two - Garforth Academy · Explanation shows a basic understanding of the working properties of the...

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Q1.

Choose two products from the table below and answer the questions that follow.

Cup

Chocolate box

Pizza

Rocking horse

Stepladder

Printed Circuit

Board

Cushion

Menu

(a) Chosen product 1

___________________________________________________________________

Main material, component or ingredient used

___________________________________________________________________

Describe one process used during manufacture

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

(b) Chosen product 2

___________________________________________________________________

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Main material, component or ingredient used

___________________________________________________________________

Describe one process used during manufacture

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

(2 × 3)

(Total 6 marks)

Q2.

The table below shows different types of material.

Choose two types of material and complete the row. (You should only complete two

rows.)

The first material in each row has been completed for you.

Type of

material

Material name

1

(Examples)

Material name

2

Material name

3

Material name

4

Paper / Card Duplex board

Timber Oak

Metal Copper

Plastic Acrylic

Textiles Wool

(Total 6 marks)

Q3.

Using notes and sketches explain how you would make a batch of 50 identical gifts based

upon your design in part (a).

Marks will be awarded for:

• an accurate description of each stage of the process

(4)

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• how you will make sure that all of your gifts are identical

(2)

• correct naming of tools and equipment

(2)

• quality of communication.

(2)

(Total 10 marks)

Q4.

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(a) Choose two products from those shown above.

For each product you have chosen, complete the table below.

An example is given for you.

Product Main material Source of material Renewable?

or

Drink can

Aluminium Bauxite ore

(6)

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(b) Choose one product from those shown above.

Name the main material and give two of its properties.

Explain why these properties make the material suitable for the product.

Product ____________________________________________________________

Material ____________________________________________________________

Property 1 __________________________________________________________

(1)

Explanation _________________________________________________________

___________________________________________________________________

(2)

Property 2 __________________________________________________________

(1)

Explanation _________________________________________________________

___________________________________________________________________

(2)

(Total 12 marks)

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Q5.

Explain the reasons why different materials are combined.

Give specific examples in your answer.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

(Total 6 marks)

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Q6.

(a) Give three examples of specific paper / card materials.

1. _________________________________________________________________

2. _________________________________________________________________

3. _________________________________________________________________

(3)

(b) Choose one type of material from the list below. Circle your choice.

Give three specific examples of your chosen material.

Non-ferrous metals Synthetic textile fibres Hardwoods Mechanical components

Manufactured boards Thermoplastics

1. _________________________________________________________________

2. _________________________________________________________________

3. _________________________________________________________________

(3)

(Total 6 marks)

Q7.

(a) Name the main material used in your design.

___________________________________________________________________

(1)

(b) Explain why your design is suitable for production in quantity.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

(2)

(Total 3 marks)

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Q8.

Products are made from different types of material.

Choose two products in the table and identify the main material type used in its

manufacture.

Draw a line to link the material type to the correct examples of specific materials in its

group.

An example is given for you.

(Total 4 marks)

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Q9.

During manufacture, materials are processed to make them into products.

Choose four materials from the list below and insert them in the table to match them to a

suitable manufacturing process.

For each of the materials you have chosen state whether it is renewable or not.

An example is completed for you.

acrylic

porcelain

pine

rice

egg

paper

wool

card

high impact polystyrene

cotton

copper

Process Material Is the material renewable?

soldering copper No

slip casting

vacuum forming

beating

cold water dyeing

laser cutting

printing

knitting

boiling

die cutting

planing

(Total 8 marks)

Q10.

In commercial production what process could be used to cut out the card part of a blister

pack?

_______________________________________________________________________

_______________________________________________________________________

(Total 2 marks)

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Mark schemes

Q1.

Cup & saucer

Mat / Comp / Ingr: Porcelain, earthenware, china clay. Clay = 0.

One mark for a correct main material, component or

ingredient = 1.

Processes: Spinning, slip casting, glazing, firing in a kiln.

Process used during manufacture with explanation = 2

Named process only = 1.

Chocolate box

Mat / Comp / Ingr: Food grade cardboard, foil lined cardboard, cardboard. Polymer

(PET, HIPS) tray. Corrugated paper / card for liner.

Note: accept chocolate

Processes: Die-cutting, embossing, laminating, offset lithography printing, vac

forming.

Note: If chocolates considered allow moulding, enrobing, moulding &

tempering.

Look for description about the process NOT the product

or the user.

N.B. If candidate talks about chocolates we will accept.

N.B. Do not accept generic material types e.g. wood,

paper, metal, textiles, cloth.

Pizza

Mat / Comp / Ingr: Flour, and specific topping materials. Salt, water. NOT DOUGH

Processes: Baking, cooking, proving & kneading.

Rocking horse

Mat / Comp / Ingr: HDPE, MDF, Plywood, Beech, Ash, CSK screws.

Processes: Rotational moulding, lamination, turning (handles), drilling (screw holes

for assembly), cutting, sawing, sanding, varnish / painting.

