Cambridge IGCSE Design and Technology 0445 — 2015 May/June Paper 3 · Variant 3

This document consists of 16 printed pages. DC (AC/FD) 101409/3 © UCLES 2015 [Turn over * 5 3 1 2 6 1 6 5 4 8 * DESIGN AND TECHNOLOGY 0445/33 Paper 3 Resistant Materials May/June 2015 1 hour Candidates answer on the Question Paper. No Additional Materials are required. READ THESE INSTRUCTIONS FIRST Write your Centre number, candidate number and name on all the work you hand in. Write in dark blue or black pen. You may use an HB pencil for any diagrams, graphs or rough working. Do not use staples, paper clips, glue or correction fluid. DO NOT WRITE IN ANY BARCODES. Section A Answer all questions in this section. Section B Answer one question in this section. You may use a calculator. At the end of the examination, fasten all your work securely together. The number of marks is given in brackets [ ] at the end of each question or part question. The total of the marks for this paper is 50. Cambridge International Examinations Cambridge International General Certificate of Secondary Education

2 0445/33/M/J/15 © UCLES 2015 Section A Answer all questions in this section. 1 Fig. 1 shows a student using a drilling machine safely. Fig. 1 State three safety precautions taken by the student using the drilling machine. 1 … 2 … 3 …[3] 2 Many items of furniture are made from chipboard. State two advantages of making furniture from chipboard rather than from solid wood. 1 … 2 …[2] 3 Complete the table below by naming a suitable adhesive for each of the described uses. Use Adhesive gluing plastic laminate to a manufactured board table top wooden boat building gluing metal parts together [3]

3 0445/33/M/J/15 © UCLES 2015 [Turn over 4 Name a suitable finish for the following products. aluminium comb … wooden chopping board … handle of a junior hacksaw …[3] 5 Fig. 2 shows a toy car and a machine part. Both are made by the die casting process. Fig. 2 Give two benefits of using the die casting process to make products. 1 … 2 …[2] 6 Name the process that uses the equipment shown in Fig. 3. Fig. 3 …[1]

4 0445/33/M/J/15 © UCLES 2015 7 Fig. 4 shows two pieces of wood nailed together. Fig. 4 (a) Give one reason why the nails are arranged as shown in Fig. 4. …[1] (b) Give the specific name of one type of nail that could be used to join wood together. …[1] (c) Name a tool that could be used to pull nails out of wood. …[1] 8 Complete the drawing below to show the marking out for a mortise and tenon joint. [3]

5 0445/33/M/J/15 © UCLES 2015 [Turn over 9 Fig. 5 shows two centre lathe operations. ZRUNURWDWHV ZRUNURWDWHV $ % Fig. 5 Select the correct centre lathe operation for A and B from the list below. cutting off parting off shearing off facing off turning off Operation A … Operation B …[2] 10 Complete the table below by naming a specific plastic for each product. 3URGXFW IRRGWUD\ SOXPELQJSLSH FXUWDLQWUDFN 6SHFLILFSODVWLF [3]

6 0445/33/M/J/15 © UCLES 2015 Section B Answer one question in this section. 11 Fig. 6 shows detailed views of a photograph holder made from 4 mm thick clear acrylic. spacer 130 130 10 4 spacer back front stand 200 # # Fig. 6 (a) Fig. 7 shows the stand for the photograph holder marked out ready to be cut to shape. ZDVWH   Fig. 7 Complete the table below by describing what each tool or item of equipment is used for. Stage Tool / item of equipment Use 1 scriber 2 hegner or scroll saw 3 hand file 4 wet and dry paper [4]

7 0445/33/M/J/15 © UCLES 2015 [Turn over (b) The front and back are joined to the spacers with acrylic cement. Give two safety precautions that must be taken when using acrylic cement. 1 … 2 …[2] (c) Fig. 8 shows views of a photograph holder made from 1 mm thick aluminium sheet. KROH  # Fig. 8 Give two properties of aluminium that make it suitable for the photograph holder. 1 … 2 …[2] (d) Use sketches and notes to show how you would cut out the square hole in the 1 mm thick aluminium sheet shown in Fig. 8. [5]

