Systems & Control – Key content — Paper 3 · IGCSE Design and Technology 0445

2 Fig. 1 shows two safety clothing [PPE] signs. Wear mask Wear gloves Fig. 1 Describe a workshop process where: (a) a mask must be worn; … (b) gloves must be worn. … [2]

2 marks

Mark scheme: 2 Mask – accept any dust related or toxic related process 1 2 Gloves – accept any heat or chemical related process 1 Must be a specific process: e.g. using a sanding disc, welding

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3 Shape Memory Alloy [SMA] is an example of a ‘smart’ material. Complete the statement by adding the correct term from the list below. heated quenched in water polished SMA will return to its original shape when it is … [1]

1 marks

Mark scheme: 3 SMA – heated 1

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10 Complete the drawing of each tool shown below and describe its use. Scriber Use Chuck key Use [4]

4 marks

Mark scheme: 10 Award 1 mark for completed drawing and 1 mark for correct use 4×1 4 Section B

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13 Fig. 15 shows an incomplete design for a toy lorry. The hopper is designed to tip. 20 hopper 300 200 wheels Ø70 × 20 Fig. 15 (a) Give three specification points for the toy lorry. 1 … 2 … 3 … [3] (b) The wheels could be made from a hardwood using a woodturning lathe. The wheels could also be made from thermoplastic and injection moulded. Fig. 16 shows both methods of manufacture. woodturning injection moulding Fig. 16 (i) Describe four stages when making a set of wheels by means of either woodturning or injection moulding. Chosen method … 1 … 2 … 3 … 4 … [4] (ii) Use sketches and notes to show how one of the wheels could be attached to the base of the lorry and allowed to turn freely. [3] (c) The hopper shown in Fig. 15 will be made from plastic by means of vacuum forming. Use sketches and notes to show a design for a former that could be used to produce the hopper. [4] (d) Use sketches and notes to show how the hopper could be made to tip as shown in Fig. 15. Include details of materials, fittings and constructions used. [6] (e) Wooden toys can be painted or varnished to protect the wood. Give one additional benefit of using: (i) paint; … … (ii) varnish. … … [2] (f) Explain the benefits to a manufacturer of producing children’s toys made from plastic rather than wood-based materials. … … … … [3]

25 marks

Mark scheme: 13(a) Accept any three sensible specification points, including: 3 references to safety in terms of shape, size, finish, appealing in terms of movement, tip up feature, possible use of colour 3×1 13(b)(i) Four stages woodturning: 4 Set up procedure on lathe including diagonals, saw cut, removal of corners. Turning using gouge/scraper, check diameter with calipers, sanding smooth, parting tool/saw off wheel 4×1 OR Four stages injection moulding: Granules fed into hopper, rotating screw takes granules into heating chamber where it is melted, hydraulic pressure moves the ram to force the molten plastic into the mould, allows to cool. 4×1 13(b)(ii) Some form of axle 1 3 Method of securing axle to base of lorry/wheel 1 Free to rotate 1 13(c) Shape of mould: inverted shape of hopper 0–2 4 Rounded corners/edges 1 Draft angles 1 13(d) Practical method of tipping includes use of pivots/pins/supports/hinges at 6 back of hopper Award 0–3 for practical method 0–3 Award 0–3 for details relating to appropriate use of materials and constructions 0–3 13(e)(i) Paint makes toys appealing/attractive. Colour used as the focus of a toy; 1 e.g. shape sorting, counting, jig saws 1 13(e)(ii) Use of varnish to enhance the appearance by showing off features of the 1 wood 1 13(f) Benefits to manufacturer: when moulds [tools] have been produced and set 3 up volume production can be quick and therefore profits can be made. Wood-based materials often require fabrication which can be costly in terms of materials and their construction. Award 0–3 dependent on quality of explanation.

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3 Complete the statement by adding the correct term from the list below. lightweight recycled smart dense A thermochromic material changes colour with changes in temperature. This is an example of a … material. [1]

1 marks

Mark scheme: 3 Smart 1

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7 The table below shows products made mainly from plastic. Complete the table by naming a suitable plastic for each product. Product Name of plastic electric plug body BATTERY plastic blister packaging knife handle [3]

3 marks

Mark scheme: 7 Electric plug body Urea/phenol formaldehyde 1 3 Plastic blister packaging Polythene, PVC, PET 1 Knife handle Phenol formaldehyde, ABS 1

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2 Fig. 1 shows two safety clothing [PPE] signs. Wear mask Wear gloves Fig. 1 Describe a workshop process where: (a) a mask must be worn; … (b) gloves must be worn. … [2]

2 marks

Mark scheme: 2 Mask – accept any dust related or toxic related process 1 2 Gloves – accept any heat or chemical related process 1 Must be a specific process: e.g. using a sanding disc, welding

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3 Shape Memory Alloy [SMA] is an example of a ‘smart’ material. Complete the statement by adding the correct term from the list below. heated quenched in water polished SMA will return to its original shape when it is … [1]

1 marks

Mark scheme: 3 SMA – heated 1

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10 Complete the drawing of each tool shown below and describe its use. Scriber Use Chuck key Use [4]

4 marks

Mark scheme: 10 Award 1 mark for completed drawing and 1 mark for correct use 4×1 4 Section B

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13 Fig. 15 shows an incomplete design for a toy lorry. The hopper is designed to tip. 20 hopper 300 200 wheels Ø70 × 20 Fig. 15 (a) Give three specification points for the toy lorry. 1 … 2 … 3 … [3] (b) The wheels could be made from a hardwood using a woodturning lathe. The wheels could also be made from thermoplastic and injection moulded. Fig. 16 shows both methods of manufacture. woodturning injection moulding Fig. 16 (i) Describe four stages when making a set of wheels by means of either woodturning or injection moulding. Chosen method … 1 … 2 … 3 … 4 … [4] (ii) Use sketches and notes to show how one of the wheels could be attached to the base of the lorry and allowed to turn freely. [3] (c) The hopper shown in Fig. 15 will be made from plastic by means of vacuum forming. Use sketches and notes to show a design for a former that could be used to produce the hopper. [4] (d) Use sketches and notes to show how the hopper could be made to tip as shown in Fig. 15. Include details of materials, fittings and constructions used. [6] (e) Wooden toys can be painted or varnished to protect the wood. Give one additional benefit of using: (i) paint; … … (ii) varnish. … … [2] (f) Explain the benefits to a manufacturer of producing children’s toys made from plastic rather than wood-based materials. … … … … [3]

25 marks

Mark scheme: 13(a) Accept any three sensible specification points, including: 3 references to safety in terms of shape, size, finish, appealing in terms of movement, tip up feature, possible use of colour 3×1 13(b)(i) Four stages woodturning: 4 Set up procedure on lathe including diagonals, saw cut, removal of corners. Turning using gouge/scraper, check diameter with calipers, sanding smooth, parting tool/saw off wheel 4×1 OR Four stages injection moulding: Granules fed into hopper, rotating screw takes granules into heating chamber where it is melted, hydraulic pressure moves the ram to force the molten plastic into the mould, allows to cool. 4×1 13(b)(ii) Some form of axle 1 3 Method of securing axle to base of lorry/wheel 1 Free to rotate 1 13(c) Shape of mould: inverted shape of hopper 0–2 4 Rounded corners/edges 1 Draft angles 1 13(d) Practical method of tipping includes use of pivots/pins/supports/hinges at 6 back of hopper Award 0–3 for practical method 0–3 Award 0–3 for details relating to appropriate use of materials and constructions 0–3 13(e)(i) Paint makes toys appealing/attractive. Colour used as the focus of a toy; 1 e.g. shape sorting, counting, jig saws 1 13(e)(ii) Use of varnish to enhance the appearance by showing off features of the 1 wood 1 13(f) Benefits to manufacturer: when moulds [tools] have been produced and set 3 up volume production can be quick and therefore profits can be made. Wood-based materials often require fabrication which can be costly in terms of materials and their construction. Award 0–3 dependent on quality of explanation.

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2 Describe a specific use for each of the chisels shown in Fig. 2. cold chisel bevel-edge chisel Fig. 2 Cold chisel … Bevel-edge chisel … [2]

2 marks

Mark scheme: 2 Cold chisel: cutting sheet metal 1 2 Bevel-edge chisel: cutting joints in wood 1

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4 SMA is a smart material that, when bent out of shape, will return to its original shape when heated. SMA stands for: Shape Memory A … [1]

1 marks

Mark scheme: 4 Alloy 1

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5 Fig. 3 shows a variety of tools used in a school workshop. A B C D E F G H Fig. 3 Complete the table below to show which tool from Fig. 3 would be used for each of the processes listed. Process Tool A–H cutting through Ø12 mild steel bar starting off a hole on a centre lathe cutting a screw thread on a round bar cutting shapes out of 1 thick copper sheet [4]

4 marks

Mark scheme: 5 F E C H 4×1 4

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9 Fig. 6 shows a hot melt glue gun. Fig. 6 Give one benefit and one drawback of using a hot melt glue gun. Benefit … … Drawback … … [2]

2 marks

Mark scheme: 9 Advantage: convenient, quick to use, precise placement of adhesive 1 2 glue dries quickly. Disadvantage: not very strong, possible danger with heat from gun 1

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11 Fig. 7 shows two bookends. The bookends could be made from plastic or metal. One bookend has two storage strips where pens and pencils could be stored. 150 storage strips 100 90 Fig. 7 (a) Complete the table below by naming a suitable specific material and appropriate thickness of material for the bookends. Material Specific name Appropriate thickness thermoplastic ferrous metal [4] (b) Fig. 8 shows one bookend marked out ready to be bent to shape. bend line Fig. 8 Name one appropriate way of marking a line on the surface of: (i) thermoplastic; … [1] (ii) ferrous metal. … [1] (c) Use sketches and notes to show how the bookends could be bent to shape when made from: (i) thermoplastic; [3] (ii) ferrous metal. [3] (d) Fig. 9 shows the storage strips that will be joined to the bookend of the same material. 20 thermoplastic ferrous metal Fig. 9 (i) Describe three main stages when joining a storage strip to the bookend permanently when made from either thermoplastic or ferrous metal. Chosen material … 1 … 2 … 3 … [3] (ii) Use sketches and notes to show a modification to the thermoplastic bookend and storage strips so that the storage strips could be attached to the bookend without using a permanent method of joining. [3] (e) (i) The thermoplastic bookend will be self-finished. Explain what is meant by the term ‘self-finished’. … … … [2] (ii) The ferrous metal bookend will be finished by dip coating with plastic. Describe three main stages in the process of dip coating with plastic. 1 … 2 … 3 … [3] (f) The bookends are to be manufactured in large quantities. Give two benefits to a manufacturer to produce the bookends without the storage strips. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) Thermoplastic: acrylic, ABS 1 4 Thickness: 3–5 mm 1 Ferrous metal: mild steel, stainless steel 1 Thickness: 1.5–2.0 mm 1 11(b)(i) Thermoplastic: marker pen, chinagraph pencil, pencil on paper covering 1 11(b)(ii) Ferrous metal: scriber 1 11(c)(i) Bending thermoplastic: 3 strip heater/line bender/hot air gun 1 use of former 1 method of retention 1 11(c)(ii) Bending ferrous metal: 3 use of folding bars, vice and scrap wood 1 use of former 1 method of force: mallet or hammer and scrap wood 1 11(d)(i) Join thermoplastic using acrylic cement, ‘Tensol’ 1 3 Apply to surface and join 1 Apply pressure, weight or clamping 1 Award 1 mark if safety consideration is stated Join ferrous metal using epoxy resin or by brazing Epoxy resin: mix equal amounts hardener and resin 1 Mix thoroughly and apply 1 Apply pressure, weight or clamping 1 or Brazing: clean/prepare joint 1 Apply flux and heat 1 Apply brazing rod/spelter to joint 1 Award marks for other intermediate relevant stages 11(d)(ii) Practical method: use of additional ‘clips’, cut out slots and ‘lugs’ 3 Award 0–3 dependent upon technical accuracy 11(e)(i) Self-finished means no applied finish 1 2 The material can be cleaned and buffed to a high quality 1 11(e)(ii) Heat metal in an oven 1 3 Plunge metal into tank of ‘fluidised’ polythene 1 Reheat metal to produce an even finish 1 11(f) Two benefits: less material used means lower costs 1 2 fewer processes means quicker production [more profit] 1

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1 Fig. 1 shows a tool box made from plastic and a symbol found on the tool box. Fig. 1 (a) Name the plastic. … [1] (b) Give one benefit of using this plastic for the tool box. … [1]

2 marks

Mark scheme: 1(a) Polypropylene 1 1(b) Tough, hardwearing, colourful, can be injection moulded, light to carry, durable, impact resistant, easily moulded shape 1

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10 Fig. 8 shows plastic cutlery used in fast food restaurants. The cutlery is produced by the injection moulding process. Fig. 8 (a) Explain why the injection moulding process is only suitable for mass production. … … … [2] (b) Explain why the use of plastic cutlery in fast food restaurants could be harmful to the environment. … … … [2]

4 marks

Mark scheme: 10(a) Cost of tooling is high 1 High volume production necessary to recover costs/make profit 1 2 10(b) Plastics dependent on oil which is a finite resource 1 Plastics not biodegradeable 1 Disposed of at landfill 1 When burnt give off toxic fumes 1 2

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9 Complete the table by naming the correct plastic from the list below to match each description. nylon melamine PVC polythene polystyrene Material Description of material hard, tough, weather resistant, used for pipes, guttering, window frames hard-wearing, strong, range of colours, used for decorative laminates lightweight plastic, absorbs shock, good heat and sound insulator [3]

3 marks

Mark scheme: 9 From the top to bottom: PVC melamine Question Answer Marks 10 A reach from head to fingers for comfortable access to keyboard/desk = 1 B seat height set at comfortable height appropriate for the individual = 1 C desk height appropriate for individual seated at the computer with space for legs = 1 3

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10 Fig. 8 shows a person sitting at a desk, using a computer. Three areas, where consideration of ergonomics is required, are labelled A, B and C. A C B Fig. 8 Describe briefly the ergonomic consideration for each of the areas A, B and C shown. A … B … C … [3]

3 marks

Mark scheme: 10 B seat height set at comfortable height appropriate for the individual = 1 C desk height appropriate for individual seated at the computer with space for legs = 1

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12 Fig. 12 shows a guitar stand made from hardwood. The stand can store up to four guitars. top rail support upright bottom rail 700 end rail 850 450 Fig. 12 (a) A parts list for the guitar stand is shown below. Number Part Length × Width × Thickness Hardwood reqd. Upright 2 700 × 40 × 15 Top rail 1 × 40 × 15 Bottom rail 2 × 40 × 12 End rail 2 450 × 60 × 15 Support 4 120 × 50 × 12 Complete the parts list by stating the two missing dimensions and naming one suitable hardwood for the guitar stand. [3] (b) Give three items of research a designer would need to consider when designing the guitar stand. 1 … 2 … 3 … [3] (c) Fig. 13 shows one support marked out ready to be cut to shape. 12 50 waste 120 Fig. 13 Complete the table below by naming specific tools or items of equipment used to produce the final shape. Stage Process Specific tool or item of equipment 1 Remove the waste 2 Produce an accurately shaped curve 3 Smooth the surfaces [3] (d) Fig. 14 shows views of a bottom rail showing rounded edges. marked out after planing Fig. 14 (i) Name a suitable plane that could be used to produce the rounded edges. … [1] (ii) Give one reason why the bottom rails are covered with fabric. … [1] (e) The end rails will be joined to the uprights by means of 25 mm long screws. Complete the drawing of the screw shown below by: • naming the type of head • showing accurately the length of the screw • naming a suitable material not to scale [3] (f) Fig. 15 shows one end of the top rail. The top rail is joined to the upright by means of dowels. 10 20 centres for dowel holes 15 Fig. 15 Use sketches and notes to show a design for a drilling jig that could be used to ensure that holes are drilled accurately in the ends of the top rails. Name the material/s from which the drilling jig is made. [5] (g) Use sketches and notes to show how a set of ‘feet’ could be added to the guitar stand. Name the material used to make the ‘feet’. [3] (h) A wax finish will be applied to the guitar stand. (i) Give one reason why two different grades of abrasive paper would be used to prepare the surfaces before the wax finish is applied. … … [1] (ii) Give one reason why the guitar stand would be waxed rather than painted. … … [1] (iii) Give one advantage of applying a wax finish rather than a polyurethane varnish finish to the guitar stand. … … [1]

25 marks

Mark scheme: 12(a) Top rail = 790–820 Hardwood: accept any named hardwood 1 3 12(b) Important areas of the guitar to measure to determine sizes, number of guitars to be stored, types of guitar, which areas of the guitar are suitable for holding/supporting, environment in which the stand is located 3 × 1 3 12(c) Stage 1: coping, Hegner or equivalent, band, Scroll, jig saws = 1 Stage 2: half-round, round [rat-tail] files, spokeshave, Surform tools, bobbin sander = 1 Stage 3: glasspaper, sandpaper, bobbin sander = 1 3 12(d)(i) Jack, smoothing, block, moulding 1 12(d)(ii) To protect the guitar from scratches 1 12(e) Head: countersink = 1 = 1 Material: steel, brass, copper, stainless steel = 1 3 12(f) 2 holes drilled in ‘plate’ = 1 location on 1 side = 1, location on 2 sides = 2, location on 3 sides = 3. Named material = 1 5 12(g) Practical idea: some form of ‘foot’ accurately drawn 1 Method of attaching ‘foot’ 1 Appropriate material 1 3 12(h)(i) 2 different grades means one grade will be finer to remove scratches of previous grade 1 12(h)(ii) Hardwood is used to show off its colour, grain, figure that would be covered by paint, paint could chip/scratch, paint could mark guitar 1 12(h)(iii) Wax finish is quicker to apply, more even finish, easy to maintain, easier to apply, does not chip/flake, quicker to dry 1

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1 Fig. 1 shows a tool box made from plastic and a symbol found on the tool box. Fig. 1 (a) Name the plastic. … [1] (b) Give one benefit of using this plastic for the tool box. … [1]

2 marks

Mark scheme: 1(a) Polypropylene 1 1(b) Tough, hardwearing, colourful, can be injection moulded, light to carry, durable, impact resistant, easily moulded shape 1

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10 Fig. 8 shows plastic cutlery used in fast food restaurants. The cutlery is produced by the injection moulding process. Fig. 8 (a) Explain why the injection moulding process is only suitable for mass production. … … … [2] (b) Explain why the use of plastic cutlery in fast food restaurants could be harmful to the environment. … … … [2]

4 marks

Mark scheme: 10(a) Cost of tooling is high 1 High volume production necessary to recover costs/make profit 1 2 10(b) Plastics dependent on oil which is a finite resource 1 Plastics not biodegradeable 1 Disposed of at landfill 1 When burnt give off toxic fumes 1 2

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6 Fig. 4 shows equipment used in a moulding process. pegs finished moulding Fig. 4 (a) Name the moulding process shown in Fig. 4. … [1] (b) State the purpose of the pegs in the moulding process.