Step ladders

Mat / Comp / Ingr: Aluminium, steel, pop rivets.

Processes: Press forming, pop riveting. Extrusion, powder coating, anodising.

Example or process description: STEP LADDERS &

extrusion is used to produce the rectangular tube, cross

section needed for the step ladders legs.

Printed Circuit Board

Mat / Comp / Ingr: Any named electronic component e.g. resistor, transistor IC

(Integrated Circuit).

Chips, wire or solder = 0

Processes: Drilling (component holes), surface mount components, soldering, flow

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soldering.

Cushion

Mat / Comp / Ingr: Any specific named fabric e.g. denim, cotton, polyester-cotton.

Wool (stuffing). Components − zip, press studs.

Processes: Patchwork, quilting, piping, plain seam stitching, sewing, batik, dye

sublimation printing, screen printing.

Menu

Mat / Comp / Ingr: Laminated card, waxed card.

Processes: Offset lithography, digital printing, lamination, die-cutting, creasing,

embossing, dye sublimation.

Copy / printer paper = 1

Card = 1

Cartridge paper = 0

[6]

Q2.

Specifically named materials such as:

Type of

Material Material name possible responses

Paper Card

Sugar paper, Cartridge paper, Tracing paper, Corrugated card, and

Mounting board, Solid white board, layout paper, foil lined board,

tissue paper, crepe paper, carton board.

Timber

Beech, Ash, Cedar, Yew, Teak, MDF, Plywood, Pine and

Mahogany, MDF, chipboard, plywood, hardboard, blockboard,

Laminboard, Parana pine, Scots pine (red deal). Any named

timber.

Metal

Aluminium, Brass, Lead, Mild Steel, Cast Iron and High Carbon

steel, Stainless steel, High speed steel, Tool steel, Tin, Zinc,

pewter, casting alloy (LM4), Guilding metal, Bronze.

Plastic

Acrylic, PVC, PET, ABS, Vinyl, Polythene, Melamine,

Formaldehyde, Polystyrene, Urea Formaldehyde, Polypropylene,

Polyester resin, PETE, HIPS, GRP, HDPE, LDPE, PF, UF,

Polyurethene (PU), fibreglass, epoxy resin, nylon.

Textiles Silk, cotton, Nylon, Elastane, Polyester and Linen, Acetate,

polyamide (nylon), Acrylic, Aramid (Kevlar), felt, Tactel.

If candidates have completed the whole table the two rows with the highest number

of correct answers will be taken. (6 × 1 mark)

[6]

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Q3.

• An accurate description of each stage of the process, sequence is clear with

no major omissions. Suitable for producing 50. (4 marks)

A generally correct sequence of manufacturing detailed but maybe some

omissions. Suitable for producing 50 (3 marks)

Some significant omissions in the sequence of manufacturing or processes (2

marks) may be incorrectly detailed. Suitable for producing 50 (2 marks)

Only part of the process superficially detailed or unsuitable for producing 50 (1 mark)

• References made to manufacturing aids, CAM, ongoing checks, final

inspections.

Reference to one with full explanation or reference to two with superficial

explanation (2 marks)

Reference to one (1 mark)

• Correctly named tools and equipment for major stages of manufacture

Some tools and equipment are correctly named (2 marks)

Look for evidence in body of process either written or drawn (1 mark)

• Quality of communication is good. Clear drawings and notes. (2 marks)

Quality of communication is sound. Drawings may lack some annotation but

are generally easy to understand (1 mark)

[10]

Q4.

(a) Please refer to table and answers below. One mark for each correct answer.

Product Main material Source Renewable?

Stainless steel

Silver

The Earth and

rocks,

oil etc

Beech

Rubberwood

Plants and

Trees

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Card

Plants and trees

Cotton Plants and trees

Polyester

wadding

The Earth and

rocks,

oil etc

PET Plastic

The Earth and

rocks,

oil etc

Cartridge paper

Plants and trees

Timber

Wood pulp

Glass

Polycarbonate

The Earth and

rocks,

oil etc

Cotton Denim

Plants and trees

6

(b) A suitable property relevant to main material. 1 mark

Explanation shows good understanding of the working properties of the

material. 2 marks

Explantion is vague and lacking in understanding of the properties of the

materials. 1 mark

Property must match product even if material is incorrect.

Please refer to table below.

Cutlery

Spatula

Greetings card

Jeans

Stainless steel:

Scratch resistant;

Beech:

Midtone colour

White board:

Strong, can be

Cotton denim:

Accepts indigo

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corrosion

resistant,

lustrous, inert –

will

not react with

drink -

impervious to

water and air;

Silver:

Lustrous,

tarnishes in air

hardwood with a

fine texture.

Close even grain,

doesn’t splinter.