8 0445/33/M/J/15 © UCLES 2015 (e) Describe how the aluminium sheet would be finished to a high quality. … … … …[3] (f) A batch of twenty identical aluminium photograph holders will be made in a school workshop. Use sketches and notes to show how the sides of the aluminium photograph holder, shown in Fig. 8, could be folded accurately. [5]

9 0445/33/M/J/15 © UCLES 2015 [Turn over (g) There are benefits of using CAD (Computer Aided Design) and CAM (Computer Aided Manufacture) when designing and making the photograph holders in Fig. 6 and Fig. 8. (i) Explain one benefit of using CAD to design the photograph holders. … … …[2] (ii) Explain one benefit of using CAM to make the photograph holders. … … …[2]

10 0445/33/M/J/15 © UCLES 2015 12 Fig. 9 shows views of a planter in which flowers can be grown. The planter is made from 15 mm thick solid wood and is sold as flat-pack for self-assembly. HQG WRSVLGH ORZHUVLGH UDLO OHJ EDVH HQGYLHZ    Fig. 9 (a) Describe one property of solid wood that makes it suitable for use in a planter. …[1] (b) Name two solid woods that would be suitable for the planter. 1 … 2 …[2] (c) Name two finishes that would be suitable for the planter. 1 … 2 …[2]

11 0445/33/M/J/15 © UCLES 2015 [Turn over (d) Use sketches and notes to show a modification to the planter that would make it easier to carry. Include details of materials and/or methods of construction. [4]

12 0445/33/M/J/15 © UCLES 2015 (e) Customers must be able to assemble the planter using only: • wood screws; • nuts and bolts; • dowels and adhesive. (i) Use sketches and notes to show how these three methods of construction could be used to join different parts of the planter. [12] (ii) List four stages in the order customers should assemble the various parts of the planter. 1 … 2 … 3 … 4 …[4]

13 0445/33/M/J/15 © UCLES 2015 [Turn over 13 Fig. 10 shows a magazine rack made from acrylic. strips 50  6 ends 10 thick base 375 200 400 Fig. 10 (a) Identify three areas of research that would need to be carried out when designing the magazine rack. 1 … 2 … 3 …[3] (b) Fig. 11 shows a template of the shape of one end of the magazine rack glued on to acrylic sheet. Fig. 11 Give two benefits of using a template when marking out. 1 … 2 …[2]

14 0445/33/M/J/15 © UCLES 2015 (c) Fig. 12 shows views of the base of the magazine rack. GHYHORSPHQW QHW    Fig. 12 (i) Use sketches and notes to show how the development (net) of the tray would be heated and bent to shape. [3] (ii) Explain why it would be an advantage to use a strip heater or line bender, rather than an oven, to heat the acrylic. … … …[2]

15 0445/33/M/J/15 © UCLES 2015 [Turn over (d) The strips will be cut from a length of acrylic. Each of the strips will be fixed to the ends using acrylic cement. (i) Describe how you would make sure that all the strips were cut and finished to the same length. … … …[2] (ii) Use sketches and notes to show how the strips could be equally spaced and held in position while the acrylic cement sets. [4] Question 13(e) is printed on the next page.

16 0445/33/M/J/15 © UCLES 2015 Permission to reproduce items where third-party owned material protected by copyright is included has been sought and cleared where possible. Every reasonable effort has been made by the publisher (UCLES) to trace copyright holders, but if any items requiring clearance have unwittingly been included, the publisher will be pleased to make amends at the earliest possible opportunity. To avoid the issue of disclosure of answer-related information to candidates, all copyright acknowledgements are reproduced online in the Cambridge International Examinations Copyright Acknowledgements Booklet. This is produced for each series of examinations and is freely available to download at www.cie.org.uk after the live examination series. Cambridge International Examinations is part of the Cambridge Assessment Group. Cambridge Assessment is the brand name of University of Cambridge Local Examinations Syndicate (UCLES), which is itself a department of the University of Cambridge. (e) (i) Many magazine racks are made from wood. Use sketches and notes to show how the magazine rack shown in Fig. 10 could be redesigned using wood. Include the specific names of the wood used and methods of construction. [6] (ii) Explain why wooden magazine racks could be considered to be more environmentally friendly than those made from plastic materials. … … … …[3]

