Core theory - Textile based materials Answers 1. Which of the following is an example of a textile from an animal-based source? [1] ⬨ Lycra ⬨ Cotton ⬨ Polyester ⬧ Silk 2. What would be a suitable fabric construction for a pair of tights? Explain how the fabric construction can improve the performance of a product. [4] Knitted (1 mark). Look for responses relating to stretch (1 mark) and thermal properties (1 mark) with justification (1 mark). 3. Blended or mixed fabrics are used to combine the most desirable properties of two or more fibres. Polycotton, made from cotton and polyester, is used by many mass- market clothing manufacturers. What are the advantages and disadvantages of using polycotton in mass-produced apparel? [6] Polycotton is used in products where affordability, durability, easy-care, and functionality are a priority e.g. low-cost clothing, sportswear, workwear. Advantages: Polyester is cheaper and is more readily available than cotton fibres. Blending the materials together makes the fabric and end-product more affordable. As a polymer-based fabric, polyester is non-absorbent and quick-drying whereas cotton is breathable and absorbent. By blending the fabrics, you can create fabric that is both breathable and sweat-resistant. Cotton is soft and comfortable but creases easily, whereas polyester is very durable and crease resistant. Furthermore, cotton is prone to shrinking. Polycotton is comfortable and less likely to crease so a garment is easier to care for and
Transcript
Core theory - Textile based materials Answers1. Which of the following is an example of a textile from an animal-based source? [1]
⬨ Lycra
⬨ Cotton
⬨ Polyester
⬧ Silk
2. What would be a suitable fabric construction for a pair of tights?
Explain how the fabric construction can improve the performance of a product. [4]
Knitted (1 mark). Look for responses relating to stretch (1 mark) and thermal properties (1 mark) with justification (1 mark).
3. Blended or mixed fabrics are used to combine the most desirable properties of two or more fibres.
Polycotton, made from cotton and polyester, is used by many mass-market clothing manufacturers.
What are the advantages and disadvantages of using polycotton in mass-produced apparel? [6]
Polycotton is used in products where affordability, durability, easy-care, and functionality are a priority e.g. low-cost clothing, sportswear, workwear.
Advantages:
Polyester is cheaper and is more readily available than cotton fibres. Blending the materials together makes the fabric and end-product more affordable.
As a polymer-based fabric, polyester is non-absorbent and quick-drying whereas cotton is breathable and absorbent. By blending the fabrics, you can create fabric that is both breathable and sweat-resistant.
Cotton is soft and comfortable but creases easily, whereas polyester is very durable and crease resistant. Furthermore, cotton is prone to shrinking. Polycotton is comfortable and less likely to crease so a garment is easier to care for and will last longer.
Disadvantages:
Polycotton is not as soft as pure cotton so it can be less comfortable Polyester is an oil-based material which means polycotton is less sustainable than
pure cotton, which comes from a renewable source (the cotton plant).
4. Match the key terms to the definitions. [4]
Key term Definition
Woven Non-woven fabric made from brushed and compressed fibres.
KnittedFabrics made by interlocking yarns that run from top to bottom (the warp) and right to left (the weft). The fabric is made on a loom.
Felted One or more non-woven fabric that has been bonded, fused or stitched to another fabric.
Bonded Fabric made from a single interlocking yarn. Construction allows fabric to stretch.
Total 15 marks
Core thoery: Polymers Answers1. State the two categories of polymer? [2]
Thermosets (thermosetting plastics) and thermoplastics2. What type of plastic is most commonly used for disposable cups, food containers,
cheap toys, and school based vacuum forming? [1]
⬨ Expanded polystyrene
⬨ High Density Polyethylene
⬧ HIPS (High Impact Polystyrene)
⬨ Acrylic
HIPS is used to make all of the above because it is cheap, hard, and can be made impact resistant. Expanded polystyrene could be used for cups and containers.
3. Complete the following table by matching each plastic (polymer) with its correct category. The first two have been completed for you. [6]
Epoxy resin XAcrylic (PMMA) XPolyvinyl chloride (PVC) XPolyester resin XPolyethylene terephthalate (PET) XLow density polyethylene (LDPE) XUrea formaldehyde (UF) X
Polystyrene (PS) X
4. Urea formaldehyde is commonly used in the manufacture of electrical plugs and fittings.Give two properties of urea formaldehyde that make it suitable for these applications. [2]
Hardwearing material, rigid and stiff, good electrical insulator, good strength properties, good heat-resistant properties, does not distort with heat, durable, fire resistant, does not melt
. Bleach bottles are commonly manufactured from HDPE.
Give two properties of HDPE that make it suitable for this use. [1]
6. Give two reasons as to why PVC is the most widely used polymer in medical applications such as blood bags, tubes, surgical and examination gloves? [2]
PVC is safe, chemically stable, inert, extremely versatile and easily fabricated. It offers the flexibility necessary for applications such as blood bags and IV containers. Medical products made from PVC are usable inside the body, easy to sterilise and simple to assemble into products that do not crack or leak.
Note: PVC as a medically safe product is under tremendous scrutiny at the moment. Not all PVC types are deemed safe these days and research is constantly finding new evidence to support claims that there may be safer alternatives.