2 marks

Mark scheme: Qu 6(a) Press 6(b) To loc uestion s forming, plug a cate the male an and yoke nd female forme ers Answer Mar 1 1 rks

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9 Fig. 7 shows a metric micrometer and a close-up view of the sleeve and thimble. sleeve 30 0 5 thimble 25 20 sleeve thimble Fig. 7 State the exact reading to one hundredth of a mm (0.01). … [3]

3 marks

Mark scheme: 9 7.00 0.50 0.24 7.74 1 1 1 3

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10 Fig. 8 shows an item of workshop equipment. Fig. 8 (a) State one specific use for the item of equipment shown in Fig. 8. … [1] (b) Give two safety precautions, other than wearing safety glasses, that must be taken when using the item of equipment. 1 … 2 … [2]

3 marks

Mark scheme: 10(a) Polishing metal or plastic 1 10(b) Two safety precautions other than safety glasses: hold work piece correctly, hair tied back, no loose clothing, fingers away from wheel, face mask 2 × 1 2

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13 Fig. 15 shows two designs of shelf units. Both designs are manufactured and sold as self-assembly products. Design A Design B hardwood shelf and brackets veneered manufactured board and stainless steel brackets Fig. 15 (a) Give one reason why the parts of Design A would have a finish applied before they are assembled. … [1] (b) Give one benefit of using stainless steel for the brackets in Design B. … [1] (c) (i) Explain why there is a possibility that the hardwood shelf could split if it was fixed permanently to the bracket in Design A. … … … [2] (ii) Use sketches and notes to show a method of fixing the shelf to the bracket in Design A that would prevent it from splitting. [2] (d) Fig. 16 shows details of one bracket used with Design A. The bracket is made by joining three strips of wood together. 200 X hardwood 25 × 25 Fig. 16 (i) Use sketches and notes to show a design for a sawing jig that could be used when sawing 200-long strips from a length of hardwood. The sawing jig must: • hold the hardwood securely; • allow the hardwood to be cut accurately to length. Include details of materials and fittings used. [6] (ii) Sketch and name a suitable joint at X in Fig. 16. [4] (iii) Name three tools used to produce the joint named in (ii). Do not include marking-out tools. 1 … 2 … 3 … [3] (e) Use sketches and notes to show details of one functional improvement that could be made to shelf unit Design A shown in Fig. 15. [2]

21 marks

Mark scheme: 13(a) Reason: difficult to clean surfaces after gluing, quicker, more efficient 1 13(b) Benefit: attractive appearance, does not corrode, easily cleaned, self-finished, covers chipboard edges 1 13(c)(i) Hardwood shelf needs allowance for movement 1 If no allowance is provided it could split 1 2 13(c)(ii) Some form of slot screw 0–2 2 13(d)(i) Sawing jog: Method of holding/securing wood while sawn 0–1 Accurate sawing to length 0–2 Ease of use 0–1 Materials and fittings used 0–2 6 13(d)(ii) Mortise and tenon, dowel, corner bridle, corner halving named 1 Butt joint: for three marks butt must be pinned or screwed and glued Award 0–3 for sketch dependent on clarity and technical accuracy 0–3 4 13(d)(iii) Three tools must relate to joint drawn in previous part (i) even if joint is inappropriate. Do not accept marking out tools. Examples include: tenon saw, coping saw, bevel edge chisel, mortise chisel, mallet, drill, dowel jog 3 × 1 3 13(e) One functional improvement to A: lipping applied above shelf level to prevent item falling off, edges radiused to relieve sharp edges, fill in triangular brackets to add strength, method of fixing shelf to bracket allows for movement, additional rail under shelf 2 13(f) Design A more expensive than Design B More constructions means more labour time, therefore greater expense Hardwood shelf more expensive than manufactured board shelf OR Design B is more expensive because of cost of stainless steel and welding processes involved 2 Question Answer Marks 13(g)(i) Benefit to consumer: cheaper than pre-assembled products, self-satisfaction, compact, easy to transport, provides practical experience 1 13(g)(ii) Benefit to manufacturer: takes up less storage, cheaper to manufacture, costs reduced 1

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2 Fig. 2 shows a variety of different plastic tubes. Fig. 2 Name the process used to make the plastic tubes. … [1]

1 marks

Mark scheme: 2 Extrusion 1

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5 Fig. 4 shows three products made from different thermosetting plastics. A B C Fig. 4 Name a different thermosetting plastic that could be used to make each of the products. A Electrical fitting … B Plastic laminate … C Two-part adhesive … [3]

3 marks

Mark scheme: 5 A urea formaldehyde B melamine C epoxy resin 3 × 1 3

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10 Fig. 8 shows a process used to make a plastic bowl. metal ring plastic sheet after heating clamp plastic sheet before heating seal air Fig. 8 (a) Name the process shown in Fig. 8. … [1] (b) Add to Fig. 8 to show how the bowl could be produced with a flat bottom. [1]

2 marks

Mark scheme: 10(a) Blow moulding, extrusion blow moulding 1 10(b) To make flat bottom a flat shape should be drawn on top of bowl shape = 1 1

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12 Fig. 12 shows an incomplete design of a desk. The desk top is made from manufactured board and the legs and rails from hardwood. end frame 60 × 20 A desk top height 700 1000 1000 600 Fig. 12 (a) (i) Name a suitable manufactured board for the desk top. … [1] (ii) Suggest an appropriate thickness of manufactured board for the desk top. … [1] (iii) Name a suitable hardwood for the legs and rails. … [1] (iv) Complete the statement below by adding the correct term from the list. mechanisms seasoning anthropometrics sustainability The designer decided to make the desk 700 mm high after studying … … [1] (b) The corner bridle joint shown below could be used to join the leg and rail at corner A in Fig. 12. (i) Name two marking out tools, other than a pencil, that could be used to mark out the corner bridle joint. 1 … 2 … [2] (ii) Name two tools that could be used to cut out the corner bridle joint. 1 … 2 … [2] (c) Use sketches and notes to show how the desk top could be fixed to the end frames. Include details of constructions and fittings used. [5] (d) Fig. 13 shows the legs and rails of one frame ready to be glued and clamped. position for cramp position for cramp Fig. 13 (i) Name the cramps that would be used to secure the joints. … [1] (ii) Name a suitable adhesive that could be used to glue the joint together. … [1] (iii) Describe two checks that would need to be carried out when the legs and rails are glued and clamped together. 1 … 2 … [2] (e) Fig. 14 shows the shape of one end frame marked out on a sheet of manufactured board. The end frame will be cut out of the sheet of manufactured board rather than using separate legs and rails. waste 1000 600 Fig. 14 (i) Give one advantage and one disadvantage of making the end frame from one piece of manufactured board rather than separate legs and rails. Advantage … … Disadvantage … … [2] (ii) Name a portable power tool that could be used to cut out the shape of the end frame. … [1] (iii) Describe two safety precautions, other than personal protection equipment, that must be taken when using portable power tools. 1 … 2 … [2] (f) Fig. 15 shows two desks. Desk A is a modern desk and desk B is a traditional design. A B Fig. 15 Explain why the design of the desk has changed. … … … … [3]

25 marks

Mark scheme: 12(a)(i) Plywood, faced chipboard, MDF, blockboard, laminboard 1 12(a)(ii) 18–20 mm 1 12(a)(iii) Wide variety available: ash, oak, beech, mahogany, teak 1 12(a)(iv) anthropometrics 1 12(b)(i) Steel rule, try square, marking gauge, mortise gauge, cutting gauge, 2 marking knife 2 × 1 12(b)(ii) Tenon saw, coping saw, chisel, mallet 2 × 1 2 12(c) Some form of added strip/blocks/brackets required 0–2 5 Processes describing methods of construction 0–2 Named adhesive 0–1 12(d)(i) Sash, bar, F, speed 1 12(d)(ii) Wide variety available: synthetic resin, PVA. Accept trade names: e.g. Evo- 1 Stik Resin W, Cascamite, Aerolite 12(d)(iii) 2 checks: joint pulled together, squareness, not in winding, removal of 2 surplus adhesive, cramps not over-tightened 12(e)(i) Advantage: no need for separate fabricated constructions, quicker = 1 2 Disadvantage: wasteful of material = 1 12(e)(ii) Jig saw, router 1 12(e)(iii) Check overall condition of tool before use, no trailing leads, no loose 2 clothing, work piece secure, hair tied back 2 × 1 12(f) Developments in flat-pack furniture design, self-assembly KD fittings, 3 social/technological trends; eg use of PCs.

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6 Fig. 4 shows equipment used in a moulding process. pegs finished moulding Fig. 4 (a) Name the moulding process shown in Fig. 4. … [1] (b) State the purpose of the pegs in the moulding process.

2 marks

Mark scheme: Qu 6(a) Press 6(b) To loc uestion s forming, plug a cate the male an and yoke nd female forme ers Answer Mar 1 1 rks

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9 Fig. 7 shows a metric micrometer and a close-up view of the sleeve and thimble. sleeve 30 0 5 thimble 25 20 sleeve thimble Fig. 7 State the exact reading to one hundredth of a mm (0.01). … [3]

3 marks

Mark scheme: 9 7.00 0.50 0.24 7.74 1 1 1 3

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10 Fig. 8 shows an item of workshop equipment. Fig. 8 (a) State one specific use for the item of equipment shown in Fig. 8. … [1] (b) Give two safety precautions, other than wearing safety glasses, that must be taken when using the item of equipment. 1 … 2 … [2]

3 marks

Mark scheme: 10(a) Polishing metal or plastic 1 10(b) Two safety precautions other than safety glasses: hold work piece correctly, hair tied back, no loose clothing, fingers away from wheel, face mask 2 × 1 2

This question in 0445/33 Oct/Nov 2018

13 Fig. 15 shows two designs of shelf units. Both designs are manufactured and sold as self-assembly products. Design A Design B hardwood shelf and brackets veneered manufactured board and stainless steel brackets Fig. 15 (a) Give one reason why the parts of Design A would have a finish applied before they are assembled. … [1] (b) Give one benefit of using stainless steel for the brackets in Design B. … [1] (c) (i) Explain why there is a possibility that the hardwood shelf could split if it was fixed permanently to the bracket in Design A. … … … [2] (ii) Use sketches and notes to show a method of fixing the shelf to the bracket in Design A that would prevent it from splitting. [2] (d) Fig. 16 shows details of one bracket used with Design A. The bracket is made by joining three strips of wood together. 200 X hardwood 25 × 25 Fig. 16 (i) Use sketches and notes to show a design for a sawing jig that could be used when sawing 200-long strips from a length of hardwood. The sawing jig must: • hold the hardwood securely; • allow the hardwood to be cut accurately to length. Include details of materials and fittings used. [6] (ii) Sketch and name a suitable joint at X in Fig. 16. [4] (iii) Name three tools used to produce the joint named in (ii). Do not include marking-out tools. 1 … 2 … 3 … [3] (e) Use sketches and notes to show details of one functional improvement that could be made to shelf unit Design A shown in Fig. 15. [2]

21 marks

Mark scheme: 13(a) Reason: difficult to clean surfaces after gluing, quicker, more efficient 1 13(b) Benefit: attractive appearance, does not corrode, easily cleaned, self-finished, covers chipboard edges 1 13(c)(i) Hardwood shelf needs allowance for movement 1 If no allowance is provided it could split 1 2 13(c)(ii) Some form of slot screw 0–2 2 13(d)(i) Sawing jog: Method of holding/securing wood while sawn 0–1 Accurate sawing to length 0–2 Ease of use 0–1 Materials and fittings used 0–2 6 13(d)(ii) Mortise and tenon, dowel, corner bridle, corner halving named 1 Butt joint: for three marks butt must be pinned or screwed and glued Award 0–3 for sketch dependent on clarity and technical accuracy 0–3 4 13(d)(iii) Three tools must relate to joint drawn in previous part (i) even if joint is inappropriate. Do not accept marking out tools. Examples include: tenon saw, coping saw, bevel edge chisel, mortise chisel, mallet, drill, dowel jog 3 × 1 3 13(e) One functional improvement to A: lipping applied above shelf level to prevent item falling off, edges radiused to relieve sharp edges, fill in triangular brackets to add strength, method of fixing shelf to bracket allows for movement, additional rail under shelf 2 13(f) Design A more expensive than Design B More constructions means more labour time, therefore greater expense Hardwood shelf more expensive than manufactured board shelf OR Design B is more expensive because of cost of stainless steel and welding processes involved 2 Question Answer Marks 13(g)(i) Benefit to consumer: cheaper than pre-assembled products, self-satisfaction, compact, easy to transport, provides practical experience 1 13(g)(ii) Benefit to manufacturer: takes up less storage, cheaper to manufacture, costs reduced 1

This question in 0445/33 Oct/Nov 2018

1 Two signs used in a workshop are shown below. Describe a specific workshop process when: ear defenders must be worn … safety glasses must be worn. … [2]

2 marks

Mark scheme: 1(b) Safety glasses: drilling machine, lathework, handling dangerous chemicals, sanding machine, belt sander. 1 2 Accept any specific process where eye protection is vital.

This question in 0445/31 May/June 2019

5 Fig. 3 shows two electric drills. plastic body aluminium alloy casing rechargeable battery mains cable Drill A Drill B Fig. 3 (a) Name the manufacturing process used to produce the casing for drill A. … [1] (b) Give one advantage of using drill B compared to drill A. … [1]

2 marks

Mark scheme: 5(a) Die-casting 1 5(b) No restriction on mains cable length, more versatile in use, safer as no lead to trip, portable 1 Do NOT accept safer without qualification, lighter

This question in 0445/31 May/June 2019

1 Fig. 1 shows a kitchen pedal bin. lid body pedal Fig. 1 Complete the list below by adding two specification points for the kitchen pedal bin. 1 The lid must open easily when the pedal is pressed. 2 … 3 … [2]

2 marks

Mark scheme: 1 Specification points include: must close automatically when foot is removed from pedal, attractive appearance, durable materials, easy to clean, stable in use, large pedal for foot 2 × 1 2 Not lightweight, use recycled/recyclable materials.

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11 Fig. 6 shows an incomplete design of a child’s novelty clock. The clock shape could be made from 5 mm thick manufactured board or 1.5 mm thick non-ferrous metal. The clock will be placed on a shelf. 12 11 1 300 10 2 9 3 8 4 7 5 6 400 Fig. 6 (a) (i) Name a suitable manufactured board for the clock shape. … [1] (ii) Name a suitable non-ferrous metal for the clock shape. … [1] (b) Fig. 7 shows a template of the shape glued to a sheet of 5 mm thick manufactured board. The centre for a hole to be drilled for the clock mechanism is shown. waste to be removed centre for hole Fig. 7 (i) Give two reasons why the sheet of manufactured board must be clamped down securely when drilling the hole. 1 … 2 … [2] (ii) Use sketches and notes to show how the shape could be cut out by hand and the edges made smooth. [3] (c) Fig. 8 shows the clock shape made from manufactured board joined to a wooden base. 12 1 2 11 3 10 4 9 5 8 7 6 wooden base 400 × 40 × 10 Fig. 8 Use sketches and notes to show how the clock shape could be joined to the base. [3] (d) The manufactured board clock shape will be finished with spray paint. Give two advantages of spray paint rather than applying the paint with a brush. 1 … 2 … [2] (e) Fig. 9 shows the clock shape made from 1.5 mm thick non-ferrous metal. Legs have been joined to the shape so that it could stand on a shelf. 12 1 2 11 3 10 4 9 5 8 7 6 legs 60 × 20 × 1.5 Fig. 9 Use sketches and notes to show how the legs could be made from non-ferrous metal and joined permanently to the clock shape. Name all the tools and equipment used. [5] (f) When the clock shape is made from non-ferrous metal it could be self-finished. Explain what is meant by the term ‘self-finished’. … … … [2] (g) Describe in detail how CAD/CAM could be used to produce the numbers 1 to 12 on the 5 mm thick manufactured board clock face. … … … … … … [4] (h) State two ways, other than shape and colour, by which designers make products used by young children appealing and exciting. 1 … 2 … [2]

25 marks

Mark scheme: 11(a)(i) Plywood, MDF, hardboard 1 11(a)(ii) Aluminium, copper, brass, gilding metal 1 11(b)(i) Two reasons include: to drill an accurate hole, to prevent the drill from snagging, to prevent distortion, safety issue of board spinning 2 × 1 2 Stop it moving is too vague 11(b)(ii) Saw to remove waste; use of coping, jig, Hegner, scroll, band saws 1 Use of files 1 Use of glasspaper 1 3 Must be hand method. Accept any other valid saw. Not laser. 11(c) Method: use of 5 mm wide mortises/added block or bracket behind clock face 0–2 Use of PVA/adhesive 1 3 Do not accept use of nails, screws or dowels into 5 mm thick manufactured board. 11(d) More even application, quicker, better finish, no brush strokes 2 × 1 2 Not easier. 11(e) Legs made from sheet metal cut to shape 1 Bending metal to shape 0–2 Method of joining: use of rivets, solder or epoxy resin adhesive 0–2 5 Use of former, jig, scrap wood, mallet, vice Use of blowtorch, flux, solder, epoxy resin Ignore details of heating to bend or use of sheet metal benders. If candidate names a non-ferrous alloy the method of joining must be appropriate. 11(f) Self-finished means no applied finish is added 1 The surface is cleaned and then buffed/polished 1 2 11(g) CAD: used to design the numbers on screen, change font, size, on-screen modelling, data transferred/downloaded to CNC machine. 0–2 CAM: numbers engraved into surface or applied to surface; use of specific machine such as CAMM 1 vinyl cutter or CNC router, laser cutter set up, tool parameters. 0-2 4 Reward answers that demonstrate genuine knowledge of CAD-CAM. 11(h) Movement, sound, lights, theme linked to TV, cinema or book character 2 × 1 2 Accept any valid methods.