Available in

planks / boards

Can be large

sections

Planed and

unplaned

Mouldings

Rubberwood:

soft wood, pale

colour, relatively

strong, used for

hard board,

particle board,

door frames,

furniture, fibre

board

printed on,

inexpensive, can

be die cut or

creased.

dye well;

hard wearing /

durable;

available in

different weights;

can be blended

with lycra to

make stretch

Oven Glove

Food packaging

Sketchbook

Wine goblet

Cotton:

Lightweight;

durable;

washable –

stains easily

removable at low

temperature;

heat resistant

Polyester

wadding:

Good insulator

PET plastic:

Clear – displays

product;

recyclable;

vacuum formed;

strong to protect

food inside; inert

– will not affect

food;

waterproof; can

be incinerated to

dispose of.

Cartridge paper:

high quality type

of heavy paper

used for

illlustration and

drawing.

Accepts drawing

and painting

media well.

Glass:

Clear; lightweight

when blown in

thin profile; can

be shaped into

3D shapes; inert

– will not react

with wine;

displays wine;

easilly broken.

Recyclable.

Polycarbonate:

Transparent,

shatterproof,

leightweight, cast

or compression

moulded.

2 × 3 marks

6

[12]

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Q5.

Materials are combined (composites) to improve the working properties of one or

both materials.

E.g. laminates – paper & foil, wood veneers, gortex; pvc coated cotton, mayonnaise

(egg acts as emulsifier, binds ingredients together), roux – butter and flour, carbon

fibre, alloys, stainless steel, steel (iron & carbon), cement, glass fibre, grp; cotton &

polyester

Response to include two materials, specifically named and suitable to be combined.

Do not accept finishes and coatings, decorative finishes or fabrication.

Explanation shows a good understanding of the working properties of the materials

and resultant material.

Reasons for combining materials fully explained and appropriate example

given. 5–6 marks

Explanation shows a basic understanding of the working properties of the materials

and resultant material.

A reason for combining materials is given but may be lacking in detail, response

may include an appropriate example. 3–4 marks

Explanation is vague and lacking in understanding of the properties of the materials

/ resultant material. Appropriate example may not have been given or an example

without reason or explanation. 1–2 marks

[6]

Q6.

(a) Any named paper or board e.g. sugar paper, cartridge paper, tracing paper,

corrugated card, mounting board, solid white board, layout paper, foil lined

board, tissue paper, crepe paper, carton board. Duplex board, newsprint,

recycled paper and board.

Do not accept wallpaper, paper (any sizes given) or card / cardboard,

laminated card. Do not accept processed finishes, e.g. waxed card. 3×1 mark

(b) Any named specific material such as:

Non-ferrous

metals

Aluminium; copper; tin; zinc; brass; pewter; casting alloy

(LM4), gold, silver.

Synthetic textile

fibres

Polyamide / nylon, Tactel, Polyester, Acrylic,

Elastane / Lycra, Aramid / Kevlar

Hardwoods Beech; oak; ash; maple; balsa; teak; mahogany; ebony,

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jelutong

Mechanical

components

Spur gears; rack and pinion; cam and follower; cranks;

pulleys; linkages; levers; worm and worm wheel; bevel

gears; chain and sprocket; pneumatic cylinders

Manufactured

boards

MDF (medium density fibreboard) HDF, LDF; plywood;

chipboard; blockboard; hardboard, lamin-board.

Thermoplastics

Polythene (High Density) HDPE; Polythene (Low Density)

LDPE; Polypropylene (PP); High Impact Polystyrene

(HIPS); Nylon; PVC (polyvinyl chloride); Acrylic

(polymethyl-methacrylate), PET / PETE

3×1 mark

[6]

Q7.

(a) Any named material which would be suitable for the idea shown.

No marks for generic names – wood, metal, plastic, fabric etc. (1 mark)

(b) Clear justifications linked to properties, manufacturing techniques, costs,

aesthetics, availability etc. (2 marks)

Superficial / single word answers e.g. “cheap”

Must relate to product material previously specified (1 mark)

[3]

Q8.

One mark per correctly identified material group, one mark per correctly linked examples.

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Max 4 marks

[4]

Q9.

Process Material Is the

material

renewable?

soldering copper

Suitable to

material

(see below)

slip casting porcelain

vacuum forming High impact polystyrene / acrylic

beating Egg

cold water dyeing Cotton / wool

laser cutting Acrylic / card / paper / HIPs / cotton

wool

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printing All except egg / rice

knitting Wool / acrylic / cotton

boiling Rice / egg

die cutting Card / paper / wool

planing Pine / acrylic

4 complete rows (1 mark per entry)

Material Renewable

Acrylic N

Porcelain N

Pine Y

Rice Y

Egg Y

Paper Y

Wool Y

Card Y

HIPs N

Cotton Y

[8]

Q10.

Die-cutting (2 marks)

Stamping, laser cutter (1 mark)

[2]

two - Garforth Academy · Explanation shows a basic understanding of the working properties of the...

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