Total 14 marks
Core theory: Metals and alloys Answers
1. Which one of the following metals is the most effective conductor of electricity? [1]
⬨ Tin
⬨ Iron
⬧ Copper
⬨ Steel
2. From the list of common items:
(a) Name the metal and state if they are ferrous or non-ferrous metals [5]
(b) Match the characteristics to the item [5]
Metal Name Characteristics
AluminiumNon-ferrous
Hard and hard wearing, less ductile
CopperNon-ferrous
Soft, malleable, good conductor
Low carbon steelFerrous
Easily machined, formed or brazed. Ductile and tough.
Cast ironFerrous
LightweightDuctileGood strength to weight ratio
High carbon steelFerrous Hard, brittle
3. Metal naturally occurs in the crust of earth. In its natural state, what is the mixture of metal and rock known as? [1]
Ore
4. Name one method of extracting metal from the earth.
Electrolysis, chemical, reduction with carbon/smelting.
5. Name one element that is combined with iron to produce steel.
Carbon
6. Name one key difference between ferrous and non-ferrous metals. [1]
Magnetism, iron content, liable to rust.
7. Explain how the addition of carbon affects the properties of steel. [1]
Adding carbon to steel can increase its hardness.
8. Explain what is meant by:
(a) ductility [1]
Will stretch or be drawn without damage.
(b) malleability [1]
Will deform under compression, can be rolled or hammered into sheets.
Total 18 Marks
Core theory: Natural and manufactured timbers Answers1. Which one of the following is a type of wood from a coniferous tree? [1]
⬨ Beech
⬨ Ash
⬨ Oak
⬧ Larch
2. Give one common characteristic of hardwood trees. [1]
Deciduous / drop their leaves; flat leaved.
3. Give one advantage of using ash to make a set of cricket stumps. [1]
Tough; flexible; shock resistant.
4. (a) Suggest an appropriate type of wood for making a model aircraft. [1]
Balsa
(b) Give two reasons for your choice. [2]
Soft; easy to work/shape; lightweight.
5. An architect has designed a house that is entirely clad in larch.
State and justify one physical or working property of larch that make it suitable for exterior cladding. [2]
Award first mark for property, and a second mark for the justification.
It is tough; which makes it durable and weather well;Contains natural oils; which reduces absorbency / provides water resistance; Contrasting grain / finishes well; aesthetically pleasing;
6. A kitchen worktop has been made from melamine laminate covered chipboard. Evaluate the use of chipboard for a kitchen worktop. [4]
Advantages
Available in large board sizes; which reduces the number of joins;Tough; which enables it to absorb shock from everyday use;Relatively inexpensive; which reduces costsLamination easily applied; comes in a huge variety of colours and finishes
Disadvantages
Edges and corners can be brittle; prone to chipping;Unless laminated / if laminate cracks; absorbent / not very resistant to moisture;Dense; very heavy in large sheets;
Marks awarded as follows:
3 - 4 marks Award full marks for a high-level response with a justification of at least one advantage and one disadvantage of chipboard as a worktop material. Response well-structured with good use of appropriate design and technology terminology and showing a good grasp of grammar, punctuation and spelling.
1 - 2 marks One advantage or disadvantage well justified, or two advantages or disadvantages stated but not fully explained. Responses may indicate a limited understanding of the relevant properties of chipboard. Response poorly structured with little or no use of design and technology terminology and with several errors in grammar, punctuation and spelling.
0 marks Nothing worthy of credit.
Total 12 marks
Core theory: Papers and boards Answers
1. Which of the following is a unit of paper measurement? [1]
⬨ Milligram
⬧ Grams per square metre
⬨ Micron
⬨ Nanometre
2. Wood fibre is used to make paper pulp. (a) Name two alternative fibres that can be used? [2]
Answer may include but are not limited to: Straw; bamboo; sugar cane; flax; cotton; hemp;
(b) Give two reasons why wood fibres are most commonly used. [2]Produces a good quality pulp; is comparatively low cost compared to alternatives; is a sustainable source; is in plentiful volume for supply;
3. Name one common paper with high absorbency. [1]
Cartridge paper, tissue paper.
4. Describe the properties of one board that make it suitable for displaying artwork. [2]
Foam core / foamboard; Mountboard (1 mark for naming a suitable board)Lightweight, rigid, suitable for cutting, paper surface suitable for mounting images.
5. Study the packaging below. Considering the physical and working properties of the materials used, explain one reason why each type of paper and board has been utilised. [6]
Potential answers (1 mark per item)
Total 14 marks
100gsm brownpaper bagThis material is used because…It is easy to print on.Cost effective.Little bleaching required.Strong enough to hold lighter items.
Duplex board containerThis material is used because…The multi-ply card has a barrier coating to make it greaseproof.It is rigid enough to maintain its shape.It helps to insulate the product.By keeping the heat inside it stops customers burning their hands.
Carton board containerThis material is used because…It is hygienic and it protects the food product inside.It is easy to print on.It can be flat packed for easy storage.
Replaced polystyrene. Compostable or recyclable.
2-ply servietteThis material is used because…It is absorbent, lightweight and cheap.
150gsm paper bag with handleThis material is used because…It is made from a heavier weight paper than the other bag so it is stronger.It helps insulate the product.By keeping the heat inside it stops customers burning their hands.
Corrugated card cup sleeveThis material is used because…The corrugations help to insulate the product inside.The material helps to protect customers from burning their hands.