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12 Fig. 10 shows views of a storage unit designed to hold a tablet, mobile phone and remote control. tablet 200 slot phone base strip 230 120 Fig. 10 (a) Give two reasons why acrylic would be a suitable material for the storage unit. 1 … 2 … [2] (b) Fig. 11 shows the development (net) of the storage unit made from 5 mm thick acrylic. slot A 190 × 60 A B slot B 190 × 40 Fig. 11 Use sketches and notes to show how the slots could be cut out by hand and the edges made smooth. [4] (c) The development (net) and slots could be cut out using a CNC machine. Describe the stages involved when using a CNC machine to cut out the development (net) and slots. … … … … … … [4] (d) Use sketches and notes to show how the acrylic development (net) could be bent to shape. [3] (e) Fig. 12 shows one of the strips that will be joined to the base of the storage unit using acrylic cement. strip 200 × 10 × 5 Fig. 12 (i) Use sketches and notes to show how the strip could be held in place while the acrylic cement sets. [2] (ii) Give one reason why each of the following items would be worn when using acrylic cement: disposable gloves … face mask. … [2] (f) The storage unit could also be made by laminating five wood veneers, each 1 mm thick. Use sketches and notes to show how the laminate could be formed to the shape of the storage unit. (g) Describe how you would evaluate the success of the final product. … … … … [2] (h) Explain why consumer demand for storage units of the type shown in Fig. 10 has increased in recent years. … … … … [2]

25 marks

Mark scheme: 12(a) Reasons include: easy to bend, variety of colours available, attractive, easy to clean, self-finishing. 2 12(b) Pre-drilled hole 1 Cut out using coping, Hegner, scroll saw 1 Removal of waste to produce shape 1 Finishing: use of wet and dry, scraper, acrylic polish 1 4 12(c) Processes/details include: design drawings transferred/downloaded to CNC machine type of CNC machine used setting up of acrylic workpiece setting of machine parameters 4 × 1 4 The transfer/download of data can be rewarded as part of the overall operation. Reward any genuine points in the overall explanation. Types of CNC machine: miller, router, engraver, laser cutter. 12(d) Use of strip heater, line bender, oven 1 Use of former or machine setting [line bender] to obtain required angle 1 Method of retention 1 3 12(e)(i) Method of clamping: G cramps or applied weights. 1 Use of scrap wood to prevent damage, distribute pressure evenly 1 2 12(e)(ii) Disposable gloves: because acrylic cement is an irritant 1 Face mask: to prevent inhaling toxic fumes/splashes 1 2 Do not accept ‘protect’ unless qualified 12(f) Sketches showing: layers of wood veneers glued 1 Use of a former/formers 0–2 Method of clamping laminate to retain shape, including vacuum bag 1 4 12(g) Evaluation carried out: insert tablet, phone and remote and test accessibility, stability, seek third party opinion re appearance 2 Accept any valid evaluation procedures. 12(h) Consumer demand due to: advances in technology, use of tablets, phones, ease of accessibility essential, fashion trends. 2 Reward well-presented comments demonstrating an understanding of issues.

This question in 0445/32 May/June 2019

1 Two signs used in a workshop are shown below. Describe a specific workshop process when: ear defenders must be worn … safety glasses must be worn. … [2]

2 marks

Mark scheme: 1(b) Safety glasses: drilling machine, lathework, handling dangerous chemicals, sanding machine, belt sander. 1 2 Accept any specific process where eye protection is vital.

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5 Fig. 3 shows two electric drills. plastic body aluminium alloy casing rechargeable battery mains cable Drill A Drill B Fig. 3 (a) Name the manufacturing process used to produce the casing for drill A. … [1] (b) Give one advantage of using drill B compared to drill A. … [1]

2 marks

Mark scheme: 5(a) Die-casting 1 5(b) No restriction on mains cable length, more versatile in use, safer as no lead to trip, portable 1 Do NOT accept safer without qualification, lighter

This question in 0445/33 May/June 2019

1 Complete the table by stating the manufacturing process used to make each plastic product. Plastic product Manufacturing process electrical plug guttering sandwich container [3]

3 marks

Mark scheme: Question Answer Marks 1 Electrical plug: injection or compression moulding 1 3 Guttering: extrusion 1 Sandwich container: vacuum forming, blow moulding 1

This question in 0445/31 Oct/Nov 2019

1 Complete the table by stating the manufacturing process used to make each plastic product. Plastic product Manufacturing process electrical plug guttering sandwich container [3]

3 marks

Mark scheme: Question Answer Marks 1 Electrical plug: injection or compression moulding 1 3 Guttering: extrusion 1 Sandwich container: vacuum forming, blow moulding 1

This question in 0445/32 Oct/Nov 2019

2 Fig. 2 shows a small wheel. The wheel could be made from wood, metal or plastic. Ø100 Fig. 2 Name a suitable manufacturing process used to produce the wheel when made from: wood … metal … plastic. … [3]

3 marks

Mark scheme: 2 Wood: woodturning, wood lathe 1 3 Metal: casting, die-casting, centre lathe turning 1 Plastic: injection moulding, blow moulding 1

This question in 0445/33 Oct/Nov 2019

8 Fig. 8 shows a child’s push-along go-kart. Fig. 8 Give two examples of anthropometric data used in the design of the go-kart. 1 … 2 … [2]

2 marks

Mark scheme: 8 Seat and backrest: width of torso and height of torso. Distance from foot steering 2 dependent on leg length. Length of steering rope dependent on arm length/reach 2×1

This question in 0445/33 Oct/Nov 2019

11 Fig. 12 shows a desk tidy made from 4 mm thick plywood. The desk tidy will be batch produced in quantity. disc Ø90 frame solid disc height 120 Fig. 12 (a) Use sketches and notes to show the construction of 4 mm thick plywood to explain why it is suitable for the desk tidy. [3] (b) Fig. 13 shows details of the two frames of the desk tidy. The frames are joined at A by means of a cross-halving joint. slot 5 × 6 A Fig. 13 Draw the cross-halving joint used at A. [3] (c) Fig. 14 shows one disc marked out, ready to be cut to shape. The Ø60 hole has been drilled in the disc. 100 Ø90 disc Ø60 hole waste 100 Fig. 14 (i) The Ø60 hole has been drilled using the tool shown below. Give the correct name of the tool shown. … [1] (ii) Describe how the Ø90 disc could be cut out of a sheet of 4 mm thick plywood and finished accurately. … … … [2] (d) Fig. 15 shows a template that could be used to mark out a large quantity of frames. Fig. 15 Give one reason why the template would need to be made from a resistant material such as wood, metal or plastic. … … [1] (e) The desk tidy could be designed using CAD. Give three advantages, other than speed, of using CAD rather than traditional drawing methods to design the desk tidy. 1 … 2 … 3 … [3] (f) The desk tidy needs to be modified so that it can rotate as shown in Fig. 16. desk tidy rotates disc Ø90 frame solid disc height 120 Fig. 16 Use sketches and notes to show how the desk tidy could be modified so that it could rotate. Include details of materials and constructions used. [6] (g) The parts of the desk tidy will be glasspapered then spray painted. (i) Explain why it is necessary to use different grades of glasspaper to prepare the surfaces for the spray paint. … … … [2] (ii) Give two safety precautions that must be taken when spray painting. 1 … 2 … [2] (h) Describe two quality control checks that would be carried out during the manufacture of a batch of desk tidies. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) 3 layers shown 1 3 Grain shown at 90° to each layer 1 Notes to explain 1 11(b) Award marks dependent on technical accuracy, orientation, proportion 0–3 3 11(c)(i) Hole saw 1 11(c)(ii) Cut out: use of variety of hand and machine saws 1 2 Finished accurately: use of disc sander, files, glasspaper 1 11(d) Large quantity of frames requires a template that will remain accurate and material such 1 as paper or card would distort/ become damaged 11(e) CAD allows on-screen modelling, more accurate, easier editing, amendments can be 3 made quicker, drawings can be transferred to CNC machines 3×1 11(f) Some form of pivot, bearing 0–2 6 Additional stand [appropriate shape/size] 0–2 Details of constructions and materials used 0–2 11(g)(i) Glasspaper scratches the surface of the plywood 1 2 Using a finer grade replaces more coarse scratches 1 11(g)(ii) Well-ventilated area, face mask to prevent inhalation of fumes, eye protection, gloves to 2 protect skin 2×1 11(h) Wide variety of dimensional checks of various parts of the desk tidy to ensure fit. Checks 2 to ensure smooth finish, no rough edges. Checks for stability of desk tidy, Checks for rotation. General visual checks.

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5 Fig. 5.1 shows a coat hook for a child. The coat hook is made from 5 mm thick acrylic and will be batch produced. fixing holes Fig. 5.1 Complete Table 5.1 by stating how each item could be used to speed up batch production of the coat hook. Table 5.1 Item How each item is used to speed up production Template Former Drilling jig [3]

3 marks

Mark scheme: 5 Template: used to mark out the shape quickly/accurately 1 3 Former: used to enable the acrylic to be bent to shape 1 Drilling jig: used to drill fixing holes quickly and accurately 1

This question in 0445/31 May/June 2020

8 Explain one advantage of using Computer Numerically Controlled (CNC) machines compared with manually operated machines for batch production. … … … [2]

2 marks

Mark scheme: 8 Explanation Advantages include: consistent quality of products, less skilled 2 labour reqd. faster production, easy to change to different products, continuous operation

This question in 0445/31 May/June 2020

10 Fig. 10.1 shows a plastic cup used for hot drinks. lid cuff cup Fig. 10.1 Explain how the designer of the cup has considered the needs of the user. … … … [2]

2 marks

Mark scheme: 10 Points include: 2 Lid to retain heat, prevent spillages. Ridged ‘collar’ for grip, prevent burns. Tapered shape for stability and safety.

This question in 0445/31 May/June 2020

11 Fig. 11.1 shows a pen and pencil holder. top: 1.5 mm thick brass leg: brass rod Ø6 base: 12 mm thick beech 135 135 Fig. 11.1 (a) Fig. 11.2 shows the top part of the pen and pencil holder with the four shapes marked out. shapes 40 × 40 20 Fig. 11.2 Use sketches and notes to show how one of the shapes could be cut out and the edges made flat and smooth. Name all the tools and equipment used. [4] (b) Fig. 11.3 shows how the legs are fitted to the top of the pen and pencil holder by means of screw threads. screw thread inside hole screw thread leg Fig. 11.3 (i) Name the tool that could be used to cut the screw thread: on the end of the leg … inside the hole. … [2] (ii) The screw thread could be replaced by a permanent method of fixing. Circle from the list below a suitable permanent method of joining the legs to the top of the pen and pencil holder. welding brazing soldering [1] (c) Fig. 11.4 shows details of the shapes to be cut out of the base of the pen and pencil holder. A drill bit has been used to remove most of the waste wood in one of the shapes. finished shape 6 mm deep waste drilled hole 12 remaining waste Fig. 11.4 (i) Use sketches and notes to show how the remaining waste wood could be removed to produce an accurate finished shape. [3] (ii) Give one benefit of using a close-grained hardwood for the base of the pen and pencil holder. … … [1] (d) Use sketches and notes to show a modification to the design of the pen and pencil holder shown in Fig. 11.1 that would make it easier to carry. Name all materials and constructions used. [4] (e) Fig. 11.5 shows a pen and pencil holder made from acrylic. tube Ø40 base Ø130 × 5 mm thick Fig. 11.5 (i) Give two reasons why acrylic is a suitable material for the pen and pencil holder. 1 … 2 … [2] (ii) Name the industrial process used to manufacture the acrylic tube. … [1] (f) Fig. 11.6 shows part of a length of acrylic tube from which the five tubes will be sawn to length. Fig. 11.6 (i) Name a suitable saw that could be used to cut the acrylic tube to length. … [1] (ii) Use sketches and notes to show a design for a sawing jig. The jig must: • hold the tube securely • enable five different lengths, 50, 80, 90, 100 and 120 mm, to be sawn accurately. [4] (g) The tubes will be joined to the base using acrylic cement. Acrylic cement gives off toxic fumes. Describe two ways by which the danger from toxic fumes can be safely reduced. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) Drill small hole 1 4 Cut out waste with piercing saw 1 File to shape 1 Correctly named tools and equipment 1 11(b)(i) On end of leg: Die 1 2 Inside hole: Tap 1 11(b)(ii) Soldering 1 11(c)(i) Use of a chisel [and mallet] to remove waste 1 3 Work piece held securely [clamped] 1 Technical accuracy 1 11(c)(ii) Benefit: close grain is unlikely to split easily. 1 Provides a tough material. 11(d) Modification: some sort of ‘handle’ recognised 1 4 Practical method 1 Appropriate materials 1 Suitable constructions 1 11(e)(i) Acrylic suitable: colourful, self-finishing, easy to work to reqd. design 2 × 1 2 11(e)(ii) Extrusion/extrusion blow moulding 1 11(f)(i) Tenon saw, hacksaw, Hegner saw, band saw 1 11(f)(ii) Hold tube securely 1 4 Does not require measuring of tube to length 1 5 different lengths can be sawn 1 Ease of ‘changing’ different lengths 1 11(g) Two ways include: wear a face mask, well-ventilated room, extraction unit 2 2 × 1

This question in 0445/31 May/June 2020

13 Fig. 13.1 shows wind chimes that will be batch produced in a school workshop. All the production methods require speed and accuracy. top piece Ø120 aluminium tubes Ø15 clapper sail Fig. 13.1 (a) Give two advantages of using a non-ferrous metal such as aluminium for the tubes rather than a ferrous metal. 1 … 2 … [2] (b) (i) Use sketches and notes to show a design for an adjustable sawing jig that could be used to cut five different lengths of tube to the following sizes: 300, 280, 250, 240 and 220 mm. Name the materials used to make the sawing jig. [4] (ii) Describe how a centre lathe could be used to produce a flat and smooth finish to the sawn ends of the aluminium tubes. … … … … … [3] (c) The aluminium tubes will have a lacquered finish. (i) Name an abrasive paper that could be used to prepare the surface of the aluminium tubes. … [1] (ii) Name a machine that could be used to produce a high quality finish on the aluminium tubes after abrasive paper has been used. … [1] (iii) State a method of applying lacquer quickly and evenly. … [1] (d) Fig. 13.2 shows a block of wood that will be used to make the top piece of the wind chimes. The shape of the top piece has been marked out and will be produced on a woodturning lathe. 8 mm thick 130 130 Fig. 13.2 (i) Circle from the list below two methods of woodturning that could be used to produce the top piece of the wind chimes. parallel between-centres taper faceplate centre [2] (ii) Use sketches and notes to show a different method of producing the shape for the top piece of the wind chimes. [3] (e) Describe two quality control checks that could be carried out at any stage during the batch production of the wind chimes. 1 … … 2 … … [4]

21 marks

Mark scheme: 13(a) Two advantages: non-ferrous metals can be self-finished, attractive, resist 2 corrosion 2 × 1 13(b)(i) Hold tube securely 1 4 Does not require measuring of tube to length 1 5 different lengths can be sawn 1 Ease of ‘changing’ different lengths 1 13(b)(ii) Tube held securely in [3 jaw] chuck 1 3 Lathe tool set up correctly 1 Lathe tool taken across the end of the tube and faced off 1 13(c)(i) Wet and dry [silicon carbide] paper, 1 1 13(c)(ii) Polishing wheel, buffing machine 1 1 13(c)(iii) Lacquer applied by brush or spray and suspended to dry to prevent marks 1 1 13(d)(i) Faceplate, between centres 2 × 1 2 13(d)(ii) Saw off the corners of the block 1 3 Use of disc sander, files, glasspaper to finish to shape 1 Correctly named tools and equipment 1 13(e) Quality control checks include: dimension checks of various component 4 parts of the wind chimes, e.g. length of tube, positions of holes, diameter of top piece. Visual check on quality of finish. 2 × 2 13(f) Practical idea: allows bracket to be fixed to a wall 1 4 chimes secure 1 materials 1 constructions 1

This question in 0445/31 May/June 2020

1 Complete Table 1.1 by naming each of the tools that are used to mark out metal. Table 1.1 Tool Name of tool [3]

3 marks

Mark scheme: Question Answer Marks 1 Dividers 1 3 Centre / dot punch 1 Odd legs/ odd leg calipers/ Jenny[s] calipers. 1

This question in 0445/32 May/June 2020

6 Fig. 6.1 shows a can opener in use. Fig. 6.1 Give three specification points for the can opener. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 6 3 points include: comfortable to hold, easy to operate/open can, safe to use, 3 easy to clean, durable materials, strong constructions 3 × 1

This question in 0445/32 May/June 2020

9 Fig. 9.1 shows views of a coffee mug. When hot liquid is added to the mug and the mug becomes warmer, a hidden image is revealed. Fig. 9.1 Complete the statement: The smart material that is added to the mug so that the image is revealed is known as … pigment. [1]

1 marks

Mark scheme: 9 Thermochromic 1

This question in 0445/32 May/June 2020

12 Fig. 12.1 shows an incomplete design for a rack to store items of equipment used for cycle maintenance. Three trays will be supported inside the rack. The rack is made from 12 × 12 mild steel tube and the trays from high impact polystyrene (HIPS). handle A top rail tray leg 800 280 300 Fig. 12.1 (a) Fig. 12.2 shows parts of the top rail and leg of the rack marked out, ready to be cut, folded and brazed to form the corner at A. A area to be cut out Fig. 12.2 Use sketches and notes to show how the joint could be cut out and the edges made flat using hand tools. [4] (b) The tubes will be joined together by brazing. Complete Table 12.1 by stating the purpose of the items used when brazing the mild steel tube. Table 12.1 Stage Item of equipment Purpose 1 emery cloth 2 firebricks 3 flux 4 blow torch 5 brazing rod [5] (c) Fig. 12.3 shows part of the handle that will be joined to the top rail by means of an M8 screw. handle 12 × 12 square tube inside size 9 × 9 top rail M8 screw Fig. 12.3 Use sketches and notes to show a modification to the end of the handle so that the top rail and handle could be joined using the M8 screw. [2] (d) Use sketches and notes to show how the handle could be made more comfortable to hold when carrying the rack. Include details of materials used. [2] (e) Fig. 12.4 shows one of the trays and a block of wood that will be shaped into a former that will be used to vacuum form the trays. Add sketches and notes to the block of wood to show the shape of a suitable former. 80 200 220 Fig. 12.4 [2] (f) Give two benefits of the vacuum forming process when making a large quantity of products. 1 … 2 … [2] (g) Use sketches and notes to show modifications to the trays and/or the rack so that each of the three trays could be supported inside the rack and be able to be removed easily. Include details of materials and constructions used. [4] (h) The rack is made from metal and the trays from plastic. Explain the effects on the environment of using metal and plastic for the product. … … … … … … [4]

25 marks

Mark scheme: 12(a) Sketches to show: 4 tube held in vice 1 hacksaw to cut tube 1 use of files to make edges flat 1 correctly named tools and equipment 1 12(b) emery cloth used to clean joint 1 5 tube positioned on firebricks, set up to produce max. heat 1 flux used to prevent oxidisation and allow spelter to flow 1 blow torch used to heat up tube to reqd. temperature 1 brazing rod heated and melted into joint 1 12(c) Steel ‘plate’ inserted into end of tube or additional nut 1 2 Hole drilled and threaded in ‘plate’ 1 12(d) Square handle made comfortable: 2 Accept any practical modification 1 Details of materials 1 12(e) Former shows draft angle/’sloping’ sides 1 2 Rounded edges to match tray shape 1 12(f) 2 benefits: 2 fast process, reusable former, repetitive accuracy 2 × 1 12(g) Method of support: extra ‘rails’ and/or modified ‘lipping’ shape 0–2 4 Ease of removal 1 Appropriate materials and constructions used 1 12(h) Metal: 4 product could be disassembled, reused and/or recycled 0–2 Plastic: is a finite/unsustainable material, difficult to recycle 0–2

This question in 0445/32 May/June 2020

5 Fig. 5.1 shows a coat hook for a child. The coat hook is made from 5 mm thick acrylic and will be batch produced. fixing holes Fig. 5.1 Complete Table 5.1 by stating how each item could be used to speed up batch production of the coat hook. Table 5.1 Item How each item is used to speed up production Template Former Drilling jig [3]

3 marks

Mark scheme: 5 Template: used to mark out the shape quickly/accurately 1 3 Former: used to enable the acrylic to be bent to shape 1 Drilling jig: used to drill fixing holes quickly and accurately 1

This question in 0445/33 May/June 2020

8 Explain one advantage of using Computer Numerically Controlled (CNC) machines compared with manually operated machines for batch production. … … … [2]

2 marks

Mark scheme: 8 Explanation Advantages include: consistent quality of products, less skilled 2 labour reqd. faster production, easy to change to different products, continuous operation

This question in 0445/33 May/June 2020

10 Fig. 10.1 shows a plastic cup used for hot drinks. lid cuff cup Fig. 10.1 Explain how the designer of the cup has considered the needs of the user. … … … [2]

2 marks

Mark scheme: 10 Points include: 2 Lid to retain heat, prevent spillages. Ridged ‘collar’ for grip, prevent burns. Tapered shape for stability and safety.

