Cambridge IGCSE Design and Technology 0445 — 2016 Oct/Nov Paper 3 · Variant 3

This document consists of 19 printed pages and 1 blank page. DC (NF/FD) 117569/2 © UCLES 2016 [Turn over Cambridge International Examinations Cambridge International General Certificate of Secondary Education * 8 1 2 2 2 0 9 5 0 1 * DESIGN AND TECHNOLOGY 0445/33 Paper 3 Resistant Materials October/November 2016 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 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.

2 0445/33/O/N/16 © UCLES 2016 Section A Answer all questions in this section. 1 Complete the table below by naming a specific material for each product. 3URGXFW PHWDOFDQ SODVWLFJHDUV PHWDOKLQJHIRUDQRXWVLGHGRRU 6SHFLILFPDWHULDO [3] 2 Add to the drawing below to show dovetail nailing. [2]

3 0445/33/O/N/16 © UCLES 2016 [Turn over 3 Fig. 1 shows an item of equipment used in a workshop. Fig. 1 (a) Name the item of equipment. … [1] (b) Add a sketch to Fig. 1 to show how the item of equipment would be used. [2] 4 Complete the drawing below to show a tongue and groove joint. [2]

4 0445/33/O/N/16 © UCLES 2016 5 Fig. 2 shows a commercially produced shelving system made from aluminium. upright bracket Fig. 2 (a) Name a process used to make the upright part of the shelving system. … [1] (b) Name two finishes that could be applied to the aluminium shelving system. 1 … 2 … [2] 6 Complete the table below by describing a specific use for each of the saws shown. Saw Specific use [3]

5 0445/33/O/N/16 © UCLES 2016 [Turn over 7 Fig. 3 shows a joint marked out on wood and a mortise gauge that will be used to mark it out. OLQHVWREHPDUNHGRXW Fig. 3 Give two stages in setting the mortise gauge before the joint can be marked out. Stage 1 … Stage 2 … [2] 8 Fig. 4 shows a handset that has been moulded to shape. Fig. 4 Name a process that could be used to make the handset when made from: (a) plastic … (b) metal … [2] 9 Fig. 5 shows a piece of hardwood that will be used as a table top. 19 thick hardwood Fig. 5 Add to Fig. 5 to show two faults that could occur to the table top due to poor seasoning. [2]

6 0445/33/O/N/16 © UCLES 2016 10 Fig. 6 shows a woodworking process. A B Fig. 6 (a) Name the process shown in Fig. 6. … [1] (b) Name the items of equipment labelled A and B. A … B … [2]

7 0445/33/O/N/16 © UCLES 2016 [Turn over Section B Answer one question in this section. 11 Fig. 7 shows views of a small table that includes a magazine rack. The product is designed as flat-pack for self-assembly. 450 350 plywood table top hardwood rack hardwood leg plywood stand Fig. 7 (a) Give two benefits to the user of buying self-assembly products. 1 … 2 … [2]

8 0445/33/O/N/16 © UCLES 2016 (b) Fig. 8 shows part of the table top with a slot marked out ready to be cut out. 40 280 20 thick Fig. 8 Use sketches and notes to show how the slot could be cut out and the edges made flat and smooth. [4] (c) Use sketches and notes to show how the stand could be joined permanently to the table top as shown in Fig. 7. Additional materials may be used. [4]

9 0445/33/O/N/16 © UCLES 2016 [Turn over (d) Fig. 9 shows details of the end of the leg. The leg will be joined to the underside of the table top by means of a glued dowel joint.   Fig. 9 (i) State an appropriate diameter of dowel to be used. … [1] (ii) Draw on Fig. 9 to show the marking out with measurements for two holes to take the dowels. [2]

10 0445/33/O/N/16 © UCLES 2016 (e) Fig. 10 shows details of the stand and the rack. rack 275 long rack 15 thick stand 15 thick Fig. 10 Use sketches and notes to show how the rack could be screwed to the stand. Give four details about the type of screw used to include: • material; • length; • type of head; • the number required. [6]

11 0445/33/O/N/16 © UCLES 2016 [Turn over (f) Fig. 11 shows two different designs of rack that could be used with the table. A B Fig. 11 (i) Decide which of the two designs, A or B, is stronger. Explain why. … … … [2] (ii) Explain why design A could be considered wasteful in terms of materials used. … … … [2] (g) Give two properties of a finish that would be applied to the table and magazine rack. 1 … 2 … [2]