Core theory: Industry and enterprise Answers1. The automotive industry makes use of robotics in production line manufacturing.
(a) Describe two factors that make the production of cars suitable for automated assembly line manufacture.
Identical products are passed through the production line; making it easy to program robots to perform repetitive operations.
The process can be broken down into stages; each of which can be repeated.
Precision is required and must be maintained; robots are able to work consistently and indefinitely.
(b) The introduction of robotics and automation in industry has impacted the design of the workplace.
(i) Explain one way in which automation may affect the physical layout of a parts warehouse.
Answers may include:
Warehouse shelving may be taller if accessed by robots; requiring less floor area. Shelving may be closer together / wider apart; with precise robots / to allow for wheeled vehicles or turning areas.
(ii) Explain one way in which automation may have changed systems and procedures in picking and packing items from the warehouse.
Answers may include:
Fully automated picking and packing may replace manual workers altogether; which means there will be fewer workers / will be faster due to highly automated retrieval systems;
Final quality control procedures will need to happen before a fully automated picking and packing system is installed; to ensure that the system is functioning correctly.
Picking may require scanners to automatically update stock levels; stock counting / checking procedures may be done automatically, requiring only a final check.
Electronic systems may have replaced manual checking systems; which means greater levels of accuracy and continually updated stock levels tracked.
2. The invention of a new and emerging technology often requires significant investment for product development and advertising before it can become mainstream.
Explain one method a small organisation might employ to increase funding or awareness of their new product.
Answers may include:
Social media; enables mass marketing; for minimal costs; can attract a global market; viral advertising campaign.
Crowdfunding; to receive investment from a group of individuals rather than a single bank or capital investor
Total 10 marks
Core theory: Sustainability and the enviromnment Answers1. Energy sources can be categorised as either finite or non-finite.
(a) State what is meant by a finite resource.
A resource that is in limited supply.
(b) Give one example of a non-finite energy source.
(c) Explain one benefit to the environment of using non-finite energy resources.
Answers include:
Non-finite resources are either in limitless supply or they are easily replaced; this means we are not using up natural resources that will one day run out.
Harnessing renewable energy is less detrimental to the environment than extracting finite materials; for example, drilling for oil, or mining coal can disrupt surrounding eco systems.
Renewable energy generates electricity which can be cleanly consumed; fossil fuels can cause pollution which can damage wildlife.
2. Manufacturers frequently make choices about their suppliers of raw materials based on their impact on society and the environment.
Examples include the use of recyclable components, fair trade textiles and biodegradable packaging.
Discuss how these choices may improve the ethical image of a company. [6]
5 – 6 marks
A fully coherent and logical discussion which features a range of points with excellent understanding of issues surrounding the selection use of materials, detailed analysis and evaluation of these issues and reasoned conclusions drawn as to why they are seen as ethical.
3 – 4 marks
Response shows some good understanding of the issues surrounding the selection use of materials demonstrating a range of points with some analysis/evaluation. Argument may lack some coherency and conclusions drawn may be unsubstantiated.
1 – 2 marks
One or two brief valid points or one point with some explanation. Answer shows limited understanding of the issues with no coherent argument. Analysis only rather than evaluation. No conclusions drawn.
0 marks – Nothing worthy of credit.
Answers may include:
Biodegradable packaging decomposes more quickly, reducing waste in landfill;Is manufactured with fewer finite resourcesRequires less energy to process into useable materialsNon-toxic when they decomposeBiopolymers reduce our reliance on imported oil
Fairtrade textile producers are paid a fair living wage for their produce, rather than minimum wageSmall scale farmers are given access to global markets that they may otherwise not be able to compete in
Recycled components reduce manufacture of new products which may contain scarce resources or precious metalsLandfill space is reduced by recyclingReduces the consumption of harmful materials in the production of, and end product of new componentsPrevents harmful materials from ending up as landfill.
3. The Japanese ‘Kaizen’ culture describes continuous improvement.
(a) Describe what is meant by ‘continuous improvement’. [2]
Constant bettering of products, services and processes; in pursuit of perfection.
(b) State how employees are commonly involved in the continuous improvement process.
Employees are rewarded for any improvements to workflow or quality that they identify and introduce to a company.
4. State one way in which manufacturing and consumption affects:
(a) pollution levels [1]
Manufacture can emit harmful gases and smoke particles; consumption of fuels can emit exhaust fumes causing smog; some smoke particles can condense forming acidic rain.
(b) global warming
Greenhouse gases such as CO2 are a by-product of burning fossil fuels.
Total 15 Marks
Core thoery: People, culture and society Answers1. ‘Technology push’ and ‘market pull’ are forces that bring new invention and discovery to
the market place.
(a) Give two reasons why a competitive advantage can be gained by a company in being the first to push a new technology onto the market.
Companies will have the ability to apply for patents to protect their designs meaning that other companies cannot copy them. It gives them a chance to hook new customers into their products and try to create brand loyalty. It shows that the company is an innovator and a market leader. The first to market often retains the
image of being the ‘original and best’ rather than an imitation from a competitor, even if the ‘imitation’ is technically better. It usually means increased sales.
(b) (i) State what is meant by ‘market pull’.
Product ideas are realised in response to market forces.
(ii) Give one example of a market pull force.