This question in 0445/33 May/June 2020

11 Fig. 11.1 shows a pen and pencil holder. top: 1.5 mm thick brass leg: brass rod Ø6 base: 12 mm thick beech 135 135 Fig. 11.1 (a) Fig. 11.2 shows the top part of the pen and pencil holder with the four shapes marked out. shapes 40 × 40 20 Fig. 11.2 Use sketches and notes to show how one of the shapes could be cut out and the edges made flat and smooth. Name all the tools and equipment used. [4] (b) Fig. 11.3 shows how the legs are fitted to the top of the pen and pencil holder by means of screw threads. screw thread inside hole screw thread leg Fig. 11.3 (i) Name the tool that could be used to cut the screw thread: on the end of the leg … inside the hole. … [2] (ii) The screw thread could be replaced by a permanent method of fixing. Circle from the list below a suitable permanent method of joining the legs to the top of the pen and pencil holder. welding brazing soldering [1] (c) Fig. 11.4 shows details of the shapes to be cut out of the base of the pen and pencil holder. A drill bit has been used to remove most of the waste wood in one of the shapes. finished shape 6 mm deep waste drilled hole 12 remaining waste Fig. 11.4 (i) Use sketches and notes to show how the remaining waste wood could be removed to produce an accurate finished shape. [3] (ii) Give one benefit of using a close-grained hardwood for the base of the pen and pencil holder. … … [1] (d) Use sketches and notes to show a modification to the design of the pen and pencil holder shown in Fig. 11.1 that would make it easier to carry. Name all materials and constructions used. [4] (e) Fig. 11.5 shows a pen and pencil holder made from acrylic. tube Ø40 base Ø130 × 5 mm thick Fig. 11.5 (i) Give two reasons why acrylic is a suitable material for the pen and pencil holder. 1 … 2 … [2] (ii) Name the industrial process used to manufacture the acrylic tube. … [1] (f) Fig. 11.6 shows part of a length of acrylic tube from which the five tubes will be sawn to length. Fig. 11.6 (i) Name a suitable saw that could be used to cut the acrylic tube to length. … [1] (ii) Use sketches and notes to show a design for a sawing jig. The jig must: • hold the tube securely • enable five different lengths, 50, 80, 90, 100 and 120 mm, to be sawn accurately. [4] (g) The tubes will be joined to the base using acrylic cement. Acrylic cement gives off toxic fumes. Describe two ways by which the danger from toxic fumes can be safely reduced. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) Drill small hole 1 4 Cut out waste with piercing saw 1 File to shape 1 Correctly named tools and equipment 1 11(b)(i) On end of leg: Die 1 2 Inside hole: Tap 1 11(b)(ii) Soldering 1 11(c)(i) Use of a chisel [and mallet] to remove waste 1 3 Work piece held securely [clamped] 1 Technical accuracy 1 11(c)(ii) Benefit: close grain is unlikely to split easily. 1 Provides a tough material. 11(d) Modification: some sort of ‘handle’ recognised 1 4 Practical method 1 Appropriate materials 1 Suitable constructions 1 11(e)(i) Acrylic suitable: colourful, self-finishing, easy to work to reqd. design 2 × 1 2 11(e)(ii) Extrusion/extrusion blow moulding 1 11(f)(i) Tenon saw, hacksaw, Hegner saw, band saw 1 11(f)(ii) Hold tube securely 1 4 Does not require measuring of tube to length 1 5 different lengths can be sawn 1 Ease of ‘changing’ different lengths 1 11(g) Two ways include: wear a face mask, well-ventilated room, extraction unit 2 2 × 1

This question in 0445/33 May/June 2020

13 Fig. 13.1 shows wind chimes that will be batch produced in a school workshop. All the production methods require speed and accuracy. top piece Ø120 aluminium tubes Ø15 clapper sail Fig. 13.1 (a) Give two advantages of using a non-ferrous metal such as aluminium for the tubes rather than a ferrous metal. 1 … 2 … [2] (b) (i) Use sketches and notes to show a design for an adjustable sawing jig that could be used to cut five different lengths of tube to the following sizes: 300, 280, 250, 240 and 220 mm. Name the materials used to make the sawing jig. [4] (ii) Describe how a centre lathe could be used to produce a flat and smooth finish to the sawn ends of the aluminium tubes. … … … … … [3] (c) The aluminium tubes will have a lacquered finish. (i) Name an abrasive paper that could be used to prepare the surface of the aluminium tubes. … [1] (ii) Name a machine that could be used to produce a high quality finish on the aluminium tubes after abrasive paper has been used. … [1] (iii) State a method of applying lacquer quickly and evenly. … [1] (d) Fig. 13.2 shows a block of wood that will be used to make the top piece of the wind chimes. The shape of the top piece has been marked out and will be produced on a woodturning lathe. 8 mm thick 130 130 Fig. 13.2 (i) Circle from the list below two methods of woodturning that could be used to produce the top piece of the wind chimes. parallel between-centres taper faceplate centre [2] (ii) Use sketches and notes to show a different method of producing the shape for the top piece of the wind chimes. [3] (e) Describe two quality control checks that could be carried out at any stage during the batch production of the wind chimes. 1 … … 2 … … [4]

21 marks

Mark scheme: 13(a) Two advantages: non-ferrous metals can be self-finished, attractive, resist 2 corrosion 2 × 1 13(b)(i) Hold tube securely 1 4 Does not require measuring of tube to length 1 5 different lengths can be sawn 1 Ease of ‘changing’ different lengths 1 13(b)(ii) Tube held securely in [3 jaw] chuck 1 3 Lathe tool set up correctly 1 Lathe tool taken across the end of the tube and faced off 1 13(c)(i) Wet and dry [silicon carbide] paper, 1 1 13(c)(ii) Polishing wheel, buffing machine 1 1 13(c)(iii) Lacquer applied by brush or spray and suspended to dry to prevent marks 1 1 13(d)(i) Faceplate, between centres 2 × 1 2 13(d)(ii) Saw off the corners of the block 1 3 Use of disc sander, files, glasspaper to finish to shape 1 Correctly named tools and equipment 1 13(e) Quality control checks include: dimension checks of various component 4 parts of the wind chimes, e.g. length of tube, positions of holes, diameter of top piece. Visual check on quality of finish. 2 × 2 13(f) Practical idea: allows bracket to be fixed to a wall 1 4 chimes secure 1 materials 1 constructions 1

This question in 0445/33 May/June 2020

10 Fig. 10.1 shows a hot melt glue gun. Fig. 10.1 Give one advantage and one disadvantage of using a hot melt glue gun compared to PVA adhesive. Advantage … Disadvantage … [2]

2 marks

Mark scheme: 10 Advantage: quick-drying process, requires no clamping 1 Disadvantage: not as strong as PVA, some risk of burns, time taken to set up glue gun, requires electrical power source 1 2 Not a quicker process Not an easier process

This question in 0445/32 Oct/Nov 2020

12 Fig. 12.1 shows a box of giant dominoes used by young children. The dominoes are made from 10 mm thick MDF and the box from 15 mm thick hardwood. 185 70 A 560 Fig. 12.1 (a) Give two advantages of using MDF rather than hardwood for the dominoes. 1 … 2 … [2] (b) Sketch and name a suitable joint, other than a butt joint, that could be used at corner A. [4] (c) A 5 mm thick MDF base will be fitted inside the box. Fig. 12.2 shows one inside corner of the box. Add sketches and notes to Fig. 12.2 to show how the base could be fitted inside the box. The edges of the base must not be seen. Fig. 12.2 [3] (d) Fig. 12.3 shows details of a bench hook and a length of MDF from which the dominoes will be sawn. Each domino is 150 mm long. 140 30 MDF 75 × 10 170 Fig. 12.3 (i) Use sketches and notes to show how the bench hook could be modified into a sawing jig so that all the dominoes could be cut exactly to the same length. [4] (ii) Use sketches and notes to show how the sawn ends of the dominoes could be made square and smooth. [3] (e) Fig. 12.4 shows one domino. Each set of numbers is represented by dots. 150 75 Fig. 12.4 Describe how CAM (Computer Aided Manufacture) could be used to make the dots on a domino. … … … … … [4] (f) The dominoes could be made in large quantities from plastic. (i) Give two advantages to the user of making the dominoes from plastic rather than MDF. 1 … 2 … [2] (ii) Name an industrial process that could be used to manufacture plastic dominoes. Give two reasons for your choice. Named industrial process … Reason 1 … Reason 2 … [3]

25 marks

Mark scheme: 12(a) Two advantages: smooth surface-no grain, stable, cheaper, easier to work, no knots, readily available 2 × 1 2 Not lighter 12(b) Dovetail, finger [comb], dowel, lapped, half-lapped, mitre named1 Suitable joint recognised 1 Correct orientation [as per Fig. 12.1] 1 Good proportion/accuracy 1 4 Mitre joint must be drawn in 3D. 2D drawing of mitre = 2 marks max. 12(c) Recognised rebate/ groove/ beads 1 Good proportion/size/accuracy 0–2 3 Do not reward methods visible on outside of box 12(d)(i) Modification to bench hook 1 ‘Stop’ to locate end of MDF length 1 150mm measured distance for saw cut Added notes/details to describe the jig 1 4 12(d)(ii) Method: use of disc sander, shooting board, belt linisher, plane 1 Accurate sketch showing method 0–2 3 Smoothing, jack, block plane Do not reward files, glass paper Question Answer Marks Guidance 12(e) Dots could be designed using CAD 1 CAD drawings are downloaded to a CNC machine 1 CNC machine and MDF are set up 1 CNC machine cuts out dots, MDF is removed 1 4 Alternative method involves use of CAD, downloaded data to vinyl cutting machine. Added details relating to setting up machine, applying vinyl to dominoes. Candidates can achieve maximum marks for this method. 12(f)(i) Plastic dominoes gives a smooth finish, inherent colour, easier to clean, safe rounded edges/corners to handle, durable 2 × 1 2 Not water resistant 12(f)(ii) Named industrial process: injection moulding 1 2 reasons: quick [after mould/tool has been produced], accurate/repetitive process, little waste/economical 2 × 1 3 For 2 marks accept one point well argued or two separate issues discussed. Not cheap, easy to set up ECF for incorrect process but correct reasons

This question in 0445/32 Oct/Nov 2020

5 Fig. 5.1 shows a leaflet holder made from acrylic sheet. A screen shot of an incomplete CAD drawing of the left-hand side of the development (net) of the leaflet holder is also shown. Fig. 5.1 (a) Circle , from the list below, the command that would be used to complete the CAD drawing of the leaflet holder. group stretch rotate mirror [1] (b) Give one benefit of using CAD to design the leaflet holder. … [1]

2 marks

Mark scheme: 5(a) Mirror 1 5(b) Benefits include: accuracy, allows for editing, on-screen modelling, can transfer design to CNC machine 1 Quicker = 0

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10 Fig. 10.1 shows a plastic fork and spoon used to feed very young children. Thermochromic pigment has been applied to the fork and spoon. Fig. 10.1 Explain how thermochromic pigment would make the fork and spoon safer to use when feeding very young children. … … … [2]

2 marks

Mark scheme: 10 Thermochromic pigment applied to the spoon will change colour when immersed in hot liquid [1] Therefore, person feeding child can monitor safe temperature [1] 2

This question in 0445/33 Oct/Nov 2020

12 Fig. 12.1 shows views of an incomplete design of a stand for a tablet. The stand is made from 5 mm thick acrylic sheet. tablet 100 100 stand 150 Fig. 12.1 (a) Give two properties of acrylic that make it suitable for the stand. 1 … 2 … [2] (b) Give two reasons why it would be important to make a model of the stand before making it from acrylic. 1 … 2 … [2] (c) Explain why the designer would need to consider ergonomics when designing the tablet stand. … … … [2] (d) Fig. 12.2 shows the development (net) of the stand. bend line cut line 150 100 waste 150 50 120 100 Fig. 12.2 Name one tool or item of equipment that could be used to mark on the surface of the acrylic: (i) a bend line … [1] (ii) a cut line … [1] (e) Before the acrylic can be bent to shape the waste material will be sawn off. (i) Give the specific name of a tool that could be used to saw off the waste. … [1] (ii) Give one reason why acrylic sheet should be supported when it is being sawn. … [1] (f) The edges of the acrylic will be finished to a high quality. (i) Circle , from the list below, the correct method of filing used to make the edges of the acrylic smooth. cross filing draw filing hand filing [1] (ii) Circle , from the list below, the most appropriate abrasive used to make the edges smooth. glasspaper emery cloth silicon carbide (wet and dry) paper [1] (g) Use sketches and notes to show how the acrylic could be bent to shape. Include details of: • the method of heating the acrylic • the method of bending the acrylic • the method of retaining the acrylic while it cools • the sequence in which the bends will be produced. [5] (h) Fig. 12.3 shows details of the tablet and the stand. 100 240 100 tablet 6 mm thick 170 150 stand Fig. 12.3 (i) Use sketches and notes to show how the stand could be modified so that the tablet is held securely in place. Name all the materials used, construction details and two important sizes. [6] (ii) Acrylic cement could be used to join parts of the modified stand. Describe two safety precautions that must be taken when using acrylic cement. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Easy to bend to shape, inherent colour, attractive, stylish, range of colours, easy to work with [2 × 1] 2 Accept any valid property. Lightweight = 0 Cheap = 0 12(b) Model can show final product, can check dimensions/function, changes can be made, avoids costly mistakes [2 × 1] 2 Accept any valid reason. 12(c) The position of the tablet on the stand must be at the correct angle for the tablet screen to be viewed comfortably [1] The tablet must be easy for the user to position on the stand [1] 2 Award marks for one point well discussed or two separate points. 12(d)(i) Marker pen, felt tip pen, chinagraph pencil 1 12(d)(ii) Scriber 1 12(e)(i) Coping, Hegner, scroll, band saws 1 Laser = 0 Acrylic cutter = 0 Tenon/hacksaw/jigsaw = 0 12(e)(ii) Acrylic sheet can crack/snap due to vibration when sawing. 1 Stop it moving = 0 12(f)(i) Draw filing 1 12(f)(ii) Silicon carbide [wet and dry] paper 1 Question Answer Marks Guidance 12(g) Method of heating acrylic: use of strip heater, line bender, heat gun [1] Bending: use of an appropriately shaped former [1] Acrylic retained by some form of clamping [1] Sequence for 3 bends [1] Technical accuracy [1] 5 Oven = 0 Award 1 mark for technical accuracy if most terms, names of tools and equipment are correct. 12(h)(i) Modification to stand to hold tablet securely: Some form of ‘lipping’ or ‘sides’ to retain the tablet [0–2] Materials and constructions used to make modification [0–2] Two important sizes [2 × 1] 6 12(h)(ii) Two safety precautions: wear protective gloves, use of barrier cream, well-ventilated area, face mask, googles [2 × 1] 2 Eye protection = 0 Glasses = 0

This question in 0445/33 Oct/Nov 2020

5 Fig. 5.1 shows vacuum formed plastic sheets, A and B, that were formed using two different moulds. A fault known as ‘webbing’ has occurred to both sheets but for different reasons. A B Fig. 5.1 Give one reason why webbing has occurred to: Sheet A … Sheet B … [2]

2 marks

Mark scheme: 5 Sheet A: mould too deep, too tall, too high 1 Sheet B: moulds too close together, too many moulds on 1 sheet 1 2

This question in 0445/32 May/June 2021

7 Fig. 7.1 shows three holes, A, B and C, drilled through 5 mm thick plywood. C Ø10 B Ø25 A Ø60 Fig. 7.1 (a) Name different types of drill bit that could be used to drill each of the holes. Hole A … Hole B … Hole C … [3] (b) State one danger that could occur when drilling thin plywood. … [1]

4 marks

Mark scheme: 7(a) Hole A hole saw, tank cutter, forstner bit 1 Hole B forstner, hole saw, sawtooth, flat bits 1 Hole C twist drill, forstner bit 1 3 Only accept name of bit used once 7(b) Splitting can occur on the underside of the sheet Snagging/spinning if not secured properly, spinning, splinters, splintering 1

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8 Complete Table 8.1 by stating the manufacturing process used to make each product. Table 8.1 Product Material Manufacturing process aluminium alloy Model toy car UPVC Guttering [2]

2 marks

Mark scheme: 8 Model toy car: die casting 1 Guttering: extrusion 1 2 Not ‘casting’

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10 Fig. 10.1 shows equipment used to apply an attractive finish on an aluminium product. cathode anode product power supply sulphuric acid tank Fig. 10.1 (a) Name the process shown in Fig. 10.1. … [1] (b) Give one reason, other than an attractive appearance, why a finish would be applied to a product made from metal. … [1]

2 marks

Mark scheme: 10(a) Anodising, electroplating, electrolysis 1 10(b) To prevent corrosion, protect, hardwearing, durable, longlasting 1

This question in 0445/32 May/June 2021

13 Fig. 13.1 shows an incomplete design for a novelty adjustable lamp made from hardwood. The lampshade has been removed to show the neck of the lamp. lampshade tail neck body pivot pivot leg Fig. 13.1 Table 13.1 shows a parts list for the adjustable lamp. Table 13.1 Part No. reqd. Length × Width × Thickness body 2 230 × 60 × 15 leg 4 200 × 50 × 15 tail 1 120 × 40 × 15 neck 1 160 × 50 × 15 (a) Name a suitable hardwood for the adjustable lamp. … [1] (b) Give two items of information that could be obtained by designing a computer-generated model of the adjustable lamp. 1 … 2 … [2] (c) Fig. 13.2 shows the length of hardwood that will be used for the tail. waste Fig. 13.2 (i) Name a type of plane that could be used to remove the waste wood. … [1] (ii) Use sketches and notes to show how the length of hardwood could be held in a vice while being planed. [2] (d) The parts of the adjustable lamp will have a clear finish applied to them before they are assembled. (i) Describe how the surfaces of the hardwood parts would be prepared before a clear finish is applied. … … … [2] (ii) Name a suitable clear finish for the hardwood parts. … [1] (iii) Give two advantages of a clear finish rather than a painted finish for the hardwood. 1 … 2 … [2] (e) Fig. 13.3 shows the rear legs, body and tail that will be joined by means of a threaded metal rod. Ø5 threaded metal rod Fig. 13.3 Use sketches and notes to show how the threaded metal rod could be used to allow the hardwood parts to be tightened and loosened by hand without the aid of additional tools. [4]