12 0445/33/O/N/16 © UCLES 2016 12 Fig. 12 shows a desk tidy made from acrylic with a hardwood base. DFU\OLFGHVNWLG\WKLFN KDUGZRRGEDVHWKLFN Fig. 12 (a) Give two properties of acrylic that make it suitable for the desk tidy. 1 … 2 … [2] (b) Give two items of research a designer would need to consider when designing the desk tidy. 1 … 2 … [2] (c) Give two reasons why the holes in the desk tidy would be drilled before the acrylic was bent to shape. 1 … 2 … [2]

13 0445/33/O/N/16 © UCLES 2016 [Turn over (d) Fig. 13 shows the development (net) of the desk tidy. A Ø50 centres for holes bend lines 120 100 60 70 Fig. 13 Use sketches and notes to show how the shape at A could be cut out and the edges made smooth. [3] (e) Use sketches and notes to show how one of the bends shown in the development (net) could be produced. Include the following details. • the method of softening the acrylic • the use of a former • the method of retaining the shape while the acrylic cools [4]

14 0445/33/O/N/16 © UCLES 2016 (f) Use sketches and notes to show modifications to the design of the desk tidy so that: • the pencils do not slide about; • a quantity of paper clips can be stored. [4] (g) Fig. 14 shows the hardwood used to make the base for the desk tidy. The base will have bevelled edges. Two bevelled edges are shown marked out. 130 80 bevelled edge Fig. 14 (i) Give one benefit of using hardwood for the base of the desk tidy. … [1] (ii) Suggest a suitable thickness for the hardwood base. … [1]

15 0445/33/O/N/16 © UCLES 2016 [Turn over (iii) Use sketches and notes to show how the two bevelled edges shown in Fig. 14 could be produced. [3] (iv) Use sketches and notes to show how the acrylic desk tidy could be joined to the hardwood base without the use of an adhesive. [3]

16 0445/33/O/N/16 © UCLES 2016 13 Fig. 15 shows an incomplete design for a bird feeder made from 1.5 thick aluminium sheet. 125 125 150 250 ; URRI Fig. 15 (a) Give two reasons why aluminium is a good choice of material for the bird feeder. 1 … 2 … [2] (b) Fig. 16 shows part of the bird feeder, without the roof, marked out on a sheet of aluminium. 150 250 waste bend lines flap 20 Fig. 16

17 0445/33/O/N/16 © UCLES 2016 [Turn over (i) Name two marking out tools used to mark out the shape. 1 … 2 … [2] (ii) Use sketches and notes to show how the shape could be cut out from the sheet. [3] (iii) Use sketches and notes to show how the aluminium would be bent to shape along the bend lines. Name all the tools and equipment used. [4]

18 0445/33/O/N/16 © UCLES 2016 (c) Fig. 17 shows the back of the roof of the bird feeder. The flaps will be pop riveted to the main part of the bird feeder. IODSVZLGH Fig. 17 (i) Describe how the roof could be attached using pop rivets. … … … … [3] (ii) Give one advantage of using pop riveting rather than the traditional riveting process. … [1] (d) A container to hold water is required. The position for the container is shown at X in Fig. 15. The container will be made from vacuum formed plastic. (i) Use sketches and notes to show a design for a vacuum formed plastic container to hold water. Show how the container will be attached to the bird feeder. [3]

19 0445/33/O/N/16 © UCLES 2016 (ii) Use sketches and notes to show the mould that will be used to vacuum form the container. [3] (iii) Name a suitable plastic for the vacuum formed container. … [1] (e) Use sketches and notes to show a modification to the design of the bird feeder so that it could be suspended from the branch of a tree. Name all the materials and fittings used. [3]

20 0445/33/O/N/16 © UCLES 2016 BLANK PAGE 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.

® IGCSE is the registered trademark of Cambridge International Examinations. This document consists of 5 printed pages. © UCLES 2016 [Turn over Cambridge International Examinations Cambridge International General Certificate of Secondary Education DESIGN AND TECHNOLOGY 0445/33 Paper 3 Resistant Materials October/November 2016 MARK SCHEME Maximum Mark: 50 Published 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 October/November 2016 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 – October/November 2016 0445 33 © UCLES 2016 Section A 1 Metal can: tin[plate], [mild]steel, aluminium (1) Plastic gears: nylon (1) Outdoor hinge: brass, aluminium, stainless steel (1) [3] 2 Award 0-2 dependent upon accuracy of sketch (0–2) [2] 3 (a) Bench hook, sawing board (1) [1] (b) Saw shown cutting wood held up against the bench hook Award 0–2 dependent upon accuracy of sketch (0–2) [2] 4 Award 0–2 dependent upon accuracy of sketch (0–2) [2] 5 (a) Extrusion [1] (b) Anodise, paint, lacquer, powder coat/dip coat, electroplating (2×1) [2] 6 Tenon saw: small scale general woodworking processes (1) Coping saw: cutting curves in thin wood (1) Hacksaw: cutting metal sections (1) [3] 7 2 stages include: set distance between spurs [with chisel], set distance from stock to first spur/pin lock stock (2 × 1) [2] 8 (a) Plastic: injection moulding (1) (b) Metal: die-casting, pressed (1) [2] 9 2 faults: end splits, splits/cracks along the grain, warping, shrinkage (2 × 1) [2] 10 (a) Laminating [1] (b) A: former, mould B: [sash/F] cramp (2 × 1) [2]