Demand or anticipated demand from consumers / a competitor launches a new product / a desire to increase a company’s market share.
2. A supplier is discovered to be selling clothing items of a similar quality significantly cheaper than any of its competitors.
(a) Discuss any ethical questions that retailers might ask before purchasing stock?
What is the country of manufacture? Some regimes are unpopular with customers.Has a fair price been paid to the labourers in producing the materials? Fairtrade regulations broken, or exploitation of workers.Have any cheap, toxic or banned substances been used in their production. May cause outcry if discovered, or cause discomfort to the user/wearer.
(b) The supplier reports that its materials are produced in a factory that is entirely automated.
Explain one reason why automation might enable a factory to reduce production costs?
Robots may replace human workers / salaries. No wages outlay once the machines have been paid for.Machines are less liable to make mistakes / have greater accuracy. No time spent correcting them / less wastage.
(c) Give one cost that may rise with an increase in automation.
Maintenance of machinery / require highly skilled staff to oversee.Outlay on machinery and robotics.
3. A new supermarket is being built on the outskirts of a town.
Discuss how its design might incorporate features to avoid negative impact on minority groups including the disabled and the elderly.
Answer may include:
Signage should be large enough to read by those with visual impairments. Symbols may be used help those who cannot read, including young children. The height of information should be considered so that those in wheelchairs are still able to read it clearly. Lifts instead of stairs may be used to assist those who find stairs difficult. Large push buttons for opening doors. Access to buildings / parking bays / toilet facilities / space for wheelchairs / electric buggies and charging bays. Change in trolley design to suit wheelchair users and to accommodate disabled children in trolley seats.
Total 15 Marks
Core theory: Production techniques and systems Answers1. Which one of the following is a principle of ‘lean’ manufacturing: [1]
⬨ Increasing production speed
⬧ Eliminating waste
⬨ Reducing quality
⬨ Improving staff morale
2. Which one of the following statements is true? [1]
⬨ Flexible Manufacturing Systems are largely manual processes
⬨ Computer Aided Manufacture is slower than using traditional machines and tools
⬨ Computer Aided Design can only produce two-dimensional designs
⬧ Computer Numerical Control is used with automated milling machines
3. Describe one feature of Flexible Manufacturing Systems (FMS) that make them suitable for producing short runs of a particular part? [2]
Automated machines are used; that can be reprogrammed / recalibrated / retooled easily between production runs.
4. A component is shown below.
(a) The part needs to be drawn to a scale of 1:4. Calculate the diameter of hole A on the new scale drawing.
40mm / 4 = 10mm (Do not accept 1cm.)
(b) The part is currently being designed in the UK using a Computer Aided Design (CAD) software package before being manufactured by an automated machine.
(i) State two advantages of using CAD software to produce the drawing.
Files can be transferred to the CAM machine; developments to the design can be created, saved and edited easily, saving time; parts of designs can be easily copied or repeated; designs can be worked on by remote teams simultaneously; designs can be rendered to look photo-realistic to gather public opinion in a range of finishes; CAD is very accurate; CAD software can process complex stress testing.
A
(ii) Give one disadvantage of using CAD to produce the design.
Software can be complex to learn; software can be expensive; software may not be compatible with other systems at the company; security issues surrounding the storage and transmission of digital design files.
(c) Explain two benefits that just-in-time (JIT) manufacturing could have for the manufacturer of the part.
Any two points that include a benefit with a suitable justification.
Less material will be held in stock; less money tied up in stock / materials they are not using
Staff can be employed on a temporary basis; with more staff as peak periods dictate / lower wage bills
Once parts have been made, they are immediately shipped; which negates any storage costs.
Total 12 Marks
Core thoery: Informing design decisions Answers1. Planned obsolescence is used to create products with a deliberately limited lifespan.
Which one of the following is not a factor in deciding the lifespan of a product: [1]
⬨ Fashion⬧ Colour⬨ Available material⬨ Function
2. Manufacturers might consider using recycled material in the construction of a new product.
(a) Identify three considerations when sourcing used parts.
Materials will need to be: cleaned; undamaged; tested; of acceptable quality and technical standard; and from a reliable and plentiful source; legally sourced (not stolen).
(b) Describe two benefits to a manufacturer of designing and making a product from recycled parts.
Answers include:
Promoting a good caring company image; as it meets customers’ environmental standards; and is delivering products that reduce environmental impact.Helps to conserve resources; meets regulations or environmental standards.Less harmful waste at end of life; design for easier recycling of the product.May receive subsidies, grants or tax incentives; which may increase profit.
The new product should be responsibly disposed of at the end of its life.
(c) Give two ways a company can design a product to improve its recyclability?
Answers include:
Using as few materials as possible; using recyclable materials; making different materials easy to separate from each other // avoiding permanent bonding methods.
3. Manufacturers can design products so that can be easily repaired or maintained.
(a) Give one design feature that makes a product easier to repair at home.
Using regular fixings that can be accessed using non-specialist tools; keep manufacture simple and easy to understand.
(b) State one advantage and one disadvantage to a company of making their products easily repairable by professionals.
Consumers are less likely to purchase a new product; consumers might ask the manufacturer to repair the products for them; the manufacturer can sell parts at greater profit margins than complete products.
(c) Why might it still be cheaper for consumers to purchase a new product rather than having it repaired by a third party?