15 marks

Mark scheme: 13(a) Wide variety of hardwoods available 1 13(b) Two items of information: appropriate sizes, proportions, appearance, manipulate adjustments to parts of the lamp 2 × 1 2 Accept any valid item of information as a result of modelling Accept only one ref. to dimensions 13(c)(i) Jack, smoothing or block planes 1 Question Answer Marks Guidance 13(c)(ii) Sketch showing [part of] woodworker’s vice 1 Hardwood shown in vice 1 2 Award 1 mark if wood is shown in engineers vice Award 2 marks if wood is shown in engineers vice with scrap wood jaws 13(d)(i) Preparation of hardwood parts: use of different grades of glasspaper/sandpaper/abrasive paper, wipe off dust, cabinet scraper, sander 2 × 1 2 Award 1 mark for one grade of glasspaper and 1 mark for a different grade of glasspaper. Not ‘use of files’, ‘sanding disc’, ‘plane’ 13(d)(ii) Clear finish: varnish, white/French polish, Danish oil, Teak oil, lacquer, [bees]wax, epoxy resin 1 13(d)(iii) Two advantages: natural grain characteristics visible, colour, some finishes [lacquer, varnish] can chip and peel, oils and polishes easier to apply 2 × 1 2 Not ‘more attractive’ or ‘aesthetically pleasing’ 13(e) Threaded rod shown through legs, tail and body 1 Some form of ‘stopper’, nut or cap on ends of rod 1 Can be finger tightened 1 Added notes and details 1 4 Accept any practical locking devices including wing nut 13(f)(i) Two advantages of veneered plywood: cheaper, more stable, less likely to split, allows for use of thinner wood-based material, lightweight 2 × 1 2 Accept any valid advantage Not ‘easier to work/cut/shape’ 13(f)(ii) Use of strips or blocks made from wood or thin metal brackets 0–2 Method of joining: use of pins, screws, adhesive 0–2 OR Accept laser cutter but must describe in detail for maximum 4 marks. 0–4 OR Award 0–2 marks for sketches and notes showing how the sides of the lampshade are cut out 0–2 OR Award 1 mark for use of suitable named adhesive. Award 1 mark for putting sides together 0–2 4 Look for answers that show additional parts. 4 mm thick plywood requires additional corner blocks as it is too thin to join without reinforcement. Accept ‘lacing’. Do not reward marking out Question Answer Marks Guidance 13(g) Some form of bracket attached to underside of lampshade 0–2 Bracket attached to underside of lampshade 0–2 4

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4 Fig. 4.1 shows a digital caliper. Fig. 4.1 Add sketches and notes to Fig. 4.1 to show two specific uses for the digital caliper. [2]

2 marks

Mark scheme: 4 Sketch showing inside Ø of tube measured 1 Sketch showing outside Ø of rod or tube, thickness of material measured 1 Depth gauge 1 2 Accept any two.

This question in 0445/33 May/June 2021

10 Fig. 10.1 shows a plastic bottle and the symbol found underneath the bottle. 1 Fig. 10.1 (a) State the process used to mass produce the plastic bottle. … [1] (b) Name the type of plastic used to make the bottle. … [1] (c) Give two reasons why many products made from plastic are not recycled. 1 … 2 … [2]

4 marks

Mark scheme: 10(a) Blow moulding 1 10(b) Polythene [terephthalate], PET, PETE, [high density] polythene 1 Do not accept LDPE 10(c) Some plastics cannot be recycled due to their chemical structure, some plastics are contaminated with food, some authorities do not accept some plastics, people do not take plastic products to be recycled, some areas have no recycling facilities, plastics thrown away, people do not know which plastics can be recycled, some plastics have other materials making them non-recyclable 2 × 1 2

This question in 0445/31 Oct/Nov 2021

11 Fig. 11.1 shows a child’s rocking horse made from hardwood. position for handhold head 40 mm thick leg rail rocker Fig. 11.1 (a) Give two properties of hardwood that make it suitable for the rocking horse. 1 … 2 … [2] (b) The position for a handhold is shown in Fig. 11.1. Use sketches and notes to show a design for a comfortable handhold and a method of fitting it to the rocking horse. [3] (c) Fig. 11.2 shows part of one leg and the rail to which it is joined. leg rail 20 25 30 Fig. 11.2 Sketch and name a suitable joint that could be used to join the leg to the rail. Name of joint…………………………………………….. [4] (d) Fig. 11.3 shows a length of hardwood that will be steam bent to make the rocker. 900 long × 50 wide × 25 thick Fig. 11.3 Use sketches and notes to show the main processes used to produce the shape of the rocker. [5] (e) Explain how the designer has considered anthropometric data when designing the rocking horse. … … … … [3] (f) Fig. 11.4 shows a different design of rocking horse made from plastic. Fig. 11.4 (i) Describe two ways in which the plastic rocking horse could be considered safer for children to use than the rocking horse made from hardwood. 1 … … 2 … … [4] (ii) Both rocking horses are batch produced in quantity. Give two detailed reasons why the hardwood rocking horse would be more expensive to batch produce than the rocking horse made from plastic. 1 … … 2 … … [4]

25 marks

Mark scheme: 11(a) Two properties: hardwearing, long lasting, tough, finishes well, attractive, durable, weather resistant, shock resistant, less likely to splinter, strong justified-[will hold a lot of weight] 2 × 1 2 Do not accept hard 11(b) Hand-hold clearly shown in position 1 Comfortable grip 1 Method of fitting to rocking horse 1 3 Do accept dowel + hole + glue for 3 marks Comfortable grip must be stated 11(c) Mortise and tenon, dowel named 1 Technical accuracy of sketch 0–3 Housing joint not suitable = 0 marks but award maximum 0–2 marks for accurate sketch ECF 4 Technical accuracy mortise and tenon: e.g. proportion, shoulders Technical accuracy dowel: e.g. spacing, two dowels shown 11(d) Rocker produced by steam bending process: Stages include: wood placed in sealed chest, chest filled with steam, wood absorbs hot steam, wood held around a former, clamped in position, allowed to dry Reward any 5 relevant stages 5 × 1 5 Question Answer Marks Guidance 11(e) Anthropometric data that could be explained: height of child, reach, seating height, leg length, larger seat area/back, greater stability Quality of explanation 0–3 3 Accept any valid anthropometric data relating child to function of rocking horse 11(f)(i) Two safer ways: lighter weight, lower to ground, more stable, rounded moulded plastic, curved shape more comfortable, easier to clean, less likely to splinter/snap, backrest prevents child falling off, wide footrest 2 × 2 4 Descriptions must be detailed for maximum marks: e.g. rounded moulded plastic [1] means that the child is less likely to ‘catch’ on any sharp corners [1] 11(f)(ii) Two reasons: beech rocking horse is fabricated which uses more materials and takes longer to produce, plastic rocking horse can be moulded quickly, reusing the mould, hardwood is more expensive justified 2 × 2 4 Accept any detailed valid reasons Points listed must be expanded upon

This question in 0445/31 Oct/Nov 2021

1 Safety precautions need to be taken when carrying out different processes in a workshop. Complete Table 1.1 by stating one safety precaution that would need to be taken for each process. Table 1.1 Process Safety precaution taken Using a pillar drill to drill sheet metal Using a disc sander to sand a hardwood block [2]

2 marks

Mark scheme: 1 Pillar drill: make sure sheet is clamped securely, check drill speed for Ø drill, use of scrap wood under workpiece, personal safety, no loose clothing, hair tied back 1 Disk sander: eye protection, mask to prevent dust inhalation 1 2

This question in 0445/32 Oct/Nov 2021

9 Complete the statement below by adding the correct term from the list. moisture temperature weight light Shape Memory Alloy (SMA) is a smart material that reacts to … [1]

1 marks

Mark scheme: 9 Temperature 1

This question in 0445/32 Oct/Nov 2021

12 Fig. 12.1 shows parts of an incomplete model car. body shell 2 mm thick polystyrene chassis 200 × 140 1 mm thick aluminium wheel support 30 × 30 Ø6 holes Fig. 12.1 (a) Give two advantages of using CAD rather than traditional drawing methods to design the body shell of the model car. 1 … 2 … [2] (b) Give two benefits of using aluminium for the chassis of the model car. 1 … 2 … [2] (c) The body shell will be produced by vacuum forming. (i) State two features of the mould used to produce a quality body shell. 1 … 2 … [2] (ii) Give two reasons why it is important to heat the polystyrene to the correct temperature when vacuum forming the body shell. 1 … 2 … [2] (iii) A flow chart showing the stages of vacuum forming the body shell of the model car is shown below. Complete the flow chart by adding the missing stages needed from the list below. Turn off vacuum Start/end Is shape fully formed? Lower mould Turn on vacuum Process Remove vacuum formed body shell Is plastic soft enough? Decision Raise mould place mould in machine clamp plastic leave to cool sheet in place heat plastic sheet No Yes Yes No [5] (d) The chassis will be cut from a sheet of 1 mm thick aluminium shown below. waste 200 30 30 200 (i) Name two hand tools that could be used to cut out the development (net) of the chassis. 1 … 2 … [2] (ii) Describe how the cut edges could be made safe to handle. … … [2] (iii) Use sketches and notes to show how the wheel supports could be bent to shape. Name the tools and equipment used. [3] (e) Fig. 12.2 shows one of the wheels that will be fitted to the model car. Ø5 hole wheel Ø40 × 8 thick Fig. 12.2 (i) Name the process used to manufacture the plastic wheel. … [1] (ii) The body shell fits over the chassis and is held securely when axles are inserted and the wheels are attached. Use sketches and notes to show how wheels could be fitted to the model car and allowed to rotate freely. [4]

25 marks

Mark scheme: 12(a) Allows for on-screen modelling and testing, easier to edit, accuracy for possible transfer to CNC machine, more accurate, more detailed, viewed from 360°, files can be shared faster, used to 3D print 2 × 1 Do not accept quicker, faster 12(b) Two benefits: lightweight, corrosion resistant, self-finishing, easy to work/cut/bend/make 2 × 1 2 Accept any valid benefits Do not accept easy to use or join, attractive, durable 12(c)(i) Two features: draft angle/tapered sides, radiused corners/ edges, no undercuts smooth surfaces 2 × 1 2 12(c)(ii) Not hot enough and the plastic will not form 1 Too hot and the plastic will melt/deform 1 2 Do accept malleability to allow the plastic to form Question Answer Marks Guidance 12(c)(iii) Is plastic soft enough 1 Raise mould or turn on vacuum 1 Raise mould or turn on vacuum 1 Is shape fully formed 1 Turn off vacuum 1 5 12(d)(i) Two hand tools: tin snips, hacksaw, guillotine, piercing saw 2 × 1 2 Do not accept metal shears, cold chisel 12(d)(ii) Edges made safe by means of filing 1 Use of abrasive paper 1 2 12(d)(iii) Use of a vice and block [former], folding bars, cramp to secure aluminium 1 Method of force: mallet or hammer and scrap wood 1 Additional annotated notes 1 3 Do not accept use of heat Award 1 mark for use of scrap wood/vice jaws to protect surface of aluminium 12(e)(i) Injection moulding, 3D printer 1 12(e)(ii) Some form of axle 1 Axle fitted onto wheel and secured 1 Free rotation 1 Use of washers/‘spacers’ 1 4 Axle could be ‘stub’ or one continuous axle fitted to two front wheels and one fitted to two rear wheels

This question in 0445/32 Oct/Nov 2021

10 Fig. 10.1 shows a plastic bottle and the symbol found underneath the bottle. 1 Fig. 10.1 (a) State the process used to mass produce the plastic bottle. … [1] (b) Name the type of plastic used to make the bottle. … [1] (c) Give two reasons why many products made from plastic are not recycled. 1 … 2 … [2]

4 marks

Mark scheme: 10(a) Blow moulding 1 10(b) Polythene [terephthalate], PET, PETE, [high density] polythene 1 Do not accept LDPE 10(c) Some plastics cannot be recycled due to their chemical structure, some plastics are contaminated with food, some authorities do not accept some plastics, people do not take plastic products to be recycled, some areas have no recycling facilities, plastics thrown away, people do not know which plastics can be recycled, some plastics have other materials making them non-recyclable 2 × 1 2

This question in 0445/33 Oct/Nov 2021

11 Fig. 11.1 shows a child’s rocking horse made from hardwood. position for handhold head 40 mm thick leg rail rocker Fig. 11.1 (a) Give two properties of hardwood that make it suitable for the rocking horse. 1 … 2 … [2] (b) The position for a handhold is shown in Fig. 11.1. Use sketches and notes to show a design for a comfortable handhold and a method of fitting it to the rocking horse. [3] (c) Fig. 11.2 shows part of one leg and the rail to which it is joined. leg rail 20 25 30 Fig. 11.2 Sketch and name a suitable joint that could be used to join the leg to the rail. Name of joint…………………………………………….. [4] (d) Fig. 11.3 shows a length of hardwood that will be steam bent to make the rocker. 900 long × 50 wide × 25 thick Fig. 11.3 Use sketches and notes to show the main processes used to produce the shape of the rocker. [5] (e) Explain how the designer has considered anthropometric data when designing the rocking horse. … … … … [3] (f) Fig. 11.4 shows a different design of rocking horse made from plastic. Fig. 11.4 (i) Describe two ways in which the plastic rocking horse could be considered safer for children to use than the rocking horse made from hardwood. 1 … … 2 … … [4] (ii) Both rocking horses are batch produced in quantity. Give two detailed reasons why the hardwood rocking horse would be more expensive to batch produce than the rocking horse made from plastic. 1 … … 2 … … [4]

25 marks

Mark scheme: 11(a) Two properties: hardwearing, long lasting, tough, finishes well, attractive, durable, weather resistant, shock resistant, less likely to splinter, strong justified-[will hold a lot of weight] 2 × 1 2 Do not accept hard 11(b) Hand-hold clearly shown in position 1 Comfortable grip 1 Method of fitting to rocking horse 1 3 Do accept dowel + hole + glue for 3 marks Comfortable grip must be stated 11(c) Mortise and tenon, dowel named 1 Technical accuracy of sketch 0–3 Housing joint not suitable = 0 marks but award maximum 0–2 marks for accurate sketch ECF 4 Technical accuracy mortise and tenon: e.g. proportion, shoulders Technical accuracy dowel: e.g. spacing, two dowels shown 11(d) Rocker produced by steam bending process: Stages include: wood placed in sealed chest, chest filled with steam, wood absorbs hot steam, wood held around a former, clamped in position, allowed to dry Reward any 5 relevant stages 5 × 1 5 Question Answer Marks Guidance 11(e) Anthropometric data that could be explained: height of child, reach, seating height, leg length, larger seat area/back, greater stability Quality of explanation 0–3 3 Accept any valid anthropometric data relating child to function of rocking horse 11(f)(i) Two safer ways: lighter weight, lower to ground, more stable, rounded moulded plastic, curved shape more comfortable, easier to clean, less likely to splinter/snap, backrest prevents child falling off, wide footrest 2 × 2 4 Descriptions must be detailed for maximum marks: e.g. rounded moulded plastic [1] means that the child is less likely to ‘catch’ on any sharp corners [1] 11(f)(ii) Two reasons: beech rocking horse is fabricated which uses more materials and takes longer to produce, plastic rocking horse can be moulded quickly, reusing the mould, hardwood is more expensive justified 2 × 2 4 Accept any detailed valid reasons Points listed must be expanded upon

This question in 0445/33 Oct/Nov 2021

5 Complete the sentence below by adding the correct statement from the list. becomes an antique takes many years to design lasts for a fixed period of time is constructed from the best materials Planned obsolescence is when a product … [1]

1 marks

Mark scheme: 5 Lasts for a fixed period of time 1

This question in 0445/32 May/June 2022

12 Fig. 12.1 shows an incomplete design for a pinball game. A 15 mm thick side base 9 10 8 7 6 4 5 40 3 600 1 2 300 Fig. 12.1 (a) The sides of the pinball game are made from beech. Give two properties of beech that make it suitable for the pinball game. 1 … 2 … [2] (b) State two ways in which the designer would need to consider safety when designing the pinball game. 1 … 2 … [2] (c) Fig. 12.2 shows part of two sides that will be joined at each corner of the pinball game. 40 15 Fig. 12.2 Sketch and name a suitable corner joint that could be used to join the sides of the pinball game together. Name of construction … [4] (d) Fig. 12.3 shows a type of drill bit that could be used to drill the Ø20 holes in the base of the pinball game. Fig. 12.3 (i) Name the type of drill bit shown in Fig. 12.3. … [1] (ii) Give two reasons why scrap wood would be clamped underneath the base of the pinball game when drilling the holes. 1 … 2 … [2] (e) Fig. 12.4 shows two methods, A and B, that could be used to fit the base to the sides of the pinball game. side base 4 mm thick A B Fig. 12.4 Give two advantages of using method B rather than method A. 1 … 2 … [2] (f) Fig. 12.5 shows the MDF sheet from which the curved shape will be produced. A 270 A 18 mm thick waste 150 Fig. 12.5 (i) Name two different machine tools that could be used to cut out the curved shape. 1 … 2 … [2] (ii) The finished shape could be glued onto the base of the pinball game using either PVA or a contact adhesive. State one benefit of using PVA and one benefit of using a contact adhesive. Benefit of PVA … … Benefit of contact adhesive … … [2] (g) To produce the curved shape from a sheet of MDF could be considered wasteful. It would be more cost-effective to use the strip of beech shown below. strip 350 × 18 × 3 Use sketches and notes to show how the strip of beech could be bent to produce the curved shape and be fitted onto the base of the pinball game. [4] (h) The pinball game needs to be supported at an angle to allow the ball to roll down the slope. Use sketches and notes to show how one end of the pinball game could be supported at the height shown in Fig. 12.6. The method of support must allow the pinball game to fold flat when not in use. Include details of the materials and fittings used. pinball game flat surface 40 Fig. 12.6 [4]