Page 3 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 33 © UCLES 2016 Section B 11 (a) 2 benefits: cheaper than pre-assembled products, can be transported home, compact, satisfaction of self-assembly. (2 × 1) [2] (b) Drill hole for saw blade, insert saw blade and reconnect, saw out waste, file edge smooth and flat. Power router. (3 × 1) Technical accuracy (0–1) [4] (c) Methods include use of added strips or blocks [above or below] (0–2) Appropriate method of permanent fixing (0–2) [4] (d) (i) Min. 6mm–12mm max.(1) [1] (ii) Spacing must not set dowels closer than 15mm from ends and be centrally positioned (0–2) [2] (e) Material: steel or brass (1) Length: minimum 19mm – maximum 35mm (1) Type of head: countersunk (1) Number required: minimum 2 – maximum 4 (1) Technical accuracy of sketch (0–2) [6] (f) (i) Explanation: B is made from 2 pieces of wood joined together and is stronger (1) A is made from a single piece with the grain weaker (1) [2] (ii) Explanation: A would be made from a single piece of wood that would need to be cut out to shape (1) The piece cut out would produce waste. (1) [2] (g) 2 properties: must be hardwearing, attractive, stainproof, heatproof, waterproof (2 × 1) [2] 12 (a) 2 properties: range of colours, inherent colour, easily formed, easily worked, cleaned easily, self-finished, attractive (2 × 1) [2] (b) 2 items of research: sizes of items to be stored, number of items, location (2 × 1) [2] (c) 2 reasons: easier to drill while flat, quicker, more accurate, safer (2 × 1) [2] (d) Use of saw to cut shape (1) Use of file to make smooth (1) Correct names of appropriate saw and file (1) [3]

Page 4 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 33 © UCLES 2016 (e) Use of strip heater or line bender (1) Appropriate former (1) Method of retention (1) Technical accuracy (1) [4] (f) Pencils prevented from sliding: use of holes in base or additional shelf added with holes drilled for pencils to locate (0–2) Method of storing paper clips: some form of container (0–2) [4] (g) (i) 1 benefit: hardwood is hardwearing, attractive, gives base weight/stability [1] (ii) Suitable thickness: minimum 10mm – maximum 20mm [1] (iii) Hardwood held in vice (1) Use of plane to remove waste (1) Technical accuracy of sketch/named tools and equipment (1) Power router (0–3) [3] (iv) Method of joining must include use of screws not adhesive Award 0–3 dependent on accuracy of spacing, number of screws and added explanatory notes [3] 13 (a) 2 reasons: aluminium can be shaped easily, does not corrode, lightweight (2 × 1) [2] (b) (i) 2 marking out tools: scriber, rule, try square, odd legs (2 × 1) [2] (ii) Shape cut out using combination of: tinsnips, guillotine, hacksaw Award 0–3 dependent on appropriately named tools and their use. [3] (iii) Aluminium sheet held securely in vice or clamped to bench (1) Appropriate use of former (1) Method of force: mallet or hammer and scrap wood (1) Technical accuracy (1) [4] (c) (i) Description includes: holes drilled in roof and back of feeder (1) Rivet is pushed into rivet gun (1) Rivet is pushed into pre-drilled holes and trigger squeezed (1) [3] (ii) Pop riveting is quicker than traditional riveting, easier, less distortion [1]

Page 5 Mark Scheme Syllabus Paper Cambridge IGCSE – October/November 2016 0445 33 © UCLES 2016 (d) (i) Award 0–3 for a practical container: appropriate size (1) appropriate shape (1) suitable method of attachment to feeder (1) [3] (ii) Mould must conform to design in previous part. Draft angles (1) Rounded corners/edges (1) Appropriate depth (1) [3] (iii) polystyrene, ABS, acrylic [1] (e) Practical solution includes the use of some form of ‘hook’ (1) Materials and fittings used (0–2) [3]