Labour costs and the cost of parts often make repairs very expensive.
Total 14 Marks
Core thoery: Energy generation Answers
1. Which of the following statements about fossil fuels is false? [1]
⬨ Fossil fuels are burned to create heat, which fires steam-driven turbines
⬨ Fossil fuels include gas, oil and coal
⬧ Fossil fuels produce no CO2 when burned
⬨ Fossil fuels cannot be replaced as fast as they are being used
2. Name three different renewable energy sources. [3]
3. The National Grid is the network of power cables that connect power sources to supply electricity to businesses and homes in the UK.
Discuss how the National Grid ensures a consistent supply of power on a cold and still winter’s evening and justify why demand might be high at this point? [5]
Indicative content:Renewables such as solar and wind will not be providing power so a higher reliance on gas, hydroelectric power (HEP) and nuclear will be required. HEP especially is very quickly controlled and can be used to manage fluctuations. Demand is at its highest due to people staying in, watching TV with heating on, cooking dinner and using kettles to make tea etc.
2 marks for justifying no solar [1] and wind [1] available
Up to 2 marks for knowing gas, HEP and nuclear are the fastest to respond to demand
1 mark for justifying why demand is high
Marks awarded as follows
5 marks A high level response with a full and comprehensive explanation of renewables. Response well-structured with good use of appropriate design and technology terminology and showing a full understanding that solar and wind would produce little power on a cold, still evening. A firm understanding of why demand might be high and that gas and HEP is quick to respond to demand.
3 - 4 marks A medium level response with a good explanation of why demand might be high with a justification of why solar and wind would be poor sources. There may be some acknowledgement of the speed of response by HEP and gas power, with some aspects of the detail omitted. Response fairly well structured with some use of design and technology terminology with a small number of errors in grammar, punctuation.
1 - 2 marks A low level response with a limited explanation of high demand and why solar and wind would be limited in their effectiveness. There may be several errors. Response poorly structured with little or no use of design and technology terminology and with several errors in grammar, punctuation and spelling.
0 marks Nothing worthy of credit.4. Explain how fossil fuels are used to produce electricity. [3]
Fossil fuels are burnt to heat water; The resulting steam turns turbines; which turn generators; which supply electricity to the National Grid.
5. Explain how shale gas is produced by fracking (hydraulic fracturing). [3]
A well shaft is drilled [1] into the shale then a mixture of water, sand and other chemicals [1] is forced under pressure into the well. The mixture enters the fissures [1] allowing shale gas to flow back up the shaft where it is collected [1] at the head of the well.
Total 15 marks
Core theory: Energy storage Answers1. Which one of the following is a type of kinetic energy? [1]
⬨ Mechanical
⬧ Sound
⬨ Chemical
⬨ Nuclear
2. Name three simple methods of storing energy that can be found in most homes or in a design and technology workshop? [3]
Answers may include:
Elastic band – tension
Balloon – compression
Spring – Tension or compression depending on the type of spring
Battery – electrical energy
Spray can – compression
Accept any alternative of merit
3. Explain the difference between potential and kinetic energy, giving one example for each. [4]
Potential energy is stored energy – Chemical, mechanical, nuclear, gravitational.
Kinetic energy is energy in motion – movement, electricity, heat, sound, light.
Accept specific examples as well as general the examples listed.
4. Describe how flywheels can be used to store surplus energy and smooth erratic energy generation from some renewable sources. [6]
During times of low demand on the National Grid surplus energy is used [1] to rotate the flywheels to a very high speed [1]. As they rotate in a near frictionless environment they maintain their momentum [1]. When demand increases, the momentum is used [1] to drive a generator [1] supplying energy back to the National Grid [1]. This has a smoothing affect helping to avoid peaks and troughs in supply [1]. It also helps to level out erratic production from some renewables such as solar and wind power [1].
5. Describe the use of energy storage systems, including kinetic pumped storage systems, to use surplus energy to help smooth peak supply and balance the demand on the National Grid.
You may use a diagram to aid your answer. [4]
Kinetic pumped energy storage using hydroelectric dams and/or reservoir systems [1] can be used to store water [1] which is pumped up during low demand times [1] and released during peak times [1].
Large banks of batteries and/or large flow batteries are charged during low demand [1] and used or ‘discharged’ to top up the National Grid during peak demand [1].
6. Standard alkaline battery cells are 1.5V.
(a) State the voltage of a rechargeable cell.
1.2V.
(b) How many rechargeable cells would be required in a 12V battery?
12 / 1.2V = 10.
Total 20 marks
Core theory: Modern materials Answers1. Which one of the following statements is false? [1]
⬨ Nanomaterials are between 1 and 1000 nanometres in size
⬨ Graphene is a carbon lattice structure one atom thick
⬧ Biodegradable polymers are made from petrochemical resources
⬨ Information is transmitted down fibre optic cables using pulses of light
2. Name three different modern materials and describe one use for each. [6]
1 mark for a correct material. 1 mark awarded for linking a correct use.