25 marks

Mark scheme: 12(a) 2 properties: hardwearing, close-grained, finishes well, high impact resistant, attractive, tough 2  1 2 Accept any valid property Durable must be qualified 12(b) 2 safety considerations: no sharp edges, fingers should not be trapped, risk of ball flying out, cover to prevent ball flying out, ball large enough to prevent choking hazard 2  1 2 Accept any valid consideration 12(c) Variety of acceptable corner constructions: butt, rebate, lap joint, mitre, dovetail, finger [comb] joint, dowel Named 1 Technical accuracy/proportion of sketched construction 0–3 4 Award maximum 2/3 for butt joint Dowel joint: maximum number of dowels 2 12(d)(i) Saw tooth bit, forstner bit 1 Not hole saw 12(d)(ii) 2 reasons: prevent damage to work surface, prevents splitting of wood as drill cuts through, cleaner cut hole, protect drill table 2  1 2 Focus on the use of scrap wood, not clamping Not provide stability, not prevent wood flying off 12(e) 2 advantages: less likely to be pulled off sides [stronger], edges not visible [more attractive], gluing not required, more secure, lasts longer 2  1 2 Not greater surface area 12(f)(i) Router, scroll saw, band saw, jig saw, laser cutter, CNC milling machine 2  1 2 Question Answer Marks Guidance 12(f)ii Benefit of PVA: stronger joint, more time to clamp parts, no toxic fumes, does not cause skin irritation 1 Benefit of contact adhesive: immediate bond, no clamping required, quicker to dry/set 1 2 12(g) Method of bending: use of steam bending process 1 use of formers/moulds 1 method of clamping 1 attachment to base 1 4 12(h) some sort of ‘leg’ support that remains upright 1 support can fold flat 1 constructions 1 materials 1 4

This question in 0445/32 May/June 2022

13 Fig. 13.1 shows an incomplete design for a child’s toy lorry that could be made in a school workshop. The sides are made from acrylic. The tipper is made from ABS. The base, cab and wheels are made from beech. tipper cab wheel side base Fig. 13.1 (a) (i) State one benefit of using plastics such as acrylic and ABS for parts of the toy lorry. … [1] (ii) State one benefit of using beech for the base, cab and wheels of the toy lorry. … [1] (b) The sides of the toy lorry have been designed using CAD. Fig. 13.2 shows one side of the toy lorry made from 5 mm thick acrylic. 120 300 Fig. 13.2 (i) Complete Table 13.1 by stating three processes to be carried out when making the side using CAM. Table 13.1 Stage Process 1 Design side of lorry using CAD and save file 2 3 4 [3] (ii) The acrylic sides could be glued to the beech base using a contact adhesive. Describe how a contact adhesive would be applied to make a strong joint. … … … [2] (c) Fig. 13.3 shows details of the tipper that will be vacuum formed using 3 mm thick ABS. 200 75 60 Fig. 13.3 (i) Give two advantages of making the vacuum forming mould from MDF rather than a solid wood. 1 … 2 … [2] (ii) State two features of the vacuum forming mould that are necessary to ensure a successfully formed product. 1 … 2 … [2] (iii) Complete Table 13.2 by stating four processes to be carried out when vacuum forming the tipper. Table 13.2 Stage Process 1 Place mould in vacuum forming machine 2 3 4 5 6 Remove vacuum formed tipper from machine [4]

15 marks

Mark scheme: 13(a)(i) Benefits: inherent colour, easily moulded, lightweight, attractive, range of colours, impact resistant, weather resistant 1 Accept any valid benefit 13(a)(ii) Benefits: hardwearing, close grained, finishes well, attractive, smooth surfaces, tough 1 Accept any valid benefit 13(b)(i) 3 processes: place acrylic on bed of machine, set tool parameters, computer ‘print’, ‘run’, transfer data to CNC machine, extractor unit on 3  1 3 Accept any valid process 13(b)(ii) Contact adhesive applied to both surfaces 1 Allow to dry then stick together on contact [impact] 1 2 No use of cramps 13(c)(i) 2 advantages: no grain texture to mark plastic, easier to work, cheaper, does not shrink or warp, smoother surfaces, more stable 2  1 2 Accept any valid advantage Not available in wider boards Question Answer Marks Guidance 13(c)(ii) 2 features: smooth surfaces, rounded corners/edges, draft angle [tapered sides] no undercuts 2  1 2 13(c)(iii) 4 processes: clamp plastic to machine, turn on heater, check pliability of plastic, raise platen, turn on pump to remove air, leave to cool 4  1 4 Ignore sequence Do reward 2 stages given as one: for example, ‘push mould into plastic [1] and turn pump on to remove air’ [1] 13(d) Some sort of hinge/pivot 1 Hinge shown in position on tipper 1 Hinge shown in position on base 1 Appropriate materials 1 Constructions 1 Fittings 1 6 13(e) Some form of axle 1 Axle fitted onto wheel and secured 1 Wheel/axle rotates freely 1 Use of washers/’spacers’ 1 4 Axle could be ‘stub’ or one continuous axle fitted to two front wheels and one fitted to two rear wheels

This question in 0445/32 May/June 2022

1 Fig. 1.1 shows building blocks used in a children’s construction set. The building blocks are made from a thermoplastic. blocks 50 × 25 × 20 Fig. 1.1 (a) Name a suitable thermoplastic for the building blocks. … [1] (b) State two specification points a designer would need to consider when designing building blocks for young children. 1 … 2 … [2]

3 marks

Mark scheme: Question Answer Marks Guidance 1(a) ABS, PP, PETE, PET, HDPE, HIPS 1 Not PVC, Acrylic, Polystyrene, Polyethene, Polyethylene 1(b) 2 spec. points: colourful, lightweight, smooth finish, ability to make rounded 2 Accept any valid spec. points corners/edges, non-toxic material, safe/suitable sizes, easy to clean, aesthetics, durable, water resistant

This question in 0445/33 May/June 2022

5 Complete the sentence below by adding the correct term from the list. construction user packaging cost Ergonomics is the term given to describe the relationship between a product and its … [1]

1 marks

Mark scheme: 5 User 1

This question in 0445/33 May/June 2022

10 Fig. 10.1 shows details of a cross head water tap. cross head 30 60 Ø10 75 Fig. 10.1 Use sketches and notes to show a design for a device that would make it easier for people with poor grip to turn the tap on or off. The device must fit either over, under or across the cross head of the water tap. [3]

3 marks

Mark scheme: 10 Device fits/grips cross head effectively 1 3 Named materials not required Head extended to provide longer lever 1 Accuracy of design idea 1

This question in 0445/33 May/June 2022

11 Fig. 11.1 shows an incomplete design for a table top organiser made from acrylic. The organiser is made up of six identical containers that will be joined together. 120 container 3 mm 100 thick acrylic Fig. 11.1 (a) Fig. 11.2 shows a screenshot of the development (net) of one of the containers produced using CAD. Fig. 11.2 Describe how the development (net) could be cut out using CAM from the CAD drawing. … … … … … … [4] (b) Explain why acrylic could be considered a ‘smart’ material. … … … [2] (c) Fig. 11.3 shows the development (net) of one container. bend lines Fig. 11.3 Use sketches and notes to show how the development (net) could be bent to the shape of the container. [5] (d) The containers will be joined together using acrylic cement. (i) State two safety precautions that must be taken when using acrylic cement. 1 … 2 … [2] (ii) Use sketches and notes to show how two containers could be clamped together after the acrylic cement has been applied. [2] (e) Children need to access the organiser when sitting at a table. Use sketches and notes to show how the organiser could be made to rotate on an additional base. Include details of the materials and constructions used. [5] (f) Use sketches and notes to show a design for a handle that could be attached to the organiser that would make it easier to carry. Include details of the materials and constructions used. [5]

25 marks

Mark scheme: 11(a) CAD file transferred/downloaded to CNC machine, type of CNC machine 4 Accept any ‘subsidiary’ stages; e.g. within named, setting up of acrylic workpiece, setting of machine parameters, turn the setting of tool parameters on machine 4 × 1 11(b) Acrylic can be heated and formed 1 2 When reheated acrylic will return to its original state 1 11(c) Use of a strip heater/line bender/hot air gun/heat gun 1 5 Method of heating can be stated or Sides of a container bent to shape 1 sketched Use of a former/block 1 Method of retention while acrylic cools 1 Repeat process to complete shape of container 1 11(d)(i) 2 safety precautions: use of gloves/barrier cream, face mask, goggles, well 2 Not Apron ventilated area, no naked flames 2 × 1 11(d)ii Use of adhesive tape, clothes peg, strap cramp, spring cramp, small G 2 Award any innovative method cramp 0–2 11(e) Additional base recognised 1 5 Organiser stable in use 1 Some form of pivot 1 Appropriate Materials 1 Practical constructions to enable device to rotate 1 11(f) Handle recognised in appropriate position 1 5 Appropriate material for handle 1 Method of attachment 0–2 Ergonomic handle 1

This question in 0445/33 May/June 2022

12 Fig. 12.1 shows a wall-mounted cycle rack made from mild steel. 150 backplate 3 mm thick 250 support rod Ø8 mm 600 A R25 90 Fig. 12.1 (a) State three items of research that a designer would need to consider when designing the cycle rack. 1 … 2 … 3 … [3] (b) Fig. 12.2 shows the backplate with centres marked where holes will be drilled to take the Ø8 support rods. centre for hole to be drilled 20 20 Fig. 12.2 (i) Table 12.1 shows three marking out tools that could be used to mark out the centres shown in Fig. 12.2. Complete Table 12.1 by naming the marking out tools shown. Table 12.1 Marking out tool Name of marking out tool [3] (ii) A centre punch would be used to make an indentation in the surface of the backplate so that the holes could be drilled accurately. Use sketches and notes to show a design for a jig that would locate the positions for the centre punch without the use of the marking out tools. Include the name of the material used to make the jig and state one important size. [5] (c) Fig. 12.3 shows a bending jig that could be used when bending the support rods to the shape shown at A in Fig. 12.1. Ø10 holes Ø50 mild steel rod mild steel plate 250 200 Ø10 mild steel pins Fig. 12.3 (i) Show the positions of the support rod and three Ø10 mild steel pins on Fig. 12.4, to produce bend A. Ø8 mild steel support rod Fig. 12.4 [3] (ii) State one benefit of heating the mild steel support rod before bending it to shape. … [1] (d) Fig. 12.5 shows an item of equipment that could be used when brazing the support rods to the backplate. Fig. 12.5 (i) Name the item of equipment shown in Fig. 12.5. … [1] (ii) Name two abrasives that could be used to clean the mild steel support rods before they are brazed. 1 … 2 … [2] (iii) Flux will be applied to the joints before brazing. State the purpose of the flux. … [1] (e) The cycle rack will have an applied painted finish. State two other suitable types of finish that could be applied to the cycle rack. 1 … 2 … [2] (f) Fig. 12.6 shows an exploded view of a modification to the design of the cycle rack shown in Fig. 12.1. The support rods and backplate have been replaced with 15 mm thick plywood. 70 back 15 mm thick plywood side 250 600 Ø8 mild steel rod Fig. 12.6 Fig. 12.7 shows one side of the cycle rack and a box that will be fitted to the side. The box will store items of equipment used for cycle maintenance. position of box 9 mm thick plywood box 430 × 100 × 70 Fig. 12.7 Use sketches and notes to show how the box could be fastened to the side of the cycle rack but could be removed quickly and easily to access the equipment. Include details of the materials and fittings used. [4]

25 marks

Mark scheme: 12(a) 3 items of research: type of cycle, tyre sizes, wheel diameter, weight of 3 Accept any valid items of research cycle, ease of access, where it is placed, method of attachment to wall, materials Do not reward height and length of bike 12(b)(i) Scriber, engineers square, try square, odd-leg/jenny calipers 3 12(b)(ii) ‘Plate’ or sheet with hole/s positioned accurately 1 5 Accept one whole sheet or corner jig Plate located against 1 edge 2 Plate located against 1 edge and 1 side 3 Important size: For example 250 × 150, 20 × Appropriate named material 1 20 or thickness of material for jig Important size 1 12(c)(i) 3 Award 1 mark for each correctly positioned pin 3 × 1 12(c)(ii) Heating softens the metal and makes it easier to bend, malleable 1 Accept prevents steel from ‘cracking’ 12(d)(i) Blowtorch, propane torch, gas torch, brazing torch 1 12(d)(ii) Emery cloth, wet and dry [silicon carbide paper], steel/wire wool 2 × 1 2 12(d)(iii) Flux keeps the joint clean, free from oxides, to allow the brazing rod to flow 1 12(e) Dip-coated, electroplated, plastic coated, oil/chemical blacking, powder 2 coating, galvanised 12(f) Method of attachment: use of screws/clips/magnets 0–2 4 Method enables quick removal 1 Technical accuracy: materials and fittings 1

This question in 0445/33 May/June 2022

2 Fig. 2.1 shows part of a manufactured board. The board will be covered with a veneer. veneer Fig. 2.1 (a) Give one benefit of using a contact adhesive to join the veneer to the manufactured board. … [1] (b) Give one drawback of using a contact adhesive to join the veneer to the manufactured board. … [1]

2 marks

Mark scheme: 2(a) Benefit: quick method, requires no clamping 1 Accept any valid benefit Not water resistant, easy to use 2(b) Disadvantage: adjustment of veneer to surface not possible, toxic, excess glue 1 Accept any valid disadvantage difficult to remove

This question in 0445/32 Oct/Nov 2022

10 A list of energy resources is given below. coal natural gas geothermal crude oil Circle , from the list, the energy resource that is renewable. [1]

1 marks

Mark scheme: 10 Geothermal 1

This question in 0445/32 Oct/Nov 2022

9 Fig. 9.1 shows a child’s counting toy that could be made in a school workshop. Ø5 metal rod plastic counters Fig. 9.1 (a) Name a process that could be used to produce the plastic counters. … [1] (b) Use sketches and notes to show how all the metal rods could be bent to the same shape. [3]

4 marks

Mark scheme: 9(a) Injection moulding 1 9(b) Metal heated 1 3 Former: base with pegs to position metal rod around former or use of metal rod/tube/cylinder held in vice with metal rod clamped in position 1 Method of bending 1

This question in 0445/33 Oct/Nov 2022

12 Fig. 12.1 shows a tray made from 5 mm thick acrylic. open corner hand hold 120 × 20 50 440 320 Fig. 12.1 (a) (i) State two properties of acrylic that make it suitable for the tray. 1 … 2 … [2] (ii) Acrylic sheet has a thin backing film covering both sides. State the purpose of the thin backing film. … [1] (b) State two items of research that a designer would need to consider when designing the tray. 1 … 2 … [2] (c) The corners of the tray shown in Fig. 12.1 are ‘open’. State one advantage of the corners being ‘open’ rather than ‘closed’. … [1] (d) Describe one example of how the designer has considered ergonomics in the design of the tray. … … [2] (e) Fig. 12.2 shows a screenshot of the development (net) of the tray produced using CAD software. Fig. 12.2 (i) State two benefits, other than speed and accuracy, of using CAD to produce the development (net) of the tray. 1 … 2 … [2] (ii) State one drawback of using CAD. … [1] (f) Fig. 12.3 shows the development (net) of the tray ready to be cut to shape. waste to be removed Fig. 12.3 (i) Name one suitable machine saw that could be used to cut out the waste acrylic. … [1] (ii) Name one suitable saw that could be used to cut out the waste acrylic by hand. … [1] (g) Fig. 12.4 shows one corner of the tray after the waste acrylic has been removed using a machine saw. sawn edges Fig. 12.4 Circle , from the list of files below, the most suitable file that could be used to make the sawn edges flat and smooth. warding hand square half-round [1] (h) Fig. 12.5 shows the development (net) of the tray ready to be heated and bent to shape. Fig. 12.5 Use sketches and notes to show how the development (net) of the tray could be heated and bent to shape. Include details showing how the acrylic could be: • heated and softened • bent to the correct shape and retained in position while it cooled. [5] (i) The tray will have a handle that would enable a person to carry it using one hand. Fig. 12.6 shows the tray with an incomplete handle that will fold flat inside the tray when it is not required. folds flat inside tray 4 mm thick acrylic handle centre of locking device Fig. 12.6 Use sketches and notes to show a completed design for the handle and show how it could be: • attached to the sides of the tray • locked securely in the upright position when the tray is carried. The method of locking and unlocking the handle must be quick and easy to operate. Include details of the materials used and give two important sizes. [6]

25 marks

Mark scheme: 12(a)(i) 2 properties: easy to form to shape, inherent colour, hygienic, does not require an 2 Accept any valid property applied finish, easy to clean, heat resistant, stain resistant, water resistant 12(a)(ii) Backing film protects the surfaces from scratches, marker pen can be used to 1 mark out on 12(b) 2 items of research: type of products that will be carried on the tray, the sizes of 2 Accept any valid item of research the products and the quantity of products, ergonomics 2  1 12(c) Advantage of ‘open’ corners: easier to form during manufacture, ease of cleaning 1 12(d) Ergonomics: size and shape of hand holds, overall size of the tray must be 2 Considerations: appropriate and comfortable to user Safety Comfort Ease of use Performance Aesthetics 12(e)(i) 2 benefits: ease of editing, ability to transfer data to connected CNC machine, 3D 2 Accept any valid benefits model can be created, shared with others on-line, files can be saved 2  1 12(e)(ii) Drawback: cost of pc, software, loss of electricity, training required, files may 1 Accept any valid drawbacks become corrupted 12(f)(i) Scroll saw, band saw, Hegner saw, jig saw 1 Not router 12(f)(ii) Coping saw, hacksaw, junior hacksaw, tenon saw, dovetail saw, abra file 1 12(g) Hand 1 12(h) Use of strip heater/line bender/hot air gun 1 5 Not oven Use of former or settings made to line bender 1 Not use of vice as a former Details relating to sequence of bends to be made 1 Method of retention while acrylic cools 1 Technical accuracy relating to the process and equipment used 1 12(i) Design of handle extends to sides of tray 1 6 Attached to sides of tray [e.g. nut and bolt] 1 Locked securely in upright position 1 2 important sizes 2  1 Materials used 1

This question in 0445/33 Oct/Nov 2022

1 Fig. 1.1 shows a cordless drill. Fig. 1.1 Identify three ergonomic features of the cordless drill. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 1 3 ergonomic features such as: shape of hand grip / ridges on chuck / easy to read settings / overall comfortable shape [3  1] 3 Accept any valid ergonomic features

This question in 0445/31 May/June 2023

9 Fig. 9.1 shows items of equipment used in a process to join metals together permanently. oxygen acetylene cylinder cylinder Fig. 9.1 Name a process in which the items of equipment would be used. … [1]

1 marks

Mark scheme: 9 Welding / brazing 1

This question in 0445/31 May/June 2023

1 Fig. 1.1 shows a variety of television remote controls. Fig. 1.1 State three specification points a designer would need to consider when designing a television remote control. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 1 Any 3 specification points from the list below: Appropriate size to fit hand [1] Must be comfortable to hold [1] As lightweight as possible [1] Easy to read numbers and symbols [1] Well-spaced numbers and symbols [1] Button placement [1] Aesthetic features must be qualified [1]

This question in 0445/32 May/June 2023

3 Fig. 3.1 shows a cross-sectional view of an injection moulding machine. A B D C B Fig. 3.1 Complete Table 3.1 by stating the name of the components B, C and D. Table 3.1 Component Name of component A Hopper B C D [3]

3 marks

Mark scheme: 3 B heater/heating chamber [1] C feed screw [1] D mould, die [1] 3 Accept any reference to ‘screw’

