3D printing video 10:13 How has rapid prototyping changed the manufacturing industry?

9. Globalisation -The modern way of producing, distributing, and consuming products -Britain grows its own apples, yet we import 60% of apples consumed in the UK come from overseas. Why?

11. 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. Just In Time Production (JIT)

12. Knock Down Fittings Knock Down fittings or KD joints are the components that fix together flat pack furniture/products. It is a temporary joining method. A company that sells Flat pack furniture is IKEA. Why is flat pack furniture cheap to make?

13. Task: List the advantages and disadvantages of flat pack furniture AdvantagesDisadvantages Gives the consumer a sense of achievement when it has been put together It may need specialist skills and equipment to put the product together It is cheaper to buy as the product has not been assembled and takes up less space whilst being transported Some people perceive this type of furniture as cheap This product is environmentally friendly as each item takes up less space. More furniture can be transported which cuts down traffic pollution. The quality of the furniture may not last as long.

14. Plastic corner block Scan fittings Cam lock You may need to name or draw a specific KD fitting

15. CAD/CAM Use of CAD packages in the school environment for producing drawings and 2D/3D images. On-screen modelling and manipulation of images. Appropriate use of text, database and graphics software in school and commercial situations Storing and sharing data electronically Application of CAD/CAM to the designing and making of models and prototypes Be familiar with Computer Numerical Control of machines (CNC) such as lathes, milling machines, routers, machining centres, laser cutters.

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

20. 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

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

22. Smart Materials Smart materials react to temperature and light and appear to act intelligently Polymorph Photochromic material Flexiply

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

24. Properties OR Working Characteristics Hardness Toughness Strength Elasticity Flexible Impact resistance Ductility Malleability Elasticity Hardness/Malleable Flexible

25. Material Properties 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

26. Wood Finishes – Protect or Decorate 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.

27. Quality It is important that you know that products need to be a certain quality to be sold commercially. Design – they have to be designed in such a way that they will perform the correct function Manufacture – they need to be made so they are both safe and don’t fall apart. – To do this the correct materials need to be chosen and the product must be made accurately Quality Control 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 – Surface finish – The consistency, composition, and structure of the materials

28. Easy marks to be gained!

29. Exam tips Read all of the questions first before you fill in the answers, especially what they are requiring, such as ‘describe’, ‘explain’, ‘discuss’. 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