Teflon – non-stick surfaces, holographic polymers and papers - anti-fraud banknotes and novelty goods, biodegradable polymers – disposable and compostable goods, Polymorph / Coolmorph – hand shaped prototyping / modelling and repairs, flexible MDF – curved furniture and interiors, titanium – dental and orthopaedic implants, lightweight components, jewellery, fibre optics – data transfer, endoscopes, optoelectronics, novelty goods, graphene – newly emerging fields, energy, electronics, biomedicine, composite materials, LCDs - battery operated handheld devices, watches, consumer and industrial electronics, nanomaterial – newly emerging fields, material technology, coating, additives, metal foams – vehicles and transport, construction, impact resistance, conductive polymers – clothing and wearable technology weatherproof electronics, any other suitable response.
3. Explain why LCD screens are appropriate for use in a battery powered metronome? [3]
The screen is compact and low profile [1], very low power consumption therefore can run a long time on batteries [1], specific layouts can be constructed to suit the task [1], lightweight making it portable [1], (relatively) robust [1].
4. Explain why biodegradable polymers are considered to be CO2 neutral. [3]
Biodegradable polymers come from vegetable starch sources [1], as the plant grows CO2 is absorbed by the plant [1], some energy is used during manufacture and transportation and often during use [1], when the plant is disposed of, the carbon is returned to the ground [1], some gases are released as the polymer decomposes [1], overall the CO2 is greatly reduced compared to petrochemical based polymers [1].
5. How might metal foams be beneficial to patients receiving orthopaedic implants? [2]
Titanium is used to make medical implants as it is nonreactive to the human body [1], the implants could be made using metal foam on the inside of the implant making it much lighter [1], and therefore easier for the patient for carry around [1], bone can regrow through the porous foam structure [1].
Total 15 marks
Core theory: Smart materials Answers1. Which one of the following smart materials does not react to electricity? [1]
⬨ Shape memory alloy
⬨ Quantum tunnelling compound
⬧ Thermochromic pigment
⬨ Piezoelectric material
2. Which smart material can be both a conductor and an insulator? [1]
Quantum tunnelling composite.
3. Explain one disadvantages of using photochromic particles with self-darkening glasses. [2]
They take up to two minutes to darken / lighten [1], which can cause issues when entering a dark building or going straight out into bright sunlight [1]. They can lose their ability to turn back to clear after time [1], which means they become less useful in different light-levelled environments [1].
4. Describe how self-healing polymers could be useful in the construction of plastic frames for glasses and sunglasses. [2]
Plastic frames frequently crack / snap [1]. Being able to hold the broken parts in place while the released resin joined the broken parts back together [1] would save on repairs and reduce waste [1].
5. Use the following key words to create a short paragraph that explains the process that self-healing concrete undergoes when activated. [3]
When stress cracks appear in self-healing concrete, water seeps into them rupturing spheres of food and bacteria. The water activates the food and bacteria and the bacteria starts to feed. The result is that calcium carbonate is formed which fills the crack bonding the concrete back together.
Award credit for logical explanation and correct process.
6. The following question is about the shape memory alloy, nitinol.
(a) Nitinol is an alloy of nickel and which other metal? [1]
It is an alloy of nickel and titanium.
(b) How is a shape ‘set’ in to the memory of nitinol? [2]
The Nitinol is held in the desired shape [1] and heated to a very high temperature / around 540°C [1].
(c) A piece of Nitinol has a shape ‘set’ in its memory.
Explain what stimulus is required to return the material to its ‘set’ shape, once deformed. [1]
It is reheated to around 70°C / moderate temperature [1] or has an electrical charge sent through it [1], which triggers the response to change to the ‘set’ shape [1].
(d) Name and briefly describe one commercial use of nitinol. [2]
It is used in fire safety devices [1] and detects heat by closing or opening alarm circuits [1].
It is used in water valves [1] to open or close the valve depending on the temperature of the water attempting to pass through [1].
It is used in stents in the medical profession [1] for opening up/improving flow in arteries [1].
It is used in frames for glasses [1] that can be straightened if bent out of shape [1].
It is used in dentistry [1] for braces and orthodontics [1] to put the teeth under tension causing them to move as they grow [1].
Total 15 marks
Core theory: Composite materials Answers1. Which one of the following is a type of Aramid fibre? [1]
⬨ Cotton
⬨ Stainless steel thread
⬨ Gore-Tex®
⬧ Kevlar®
2. What is meant by a ‘composite’ material? [2]
One which contains two or more different materials that are combined [1] to create a material with improved properties and functionality [1].
3. Put the following steps, for forming a single layer glass reinforced plastic component, in the correct order. Draw lines between the steps. [8]
Step 1 5. Apply resin and work evenly into matting
Step 2 6. Clamp in position and leave to cure
Step 3 4. Apply GRP matting
Step 4 8. Trim and finish workpiece
Step 5 1. Prepare mould
Step 6 3. Apply gel coat
Step 7 2. Apply release agent
Step 8 7. Release the workpiece from the mould
4. Explain how a Gore-Tex® membrane works. [3]
The Gore-Tex membrane has millions of holes per cm2 [1] meaning water droplets are too large to penetrate the fabric [1]. This creates a waterproof layer, keeping the wearer dry [1].
5. Gasses, liquids and solids can be microencapsulated in a fabric.
Give two applications of microencapsulation within a technical textile [2]
Description relating to thermochromic dyes, antibacterial agents, pesticides and detergents, perfumes and scratch’n’sniff products, slow release drugs/patches.
Accept other suitable responses.