This question in 0445/32 May/June 2023

10 Fig. 10.1 shows a trophy made of 5 mm thick acrylic. The trophy has been produced using CAD/CAM. The words ‘Top Team 2023’ have been engraved on the star shape of the trophy. star shape 200 base Fig. 10.1 Complete Table 10.1 by describing three stages that could be carried out to produce the engraved words on the star shape of the trophy using CAD/CAM. Table 10.1 Stage Description of stage 1 Design star shape of trophy using appropriate software 2 3 4 5 Start CNC machine [3]

3 marks

Mark scheme: 10 Stage 2 transfer data to CNC machine [1] Stage 2 position workpiece on bed of CNC machine [1] Stage 3 set machine parameters [1] 3 Accept any valid stages. Do not accept repeats of designing process given in Table. Do not accept use of extraction unit

This question in 0445/32 May/June 2023

8 Fig. 8.1 shows three recycling symbols, A, B and C, that relate to different materials. 6 alu PS A B C Fig. 8.1 State the name of the material that each symbol relates to. A … B … C … [3]

3 marks

Mark scheme: 8 A polystyrene [1] B aluminium [1] C steel [1] 3

This question in 0445/33 May/June 2023

10 Fig. 10.1 shows a battery with a test strip that allows the user to check the condition of the battery. When a finger is pressed against each end of the test strip, a current from the battery flows through the strip, creating heat. The heat causes the test strip to change colour, indicating the condition of the battery. test strip Fig. 10.1 Name the smart material used to coat the test strip. … [1]

1 marks

Mark scheme: 10 Thermochromic ink 1

This question in 0445/33 May/June 2023

11 Fig. 11.1 shows views of a photograph frame held in a stand. The frame is made from MDF. The stand is made of hardwood. The frame can be made to rotate inside the stand to show two photographs. dowel 15 thick A frame 250 acrylic 175 stand photographs 35 Fig. 11.1 (a) Circle from the list below two hardwoods that could be used to make the stand. cedar oak chipboard balsa teak [2] (b) The frame is made from MDF. Other manufactured boards such as plywood could be used. Give two advantages of using MDF rather than plywood for the frame. 1 … … 2 … … [2] (c) A batch of 20 photograph stands is to be produced in a school workshop. Fig. 11.2 shows a bench hook that can be used when sawing wood to length. Fig. 11.2 Use sketches and notes to show how the bench hook could be modified to produce a jig for use when sawing two different lengths of hardwood, 250 mm and 145 mm, for the rails and uprights of the stand. Name any additional materials and constructions used. [5] (d) Fig. 11.3 shows two constructions that could be used to join the parts of the stand. pin and glue dowel Fig. 11.3 Give two reasons why the dowel joint is stronger than the pin and glue construction. 1 … 2 … [2] (e) Fig. 11.4 shows the positions for the dowel joint at corner A shown in Fig. 11.1. 15 35 Fig. 11.4 Design a drilling jig that could be used to speed up batch production of the stands. Name the material from which the jig is made. [4] (f) Fig. 11.5 shows the MDF frame with the cut-out shape marked out. A power router will be used to remove the shape. shape to be removed 135 × 95 × 20 Fig. 11.5 State two checks that need to be made when setting up the power router before it is used to cut out the shape. 1 … 2 … [2] (g) Fig. 11.6 shows details of the photographs ‘sandwiched’ between two sheets of 2 mm thick acrylic. The photographs and acrylic sheets will be fitted inside the frame. dowel frame acrylic 2 mm thick 20 photographs Fig. 11.6 Use sketches and notes to show modifications to the frame so that the photographs could be held securely inside the frame. The modifications must allow the photographs to be changed easily. Give details of additional materials and constructions used. [6] (h) The hardwood stand will have a clear polished finish. Give two benefits of applying a clear polished finish to the hardwood stand. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) Oak [1] Teak [1] 2 11(b) 2 advantages: easier to work / no grain pattern / smoother finish possible / cheaper [2  1] 2 11(c) Practical modification: Wood lengths held securely while sawn [1] 2 different lengths can be sawn accurately without need to measure [2 x 1] Appropriate materials named [1] Methods of construction clear [1] 5 11(d) Any 2 reasons such as: greater gluing/surface area / dowels less likely to twist or break [2  1] 2 Accept any valid reason 11(e) Template with 2 holes drilled [1] OR Template + 1 side located [2] OR Template + 2 sides located [3] OR Template + 1 side and 1 end located [3] Appropriately named material [1] 4 11(f) 2 checks: select correct type of cutter / secure cutter in router / adjust depth of cut / test on scrap wood / router switched off [2  1] 2 Do not accept ‘workpiece secured’ Do not accept references to personal checks; e.g. PPE 11(g) Method of retaining acrylic in frame such as: applied beads / cut rebate / slots in top and side of frame / allow for removal of top and/or side pieces of frame [0–3] Photos can be changed easily [1] Named materials [1] Quality of annotation [1] 6 Frame must not be completely disassembled 11(h) Any 2 benefits: clear finish allows natural beauty of grain to be seen / allows for additional polishing / preserves / protects / moisture resistant / aesthetically pleasing [2  1] 2

This question in 0445/33 May/June 2023

13 Fig. 13.1 shows a paint palette made of 3 mm thick acrylic. The paint palette has been designed using CAD and will be made by hand in a school workshop. paint pot 20 mm deep Ø60 230 25 90 Fig. 13.1 (a) Fig. 13.2 shows a screenshot of the CAD drawing of the development (net) of the palette. Fig. 13.2 Give two benefits of using CAD to design the paint palette. 1 … 2 … [2] (b) Fig. 13.3 shows one of the Ø60 holes that has been cut out using a drill and a saw. finished line waste to be removed Fig. 13.3 (i) Give one reason why the holes would be cut out of the acrylic before it is bent to the shape of the palette. … [1] (ii) Name a specific shape of file that could be used to remove the waste acrylic up to the finished line. … [1] (iii) The engineer’s vice shown in Fig.13.4 is used to hold the acrylic while it is being filed. There is a possibility of damaging the acrylic. Fig. 13.4 State one possible cause of damage and describe how it could be prevented. Possible damage … … Method of prevention … … [2] (c) Fig. 13.5 shows a buffing/polishing machine. The edges of the acrylic could be polished to a high quality before the acrylic is bent to the shape of the palette. Fig. 13.5 Give two safety precautions that must be taken, other than the use of Personal Protective Equipment, (PPE), when using a buffing/polishing machine. 1 … 2 … [2]

8 marks

Mark scheme: 13(a) 2 benefits: the data from the CAD drawing could be transferred to a CNC machine / editing tools available / on-screen modelling / speed / accuracy / adjustments made quickly / easy to generate ideas / view from different angles / share data electronically [2  1] 2 Do not accept ‘easy to use’. Do not accept ‘more accurate’ without stating what it is being compared with. 13(b)(i) The holes would be more difficult/awkward to drill after bent to shape 1 13(b)(ii) Round or rat tail file / half-round file 1 13(b)(iii) Possible damage: scratch the surface of the acrylic [1] Prevention: soft vice jaws or insert ‘padded’ material [1] OR Possible damage: acrylic vibrates and cracks if too high in vice [1] Prevention: lower in vice or provide support to both sides of acrylic [1] 2 Award 1 mark for Damage and 1 mark for Prevention 13(c) 2 safety precautions: no loose clothing / long hair tied back / hold work piece firmly and apply pressure to underside of polishing mop / location of emergency stop button / fix work to larger piece of scrap material to hold against mop [2  1] 2 13(d) Reason: to ensure that the acrylic is heated thoroughly from both sides / Makes it easier to bend / evenly heated 1 13(e) Acrylic clamped horizontally [1] Acrylic clamped vertically [1] 2 Accept use of blocks with relevant annotation 13(f)(i) MDF 1 Question Answer Marks Guidance 13(f)(ii) Draft angle indicated correctly 1 13(f)(iii) Purpose: to allow the plastic to be released from the mould 1 13(g) A faceplate [1] B between centres [1] 2 13(h)(i) Award [1] mark for any relevant stage in the vacuum forming process, up to 5 marks [5  1] Award [1] mark for technical accuracy / correct terminology / named components [1] 6 Stages include: position mould on platen, clamp plastic, heat plastic, raise platen, turn on pump to extract air, lower platen, turn off machine, leave to cool, remove from mould 13(h)(ii) Waste removed using a wide variety of saws / trimmer / ‘gerbil’ / craft knife / tin snips [1] Finished shape using sanding disk/belt sander and use of files/wet and dry [silicon carbide] paper/glasspaper [0–2] 3 Accept coping saw, bandsaw, Hegner saw or equivalent

This question in 0445/33 May/June 2023

1 Fig. 1.1 shows a student using a pillar drill. Fig. 1.1 Identify three safe working practices when using a pillar drill. 1 … 2 … 3 … [3]

3 marks

Mark scheme: Question Answer Marks Guidance 1 3 safe working practices: 3 Accept any valid safe working practices. • work secure Do not accept use of gloves, keep • guard in position fingers out of way of drill • face mask worn Do not accept sacrificial wood under • no loose clothing workpiece • hair tied back • wear apron • location of emergency STOP button • drill bit secure in chuck [3  1]

This question in 0445/31 Oct/Nov 2023

4 Table 4.1 shows three products each made of a different plastic. Complete Table 4.1 by naming a suitable specific plastic that could be used for each product. Table 4.1 Product Specific name of plastic crate electrical switch electrical insulation [3]

3 marks

Mark scheme: 4 Crate: polypropylene, ABS, HIPS, HDPE [1] 3 Electrical switch: urea formaldehyde [1] Electrical insulation: PVC [1]

This question in 0445/31 Oct/Nov 2023

5 Complete the sentence below by selecting the correct term from the list. sustainability generation of ideas research quality control During manufacture, a product is required to meet specific standards and requirements. Monitoring these standards is known as … [1]

1 marks

Mark scheme: 5 Quality control 1

This question in 0445/31 Oct/Nov 2023

9 Complete the sentence below by selecting the correct term from the list. case harden change shape become softer change colour When exposed to a change in temperature, thermochromic materials … … [1]

1 marks

Mark scheme: 9 Change colour 1

This question in 0445/31 Oct/Nov 2023

10 Fig. 10.1 shows a sectional view through part of a vacuum forming machine and a wooden mould that will be used when vacuum forming the thermoplastic sheet. toggle clamp thermoplastic sheet platen wooden mould vacuum pump Fig. 10.1 Add sketches and notes to the vacuum forming machine shown in Fig. 10.1 to show the position of: (a) the heater (b) the wooden mould. [2]

2 marks

Mark scheme: 10 2 Reward positions shown and not the drawings of the mould and heater. [2  1]

This question in 0445/32 Oct/Nov 2023

11 Fig. 11.1 shows an incomplete design for a paint holder that will be used when painting from a ladder. rung Ø30 support rod aluminium Ø5 ladder 65 × 25 pine rung tray sides 40 × 10 pine Fig. 11.1 (a) State three items of research the designer would need to consider when designing the paint holder. 1 … 2 … 3 … [3] (b) Give two properties of aluminium that make it suitable for the support rods. 1 … 2 … [2] (c) Fig. 11.2 shows details of the tray in which tins of paint and brushes could be placed while painting from the ladder. Mitre joints are used to join the sides at each corner of the tray. 40 280 240 Fig. 11.2 Use sketches and notes to show how one mitre joint could be marked out and cut out. Name the tools and equipment used to produce the mitre joint. [4] (d) Fig. 11.3 shows two constructions, A and B, that could be used to fit a 6 mm thick plywood base to the tray. drawer side plywood base A B Fig. 11.3 (i) State the name of each method of construction, A and B. Construction A … Construction B … [2] (ii) State two advantages of using construction A rather than construction B to fit the plywood base to the tray. 1 … 2 … [2] (e) Fig. 11.4 shows views of the tray and an incomplete support rod. The rod has been bent to fit the tray but the bend to fit around the top rung has yet to be produced. top rung Ø30 aluminium rod Ø5 380 290 Fig. 11.4 Use sketches and notes to show how the bend to fit around the top rung could be produced. Name the tools and equipment used to produce the bend. [4] (f) Fig. 11.5 shows a sectional side view of the ladder with the paint holder in position. In use the tray must be supported by the lower rung. top rung support rod tray lower rung Fig. 11.5 Use sketches and notes to show how the tray could be supported by the lower rung. Include details of all materials and constructions used. [4] (g) The paint holder will be used outdoors. Identify two problems facing designers of products that are used outdoors. Describe how the problems can be overcome. Problem 1 … … How overcome … … Problem 2 … … How overcome … … [4]

25 marks

Mark scheme: 11(a) Any three of: 3 Accept any valid research items. Do not accept one-word answers. • Shape and size of paint tins • weight of paint tins • brushes • dimensions of ladder • outdoor materials • finishes • constructions [3  1] 11(b) 2 properties: 2 Accept any valid properties corrosion resistant / easily shaped / ductile / lightweight / malleable [2  1] 11(c) Mitre joint marked out: use of mitre square and pencil or marking knife [2  1] 4 Accept sliding bevel. Mitre joint cut out: use of tenon saw and sanding disk / belt sander [2  1] Accept sanding disk: for max. 4 marks details showing ‘slide’ adjusted to 45° must be given 11(d)(i) A groove [1] 2 B rebate, lapped / lap joint [1] 11(d)(ii) 2 advantages: 2 • no nails or adhesive required • stronger construction to take weight of items stored • stable • more secure [2  1] 11(e) Heat aluminium rod [1] 4 Accept any method of heating except Use of a Ø30 former / rod [1] furnace and those that melt the rod Held securely in a vice or cramp [1] Method of force: mallet or hammer [1] 11(f) Practical idea: some form of ‘hook’ or bracket to fit over / around rung [0 – 2] 4 Suitable materials named [1] Constructional details [1] 11(g) 2 problems: 4 Accept any valid problems and Climate: effect of wind and rain, hot and cold conditions [2  1] sensible methods of how they could be overcome Vandalism: How overcome: Use of durable materials and finishes to cope with climate Products secured to avoid theft, special materials to deal with vandalism [2  1]

This question in 0445/32 Oct/Nov 2023

1 Fig. 1.1 shows a student using a pillar drill. Fig. 1.1 Identify three safe working practices when using a pillar drill. 1 … 2 … 3 … [3]

3 marks

Mark scheme: Question Answer Marks Guidance 1 3 safe working practices: 3 Accept any valid safe working practices. • work secure Do not accept use of gloves, keep • guard in position fingers out of way of drill • face mask worn Do not accept sacrificial wood under • no loose clothing workpiece • hair tied back • wear apron • location of emergency STOP button • drill bit secure in chuck [3  1]

This question in 0445/33 Oct/Nov 2023

4 Table 4.1 shows three products each made of a different plastic. Complete Table 4.1 by naming a suitable specific plastic that could be used for each product. Table 4.1 Product Specific name of plastic crate electrical switch electrical insulation [3]

3 marks

Mark scheme: 4 Crate: polypropylene, ABS, HIPS, HDPE [1] 3 Electrical switch: urea formaldehyde [1] Electrical insulation: PVC [1]

This question in 0445/33 Oct/Nov 2023

5 Complete the sentence below by selecting the correct term from the list. sustainability generation of ideas research quality control During manufacture, a product is required to meet specific standards and requirements. Monitoring these standards is known as … [1]

1 marks

Mark scheme: 5 Quality control 1

This question in 0445/33 Oct/Nov 2023

9 Complete the sentence below by selecting the correct term from the list. case harden change shape become softer change colour When exposed to a change in temperature, thermochromic materials … … [1]

1 marks

Mark scheme: 9 Change colour 1

This question in 0445/33 Oct/Nov 2023

10 Fig. 10.1 shows a variety of food containers made of plastic and manufactured by the vacuum forming process. One benefit of using this process is that the containers can be produced quickly. Fig. 10.1 Give two other benefits of using the vacuum forming process to manufacture the food containers. 1 … 2 … [2]

2 marks

Mark scheme: 10 Any two benefits: little waste, waste can be recycled, relatively cheap after initial tooling, repetitive accuracy of product [21]

This question in 0445/31 May/June 2024

12 Fig. 12.1 shows an incomplete design for a unit to store items used in a shower room. A parts list gives details of the materials and their sizes. back rail A Parts List shelf Part No. Size Material back 1 480 × 70 × 10 Teak shelf 2 300 × 90 × 10 Teak rail 4 450 × ∅5 Aluminium Fig. 12.1 (a) The back will be screwed and glued to the shelves. Fig. 12.2 shows an exploded view of one shelf and part of the back, showing the positions for the screws. shelf centres for screws Ø5 holes for rails back Fig. 12.2 Table 12.1 shows four items of information required when selecting screws. Complete Table 12.1 to give details of suitable screws that could be used to join the shelves to the back of the unit. Table 12.1 Item of information required Selection Diameter Material Length Type of head [4] (b) Fig. 12.3 shows the hook shape of the back of the storage unit marked out, ready to be cut out and shaped. Use sketches and notes to show how the shape could be produced. Name all the tools and equipment used. 70 Ø30 100 Fig. 12.3 [5] (c) (i) Fig. 12.4 shows the dimensions of rail A in Fig. 12.1. The rail is made from ∅5 aluminium rod and is bent to shape. Use sketches and notes to show how rail A could be produced. Name all the tools and equipment used. 120 45 140 80 Fig. 12.4 [5] (ii) Give two reasons why the aluminium rails should be anodised. 1 … 2 … [2] (iii) The rails will be glued into holes drilled in the back and shelves of the storage unit using an epoxy resin adhesive. Describe how the adhesive would be prepared before gluing the rails into the holes. … … … [2] (d) When the shower is switched on it is likely that the shelves will become wet. Use sketches and notes to show modifications to the design of the shelves so that any water could drain away. Give details to show how the modified design could be made in a school workshop. [5] (e) Many products used in shower rooms are made entirely of plastic. State two properties of plastic that make it suitable for use in a shower room. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Material: steel, stainless steel, brass, aluminium [1] Length: minimum 15mm- maximum 30 mm [1] Type of head: countersunk [1] 12(b) Drill Ø30 hole, cut inside and outside curves, sanding disc/file outside curves, file inside curve, accurately named most tools and equipment [5x1] 5 Accept any practical processes 12(c)(i) 3 accurate at 90º bends [31] Tools/equipment: vice/clamping method, mallet or hammer + scrap wood [21] 5 12(c)(ii) Anodising gives a protective layer, greater corrosion resistance, attractive [coloured] appearance [21] 2 12(c)(iii) Epoxy resin 2 parts: resin and hardener [1] Equal amounts mixed together [1] 2 12(d) Practical idea: use of holes drilled in shelves/grooves cut out of shelves [1] Details of drilled holes: number of holes + diameter + type of drill bit + spacing position [41] OR Details of router: width + length of groove, spacing, set up of router [41] 5 Question Answer Marks Guidance 12(e) Any two properties: attractive colours to match environment, corrosion resistance in wet areas, easily cleaned [21] 2 Accept any other valid properties

This question in 0445/31 May/June 2024

3 Many products are manufactured with built-in obsolescence. Explain, by giving an example of a specific product, what is meant by the term ‘built-in obsolescence’. … … … [2]

2 marks

Mark scheme: 3 Explanation: when a product is designed and manufactured so that it can only be used for a limited time before it has to be replaced [1] Specific product [1] 2 Do not reward named product without correct explanation.