® IGCSE is the registered trademark of Cambridge International Examinations. CAMBRIDGE INTERNATIONAL EXAMINATIONS Cambridge International General Certificate of Secondary Education MARK SCHEME for the May/June 2015 series 0445 DESIGN AND TECHNOLOGY 0445/33 Paper 3 (Resistant Materials), maximum raw mark 50 This mark scheme is published as an aid to teachers and candidates, to indicate the requirements of the examination. It shows the basis on which Examiners were instructed to award marks. It does not indicate the details of the discussions that took place at an Examiners’ meeting before marking began, which would have considered the acceptability of alternative answers. Mark schemes should be read in conjunction with the question paper and the Principal Examiner Report for Teachers. Cambridge will not enter into discussions about these mark schemes. Cambridge is publishing the mark schemes for the May/June 2015 series for most Cambridge IGCSE®, Cambridge International A and AS Level components and some Cambridge O Level components.

Page 2 Mark Scheme Syllabus Paper Cambridge IGCSE – May/June 2015 0445 33 © Cambridge International Examinations 2015 Section A 1 Three safety precautions: [3] visor, work clamped, chuck guard, apron, fingers behind work, hair back, no loose jewellery NOT ear defenders 3×1 2 Two advantages of chipboard: [2] stable/will not warp, cheaper than solid wood, availability, wide boards, recycled wood, fewer defects, can be veneered to look like solid wood, environmentally friendly 2×1 NOT durable, easy to work, doesn’t splinter, stronger, cheap 3 [3] Use Adhesive gluing plastic laminate to a manufactured board table top Impact / contact adhesive, ‘Thixofix’ wooden boat building Synthetic resin, ‘Cascamite’, waterproof PVA gluing metal parts together Epoxy resin, ‘Araldite’ NOT superglue 4 aluminium comb: anodised 1 [3] NOT self-finished, electoplating wooden chopping board vegetable/olive oil / no finish 1 NOT teak oil handle of junior hacksaw: plastic / dipcoated/ powder coat 1 5 Two advantages of die casting: intricate designs possible, reusable moulds, little or no [2] machining necessary, fast process, identical multiple parts, mass production possible 2×1 NOT accurate, water resistance 6 Riveting / pop riveting [1] 7 (a) stronger, avoid splitting, more stable [1] (b) round wire, French wire, oval wire/brad, panel pin [1] (c) pincers, claw hammer [1] 8 Completed marking out of mortise and tenon joint. 3×1 [3] 1 mark = tenon, 1 mark = mortise, 1 mark correct spacing Award 1 mark for drawing of completed M&T joint

Page 3 Mark Scheme Syllabus Paper Cambridge IGCSE – May/June 2015 0445 33 © Cambridge International Examinations 2015 9 A facing off B parting off 2×1 [2] 10 Food tray polypropylene, GRP, melamine 1 [3] Plumbing pipe MDPE, polythene, PVC, ABS 1 Curtain track nylon, polypropylene, polythene NOT HDPE 1

Page 4 Mark Scheme Syllabus Paper Cambridge IGCSE – May/June 2015 0445 33 © Cambridge International Examinations 2015 Section B 11 (a) [4] Stage Tool / item of equipment Use 1 Scriber Mark lines to be sawn 2 Hegner or scroll saw Cut off waste 3 Hand file Make edges flat / smooth/accurate shape 4 Wet and dry paper Fine finishing (b) Two safety precautions: well-ventilated area, face mask, gloves or barrier cream, [2] safety glasses, use tool to apply it 2×1 NOT apron (c) Two properties of aluminium: easily bent, self-finished, attractive, malleable [2] 2×1 NOT does not rust, waterproof, lightweight, durable (d) Award 3×1 stages: Do not reward marking out [5] • Drill hole 1 • Insert abra file blade, Hegner saw [or equivalent] piercing saw to saw to line 1 • File flat and smooth 1 • Technical accuracy: 2 correctly named tools / equipment 0–2 Use of cold chisel/hacksaws/ tinsnips: award maximum 4 marks NOT laser cutter (e) Correct sequence of stages include: [3] degrease, steel wool, wet and dry [medium grit], wet and dry [fine grit], polishing mop, polishing compound, metal polish [Brasso] 3×1 NOT use of files, emery cloth, applied finishes (f) Wooden former / jig / folding bars required 1 [5] Method of securing former / jig 1 Application of force: mallet or hammer and scrap wood 1 Ease to batch produce 1 Technical accuracy 1 NOT use of bending machine