6. Discuss the environmental concerns regarding microfibre products such as the cleaning glove shown below. [4]
Microfibres are incredibly small [1] and can break off products when they are washed [1]. These wash away with the waste water but are too small to be filtered out by the water treatment plants [1] and therefore make their way into watercourses and rivers and eventually the oceans [1]. The fibres attract pollutants from the water such as oil and other toxins [1]. Aquatic animals swallow the microfibres [1] other mammals and humans eat the aquatic animals which can potentially cause health issues [1].
Core theory: Systems approach Answers1. Which one of the following components is used to detect light levels? [1]
⬨ LED
⬨ Thermistor
⬧ LDR
⬨ Resistor
2. Which one of the following is an output component? [1]
⬧ Speaker
⬨ PTM switch
⬨ Pressure pad
⬨ Microphone
3. Explain the functional difference between a closed loop system and an open loop system. [2]
A closed loop system makes decisions based on feedback; often from a sensor.
4. This question is about connecting components together in a circuit.
(a) What is the name for the style of circuit drawn below? Schematic diagram. [1]
(b) Which electronic component is labelled SW1? Push-to-make switch (PTM). [1]
(c) Which electronic component is labelled D1? Light emitting diode (LED). [1]
(d) Explain the function of resistor R1. [2]
It is a pull-down resistor [1] ensuring pin 2 is low except when SW1 is pressed [1] to prevent pin 2 floating [1].
(e) Split the timing circuit below into three blocks by drawing two vertical lines across it.
Label each of the blocks, stating whether it is the input, output or process. [3]
Input Process Output
Homework 7: Electronic systems processing Answers
1. Which one of the following components will give a digital signal? [1]
⬨ Microphone
⬨ Light dependent resistor
⬧ Toggle switch
⬨ Thermistor
2. Using notes and sketches, explain the characteristics of the following types of signal. [4]
Analogue: Digital:
An analogue signal has an infinite amount of values between high and low.
A digital signal is a series of 0s (low) and 1s (high). There are no other possible states.
One mark for each correctly drawn graph and one mark for each appropriate explanation.
3. Explain how a microcontroller can be programmed. [2]
A program can be written in special software / as a flowchart or it can be written in a coding language such as Basic [1]. The program is usually sent from the computer to the device via a download cable // however some more complex devices can receive programs via Infrared, Wi-Fi and Bluetooth etc.
4. A digital egg timer uses an input, process and output.
(c) Circle the most appropriate device below to be used for the timing process. [1]
Monostable
Astable
Total 10 marks
Core theory: Mechanical devices Answers1. Which one of the following motions describes travel along a straight path? [1]
⬨ Reciprocating motion
⬧ Linear motion
⬨ Rotary motion
⬨ Oscillating motion
2. Which type of motion best describes the movement of a washing machine drum? [1]
Rotary.
3. Which class of lever best describes the action of lifting a wheeled suitcase? [1]
Class 2 lever / Second order level.
4. What is meant by the term equilibrium when applied to levers? [1]
When the load and effort are equal, equilibrium is created in a mechanism.
5. Give two functions of a linkage. [2]
Change the magnitude of force [1] Change the direction of a force [1] Transform it into a different motion [1].
6. A crank and slider converts one motion into another. State both motions. [2]
Rotary to reciprocating or vice versa.
7. For each of the following statements, state the type of cam described.
(a) A round cam with a hole for the camshaft positioned off centre. Eccentric cam. [1]
(b) A cam with a long dwell, a slow rise and a sudden drop. Snail cam. [1]
(c) A cam designed to have no dwell period. Heart-shaped/constant velocity cam. [1]
(d) A cam with a long dwell and a rapid rise and fall. Pear cam. [1]
8. Which type of follower is the most accurate but most prone to wear? [1]
Knife edge follower.
9. Explain the use of an idler gear? [2]
It is positioned in between the drive and driven gear to transfer the drive [1] so that the driven gear rotates in the same direction as the drive gear [1].
Total 15 marks
Timber knowledge: Sources, origins and properties Answers
1. Which of the following pairs of production methods are used with manufactured boards:[1]
⬨ Compression and steaming
⬨ Warping and compression ⬧ Compression and lamination
⬨ Suspension and steaming
2. What does the term 'timber conversion' refer to? [1]
⬨ The cutting down of trees once they have reached maturity
⬨ The drying out of timber to a usable moisture content
⬧ The process of cutting timber into standard sized planks
⬨ The manufacture of waste material from the timber industry into boards
3. State and explain two processes carried out in managed forests that help to make them sustainable.
(i) Process: [1]
Explanation: [1]
(ii) Process: [1]
Explanation: [1]
Possible responses:
Young trees are thinned at around 5 years old; giving stronger young trees room to grow and thriveThinnings and waste materials are reused; for fence posts or fuel, waste like wood chip may be used in manufactured board production.When trees are finally felled they are replaced with new seedlings and the cycle begins again; to ensure the long-term future of the product
4. When converting timber into planks, what do the initials PAR stand for? [1]
Planed all round.
5. Justify one suitable use of PAR timber. [2]
Internal applications; including furniture, stairs, door and window frames; since it has a more aesthetic finish which is also better for the application of paint or stain.
6. Give one advantage of kiln drying timber over air drying. [1]
The moisture content of the timber can be controlled depending on the end use of the timber.It is a much quicker process meaning that it is ready for sale sooner.With kiln drying lower moisture contents can be achieved than with air drying.Reduces the chance of insect or fungal attack.