Page 5 Mark Scheme Syllabus Paper Cambridge IGCSE – May/June 2015 0445 33 © Cambridge International Examinations 2015 (g) (i) CAD accuracy, ease of editing, on-screen modelling, send designs electronically to [2] clients, fully dimensioned drawings, can be outputted to linked machines NOT quicker, faster (ii) CAM consistent quality, repetitive accuracy, quicker production times, complex [2] shapes can be created, minimum waste 12 (a) Durable, hardwearing, water/weather resistant, attractive, tough [1] (b) Wide range of hardwoods available: elm, oak, mahogany, teak and [2] softwoods including Douglas fir, cedar, pine 2×1 NOT beech (c) Paint, wood preservative, polyurethane varnish, oil, teak oil, lacquer [2] 2×1 NOT beeswax (d) Modifications include added handles, cut out hand holds, rope and drilled holes [4] Practical idea 0–2 Details of materials used AND/OR method of construction 0–2 (e) (i) For maximum 4 marks for each, full details must be provided and must be [12] appropriate to the specific parts of the planter Wood screws: rail---leg rail---base lower side---base NOT sides---ends leg---lower side Nuts and bolts: rail---leg rail---base Dowels and adhesive: top side---lower side sides---ends leg---lower side rail---base Look for technical accuracy, appropriate construction 3×4 Award 1 mark if only the parts of the planter are shown (ii) Stages include: [4] 4×1 Top and lower sides to ends Top side to lower sides Rails to legs Rail to base Leg to lower side Base to ends and/or lower sides Rails and legs to base Correct sequence not essential as the parts can be assembled in different ways.

Page 6 Mark Scheme Syllabus Paper Cambridge IGCSE – May/June 2015 0445 33 © Cambridge International Examinations 2015 13 (a) Award 3 areas of research identified: [3] 3×1 Available resources/materials Relevant sizes of magazines, types and quantity required. Allow sizes only once. User preferences Location/environment Costs Existing products NOT weight of magazines (b) speed, accuracy, awkward shapes can be repeated quickly, fewer mistakes means less [2] waste 2×1 (c) (i) heated by means of strip heater/line bender 1 [3] use of former to bend around 1 retain while acrylic cools 1 NOT left under water to cool (ii) the oven heats the whole of the acrylic 1 [2] making it difficult to achieve the sharp bend achieved by either the strip heater or the line bender 1 (d) (i) Principle is to use some form of jig or to tape the strips together. [2] After using one strip use it as a measure for next strip. Award 0–2 marks dependent on technical appropriateness. NOT laser cutter, template (ii) Award 0–2 marks for showing how the strips could be fixed and equally spaced [4] Award 0–2 marks for showing how the strips would be held while the cement sets Equal spacing requires some form of spacer the same size 0–2 as the strip Method of fixing in position using cramps 0–2 NOT use of a rule to measure gap (e) (i) Ends shaped and made from specific named manufactured board: [6] plywood, MDF 0–2 Strips shaped and made from specific named solid wood: wide variety available 0–2 Methods of construction: use of pins and/or screws with glue 0–2 Award maximum 3 marks for total redesign

Page 7 Mark Scheme Syllabus Paper Cambridge IGCSE – May/June 2015 0445 33 © Cambridge International Examinations 2015 (ii) Answers may include reference to specific points including: Some plastics are not recyclable Plastics are not biodegradable Plastics made from oil, finite source Plastics give off poisonous fumes during manufacture Wood used to manufacture can be replaced Woods can be recycled into manufactured boards Award 1 mark for each relevant point made 0–3 [3]