7. Discuss the possible environmental impact of using chipboard to make flat-packed furniture.
Your answer should include reference to:• sourcing the raw material• the manufacture of the board• the end of the product’s life
[10]
Award marks for details relating to the environmental impact of using Chipboard to make flat packed furniture.
Students may qualify each of these points for additional marks.
Possible responses include: Chipboard is made from wood; wood is a renewable resource; Chipboard can be made from recycled wooden products; Chipboard can be made from parts of the tree normally thrown away; The process of manufacturing chipboard uses fossil fuels; fossil fuels are a
finite resource; the burning of fossil fuels damages the environment; Chipboard is manufactured using adhesives that are not environmentally friendly; Chipboard needs to be transported using vehicles that cause pollution; Chipboard products are seen as 'cheap' and often thrown in landfill at the end of
their life; Chipboard products are not easily recycled at the end of their life; Chipboard is often faced with melamine/Formica which are not easily recycled;
[Total 20 Marks]
Timber knowledge: Working with timber Answers1. Study the picture of the hand-held disc sander shown below.
Complete the table below by identifying a hazard and stating a precaution.
An example has been given.
Hazard PrecautionLong hair could get caught in the disc Ensure long hair is tied back
Dust could enter your lungs Only one person should be near the machine
Dust could fill the workshop Wear a dust mask
Dust and wood chips could get into your eyes
Ensure the extraction equipment is turned on.
Trailing lead could be a trip hazard Ensure the tool rest is close to the workpiece
Work space is untidy / cluttered / cramped with many people working closely
Wear a face mask/visor
Possible answers above. (10 x1 mark)Award one mark for each correctly identified hazard.Award one mark for each relevant precaution.
2. Name each of the following tools. Give details of a specific process where you would use each tool.
NameCoping saw
Process When cutting a detailed shape in a piece of wood.
When cutting a curved shape in a piece of wood.
NameSmoothing plane
Process Removes fine strips of wood, used to flatten an uneven edge or face, used along the grain of the wood, used to create an accurate 90 degree face side and edge, used to finish wood before final sanding.
Award one mark for each correctly identified tool and one mark for a correctly identified, specific, process. (4 x1 mark)
3. A timber 'moulding' would be suitable for which one of the following applications?
⬨ Reinforcing a wood joint
⬧ A skirting board
⬨ Shaping a steam bent plank
⬨ A kitchen worktop
4. What is the function of a surform?
⬨ To route a groove in wood
⬨ To remove wood from rebates and recesses
⬨ To smooth a surface
⬧ For the fast removal of material
5. State two advantages of having stock forms and sizes of timber readily available.
Components are commonly manufactured to fit and work with stock forms.Shapes, sizes and quantities are recognised by those who use timber.Ensures a cheaper supply of standard sized materials.Available immediately without the need to wait for bespoke materials. The primary processing has already been completed.Storage, transportation and handling can be easier since machinery has been manufactured to work more easily with it.Processing machinery is commonly set up to work with standard sizes of materials.
6. Briefly explain the process of steam bending a piece of timber.
Insert timber plank into steam box or soak in water to increase moisture content.Force the part around a former using a strap and/or clampsClamp and leave the part to cool and dry out
[20 marks]
Timber knowledge: Manufacturing and finishing Answers
1. Give four advantages to a manufacturer of using CNC machinery to produce a range of timber based products.
CAD software allows them to plan layouts, minimises waste, fast and efficient, accurate, doesn't require a skilled craftsman, cost effective after set up costs are paid off, all processes can be completed in one go.
2. A mass produced breadboard has been produced using a CNC router.
(a) Describe two factors that make the board suitable for CNC manufacture. [2]
Identical shaped and sized products are produced in large batches, the board and the hole can be cut in one go and this can be repeated, CNC machine can change its tools to produce each hole, cut or groove, precision is required and CNC routers can run consistently and repetitively.
(b) What quality control measure could a manufacturer use to ensure that all the hole cut in the board is within a specific tolerance? [1]
A go/no go fixture / gauge.
(c) In the space below, design and annotate a component to explain your answer to part (b) above. [4]
Award marks for the right tool, for pictorial/annotated explanation of use, mention of tolerance/dimensions, care taken over the drawing.
3. Give two reasons why a manufacturer uses systems to ensure the accuracy of their products.
To ensure consist high quality, to ensure parts fit / work / don’t break. Fewer faulty products. Fewer returns. Improves consumer satisfaction, saves money and waste, increases sales with greater reputation.
4. A company manufacturing children’s furniture wants to extend their range to include high quality educational toys.
Name one suitable material that you would recommend to manufacture the toys from.
Suitable material – Beech or other suitable hardwood.
6. Which one of the finishes below is not suitable for use on an external window frame?
⬨ Varnish
⬧ Wax
⬨ Paint
⬨ Stain
⬨ Wood preservative
7. When purchasing rough-sawn timber for outdoor use, you may opt to have tantalised timber.
(a) Explain the process of tanalising. [3]
Timber is immersed in a preservative; which is forced into the wood; under high pressure.
(b) State two advantages of tanalising timber. [2]
Helps delay the rotting process; protects against insect / fungal attack.