This question in 0445/32 May/June 2024

6 Fig. 6.1 shows what happens to shape memory alloy (SMA) when it is heated. Stage 1 original shape at BENT low temperature COOLED Stage 2 deformed shape at Stage 3 low temperature HEATED Fig. 6.1 Complete Fig. 6.1 by drawing the shape of the SMA at Stage 3. [1]

1 marks

Mark scheme: 6 The shape will be the same as at stage 1 [1] 1 Accept written statement only.

This question in 0445/32 May/June 2024

9 Fig. 9.1 shows a plastic vending cup and the symbol for the plastic from which the cup is made. PS Fig. 9.1 (a) Name the type of plastic from which the vending cup is made. … [1] (b) Many fast-food outlets are encouraging customers to reuse their drinks cups. Give two benefits of reusing drinks cups. 1 … 2 … [2]

3 marks

Mark scheme: 9(a) Polystyrene 1 9(b) Any two benefits: less waste, less resources used, less litter, lower manufacturing costs, less landfill [21] 2 Accept any valid benefits. Do not accept ‘better’ for environment/planet.

This question in 0445/32 May/June 2024

7 Thermochromic materials change colour at specific temperatures. Describe how the use of thermochromic pigment can improve the function of a product. … … … … [2]

2 marks

Mark scheme: 7 Explanation: Improves function by giving ‘warning’ of temperature changes Examples include: baby spoons and cups, ceramic mugs, battery test strip Maximum marks can still be awarded without an example.

This question in 0445/33 May/June 2024

8 Fig. 8.1 shows a stage in a process to shape thermoplastic sheet. clamping ring clamp heated thermoplastic sheet compressed air Fig. 8.1 (a) Name the process shown in Fig. 8.1. … [1] (b) Draw on Fig. 8.1 to show what happens to the thermoplastic sheet when compressed air is applied. [1]

2 marks

Mark scheme: 8(a) Blow moulding 1 8(b) Sketch should show ‘dome’ shape between the clamping rings [1] 1

This question in 0445/33 May/June 2024

2 Energy can be generated from natural sources. State three natural sources of energy. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 2 Any 3 sources such as: solar, wind, tidal, geothermal, hydro, 3 Not ‘light’ water, sun [3  1]

This question in 0445/31 Oct/Nov 2024

8 Shape memory alloy (SMA) is a smart material. The most common shape memory alloy (SMA) is Nitinol. Complete the names of the two metals that are combined to make Nitinol. N … T … [2]

2 marks

Mark scheme: 8 Nickel Titanium [2  1] 2

This question in 0445/31 Oct/Nov 2024

10 Fig. 10.1 shows a food container made from plastic with an integral lid. Fig. 10.1 Give one benefit of an integral lid. … … [1]

1 marks

Mark scheme: 10 The lid is not a separate part of the container as it is 1 Accept any other valid benefit attached, lid cannot be lost or misplaced, the lid is easy to open and close

This question in 0445/31 Oct/Nov 2024

11 Fig. 11.1 shows a condiment holder that has been designed and made by a group of Design & Technology students. The condiment holder is made mainly from softwood and will be used in the school dining hall. handle end partition 10 mm thick 200 rail 200 160 Fig. 11.1 (a) State three questions the students could have asked the catering staff to help them design the condiment holder. 1 … 2 … 3 … [3] (b) (i) Give one reason for making the condiment holder from softwood rather than hardwood. … [1] (ii) Name a suitable manufactured board that could be used for the 5 mm thick base of the holder. … [1] (c) Fig. 11.2 shows one end of the holder marked out, ready to be cut to shape. waste centre for Ø12 hole waste 10 mm thick Fig. 11.2 Use sketches and notes to show how the waste could be removed and the edges made smooth. Name all the tools and equipment used. [4] (d) Fig. 11.3 shows the position where the partition will be joined to an end. end 10 mm thick partition 90 × 10 Fig. 11.3 Sketch and name a suitable construction that could be used to join the partition to the end. [4] (e) A batch of ten holders is to be produced. Use sketches and notes to show a design for a jig that could be used to saw 200 mm lengths of softwood for the rails of the condiment holder. [4] (f) Fig. 11.4 shows one of the rails with the edges planed to produce a chamfer. chamfer waste Fig. 11.4 (i) Use sketches and notes to show how the length of softwood for the rail could be held while one edge is planed. [2] (ii) Name a specific type of plane that could be used to remove the waste. … [1] (g) Fig. 11.5 shows three rails joined to an end using nails and an adhesive. rails 20 × 10 Fig. 11.5 (i) Name a specific type of nail that could be used to join the rails to the ends. … [1] (ii) Name a tool that could be used to sink the head of the nail below the surface of the softwood. … [1] (h) Describe how the success of the design of the holders could be evaluated by the Design and Technology students. … … … … … … [3]

25 marks

Mark scheme: 11(a) Any 3 questions such as: how many reqd. what type of 3 Accept any other valid questions condiments, how many different condiments in each holder, where will they be used/stored/cleaned, portable, how large could it be, budget, weight of condiments, water resistant [3  1] 11(b)(i) Softwoods are more readily available, cheaper 1 Accept any other valid reasons Not easier to work, more attractive 11(b)(ii) Plywood, MDF, hardboard 1 Not blockboard 11(c) Cut out using coping, Hegner, scroll, band, jig saws [1] 4 Sketches of tools used to cut and file reqd. Use of files to smooth sawn edges [1] Use of glasspaper to smooth sawn edges [1] Accept ‘abrasive paper’ Quality of communication [sketches and notes] [1] 11(d) Dowel, mortise and tenon, housing joint, domino, biscuit 4 Do not accept use of glue only named [1] Technical accuracy of construction: proportion, orientation [0 – 3] 11(e) Saw cut guide or ‘stop’ for saw blade [1] 4 200mm length measurement marked clearly on jig [1] Jig secured in position during use [1] Softwood held securely while sawn [1] 11(f)(i) Methods include: 2 Accept any other practical methods; e.g. use of sash in a vice [1] cramps, G cramps held horizontally [1] G cramps must not interfere with planing OR against a bench stop [1] held flat on bench [1] 11(f)(ii) Jack, smoothing, block planes 1 11(g)(i) Panel pin, round (wire) nail, oval (brad) 1 No alternative variations accepted 11(g)(ii) Nail/pin punch 1 11(h) In use ask students for feedback, analyse, ask members of 3 Accept separate methods listed or one in-depth method catering staff, examine design against original specification, use questionnaire, survey [0 – 3]

This question in 0445/31 Oct/Nov 2024

6 Fig. 6.1 shows details of a steam chest that would be used to steam bend wood. vent end sealed end sealed steam feed pipe drain hole / pipe steam generator bucket Fig. 6.1 List three stages to describe how the steam chest would be used to steam bend wood. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 6 Any 3 stages such as: insert wood into steam chest and seal, steam is 3 Accept any valid stages with reference to produced, steam is fed into chest where wood absorbs the hot moisture, wood any of the labelled parts in Fig. 6.1 becomes pliable [3  1]

This question in 0445/32 Oct/Nov 2024

9 Fig. 9.1 shows a variety of supermarket shopping bags made from plastic and the symbol showing the type of plastic from which the bags are made. 4 LDPE Fig. 9.1 (a) Name the type of plastic from which the bags are made. … [1] (b) Many supermarket shopping bags are thrown away. State two ways supermarkets could reduce the environmental waste produced by the use of plastic shopping bags. 1 … 2 … [2]

3 marks

Mark scheme: 9(a) Low density polythene / polyethylene 1 Must include ‘Low Density’ 9(b) Any 2 ways such as: replace with paper bags, ‘bag for life’, encourage 2 Accept any valid ways customers to provide their own, charging customers for bags as a deterrent, recycle used bags in store [2  1]

This question in 0445/32 Oct/Nov 2024

11 Fig. 11.1 shows an incomplete design for a tablet stand made of hardwood. 300 support platform 200 140 base base and support frames 25 mm wide × 10 mm thick platform 10 mm thick Fig. 11.1 (a) Give two benefits of using hardwood for the tablet stand. 1 … 2 … [2] (b) The four sides of the base will be marked out and cut from a 700 mm length of hardwood. (i) Name two tools that could be used to mark out the sides of the base. 1 … 2 … [2] (ii) Name a specific type of saw that could be used with a bench hook to saw the sides to the required lengths. … [1] (c) Fig. 11.2 shows a dowel joint used at the corners of the base and support. each side 25 × 10 Fig. 11.2 Use sketches and notes to show a design for a jig that could be used when marking out the positions for the holes to be drilled for the dowels. [4] (d) Fig. 11.3 shows the base of the tablet stand glued and clamped together. sash cramp 140 sash cramp 200 Fig. 11.3 Add sketches and notes to Fig. 11.3 to show two methods of checking that the sides are clamped squarely to each other. [4] (e) The platform and the support will be joined to the base by means of butt hinges. (i) Complete Fig. 11.4 to show a butt hinge. Fig. 11.4 [3] (ii) Name a different type of hinge that could be used to join the platform and the support to the base. … [1] (f) Use sketches and notes to show modifications to the tablet stand so that the platform could be tilted and locked securely at three different angles. Give details of all materials and constructions used. [4] (g) Describe one way in which the designer has considered each of the following when designing the tablet stand. (i) ergonomics … … [2] (ii) sustainability of materials used … … [2]

25 marks

Mark scheme: 11(a) Any 2 benefits such as: hardwearing, attractive appearance / grain markings, 2 Accept any other valid benefits polishes well, durable, hard, tough [2  1] Not strong 11(b)(i) Any 2 tools: pencil, marking knife, steel rule, try square [2  1] 2 Accept ruler, metre rule, measuring tape 11(b)(ii) Tenon saw, dovetail saw, backsaw 1 11(c) ‘Template’ [with 2 holes drilled] [1] 4 Award 1 max for use of panel pins to mark ‘Template’ + one side or one edge located [2] centres ‘Template’ + one side and one end located [3] Notes to describe features of jig [1] 11(d) Method one: use of try square [1] shown in corner of frame [1] 4 Accept use of set square for try square Method two: long rule / straight edge [1] shown measuring Diagonal measurement must be inside diagonal distance [1] frame 11(e)(i) Right hand leaf accurately drawn [1] 3 Accept 3 holes staggered Butt hinge has min. 2– max. 3 holes in leaf [1] Knuckle / pin recognised [1] 11(e)(ii) Flush hinge, piano hinge, back flap hinge 1 11(f) Practical idea: some form of ‘stop’ applied to back of platform or recesses cut 4 in back of platform [1] 3 different angles [1] Additional materials named + constructional details [0 – 2] 11(g)(i) Ergonomics: 3 different angles [1] for different users to view tablet 2 Accept: easy to transport, people of comfortably [1] different heights 11(g)(ii) Sustainability: hardwood trees that are cut down to provide the wood [1] 2 can be replaced with ‘new’ trees, durability of materials means products last longer / less need to replace [1]

This question in 0445/32 Oct/Nov 2024

2 Energy can be generated from natural sources. State three natural sources of energy. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 2 Any 3 sources such as: solar, wind, tidal, geothermal, hydro, 3 Not ‘light’ water, sun [3  1]

This question in 0445/33 Oct/Nov 2024

8 Shape memory alloy (SMA) is a smart material. The most common shape memory alloy (SMA) is Nitinol. Complete the names of the two metals that are combined to make Nitinol. N … T … [2]

2 marks

Mark scheme: 8 Nickel Titanium [2  1] 2

This question in 0445/33 Oct/Nov 2024

10 Fig. 10.1 shows a food container made from plastic with an integral lid. Fig. 10.1 Give one benefit of an integral lid. … … [1]

1 marks

Mark scheme: 10 The lid is not a separate part of the container as it is 1 Accept any other valid benefit attached, lid cannot be lost or misplaced, the lid is easy to open and close

This question in 0445/33 Oct/Nov 2024

11 Fig. 11.1 shows a condiment holder that has been designed and made by a group of Design & Technology students. The condiment holder is made mainly from softwood and will be used in the school dining hall. handle end partition 10 mm thick 200 rail 200 160 Fig. 11.1 (a) State three questions the students could have asked the catering staff to help them design the condiment holder. 1 … 2 … 3 … [3] (b) (i) Give one reason for making the condiment holder from softwood rather than hardwood. … [1] (ii) Name a suitable manufactured board that could be used for the 5 mm thick base of the holder. … [1] (c) Fig. 11.2 shows one end of the holder marked out, ready to be cut to shape. waste centre for Ø12 hole waste 10 mm thick Fig. 11.2 Use sketches and notes to show how the waste could be removed and the edges made smooth. Name all the tools and equipment used. [4] (d) Fig. 11.3 shows the position where the partition will be joined to an end. end 10 mm thick partition 90 × 10 Fig. 11.3 Sketch and name a suitable construction that could be used to join the partition to the end. [4] (e) A batch of ten holders is to be produced. Use sketches and notes to show a design for a jig that could be used to saw 200 mm lengths of softwood for the rails of the condiment holder. [4] (f) Fig. 11.4 shows one of the rails with the edges planed to produce a chamfer. chamfer waste Fig. 11.4 (i) Use sketches and notes to show how the length of softwood for the rail could be held while one edge is planed. [2] (ii) Name a specific type of plane that could be used to remove the waste. … [1] (g) Fig. 11.5 shows three rails joined to an end using nails and an adhesive. rails 20 × 10 Fig. 11.5 (i) Name a specific type of nail that could be used to join the rails to the ends. … [1] (ii) Name a tool that could be used to sink the head of the nail below the surface of the softwood. … [1] (h) Describe how the success of the design of the holders could be evaluated by the Design and Technology students. … … … … … … [3]

25 marks

Mark scheme: 11(a) Any 3 questions such as: how many reqd. what type of 3 Accept any other valid questions condiments, how many different condiments in each holder, where will they be used/stored/cleaned, portable, how large could it be, budget, weight of condiments, water resistant [3  1] 11(b)(i) Softwoods are more readily available, cheaper 1 Accept any other valid reasons Not easier to work, more attractive 11(b)(ii) Plywood, MDF, hardboard 1 Not blockboard 11(c) Cut out using coping, Hegner, scroll, band, jig saws [1] 4 Sketches of tools used to cut and file reqd. Use of files to smooth sawn edges [1] Use of glasspaper to smooth sawn edges [1] Accept ‘abrasive paper’ Quality of communication [sketches and notes] [1] 11(d) Dowel, mortise and tenon, housing joint, domino, biscuit 4 Do not accept use of glue only named [1] Technical accuracy of construction: proportion, orientation [0 – 3] 11(e) Saw cut guide or ‘stop’ for saw blade [1] 4 200mm length measurement marked clearly on jig [1] Jig secured in position during use [1] Softwood held securely while sawn [1] 11(f)(i) Methods include: 2 Accept any other practical methods; e.g. use of sash in a vice [1] cramps, G cramps held horizontally [1] G cramps must not interfere with planing OR against a bench stop [1] held flat on bench [1] 11(f)(ii) Jack, smoothing, block planes 1 11(g)(i) Panel pin, round (wire) nail, oval (brad) 1 No alternative variations accepted 11(g)(ii) Nail/pin punch 1 11(h) In use ask students for feedback, analyse, ask members of 3 Accept separate methods listed or one in-depth method catering staff, examine design against original specification, use questionnaire, survey [0 – 3]

This question in 0445/33 Oct/Nov 2024

2 Fig. 2.1 shows two products, lengths of tube and a washing-up bowl, made from plastic. tubes washing-up bowl Fig. 2.1 Name a specific process that could be used to manufacture: (a) the tubes … [1] (b) the washing-up bowl. … [1]

2 marks

Mark scheme: 2(a) Extrusion 1 2(b) Injection moulding, vacuum forming, press forming 1

This question in 0445/31 May/June 2025

6 Fig. 6.1 shows a handle made from polymorph. Polymorph is a thermoplastic supplied as granules. Fig. 6.1 Describe how the granules are used to make the finished handle. … … … … [2]

2 marks

Mark scheme: 6 Polymorph is immersed in hot water, 2 Do not reward ‘moulded by hand’ on its own Material becomes soft and is moulded by hand [2  1]

This question in 0445/31 May/June 2025

13 Fig. 13.1 shows a basic design for a headphone stand made from 5 mm thick acrylic. 50 support upright 250 base 90 90 Fig. 13.1 (a) Give two properties of acrylic that make it suitable for the headphone stand. 1 … 2 … [2] (b) Fig. 13.2 shows the development (net) of the headphone stand marked out, ready to be cut to shape. Key: waste bend lines 90 15 50 25 130 250 90 Fig. 13.2 (i) Name one machine saw that could be used to remove the waste acrylic. … [1] (ii) Name a specific type of file that could be used to make the sawn edges flat and smooth. … [1] (iii) Give the name of an abrasive paper that could be used to produce a smooth finish to the edges of the acrylic. … [1] (iv) Fig. 13.3 shows a buffing wheel that could be used to polish the edges of the acrylic. A polishing mop rotates B C Fig. 13.3 Select the correct position, A, B or C, to show where the acrylic should be placed against the polishing mop. Position … [1] (c) The headphone stand could be produced using CAD/CAM. (i) Give two benefits of using CAD to design the headphone stand. 1 … 2 … [2] (ii) Give two advantages of using CAM, rather than using hand tools and equipment, to cut out the headphone stand. 1 … 2 … [2] (d) Fig. 13.4 shows details of the support part of the headphone stand. 25 50 2525 support 15 Fig. 13.4 Use sketches and notes to show how male and female formers would be used to produce the shape of the support. [4]

14 marks

Mark scheme: 13(a) Properties include: attractive, variety of colours, self- 2 finishing, easily shaped, easy to work, easy to clean, lightweight to carry, durable [2  1] 13(b)(i) Hegner, band, scroll saw 1 Do not accept jig saw 13(b)(ii) Hand, flat or half round file 1 13(b)(iii) Wet and dry (silicon carbide paper) 1 13(b)(iv) Position C 1 13(c)(i) 2 benefits: ease and speed of editing, data can be 2 Accept any valid benefit transferred to a CNC machine, view from all angles, 3D views, accurate measurements, drawings can be sent electronically [2  1] 13(c)(ii) 2 advantages: speed, accuracy, repetitive accuracy, no 2 Accept any valid advantage edge finishing reqd. time efficient, less waste of materials [21] 13(d) Male former shown [1] 4 Female former shown [1] Acrylic heated in an oven [1] Acrylic clamped between formers [1] 13(e) Does it make the stand more stable 4 Modifications added to the top of the stand = 1 [0 – 2] Named materials appropriate [1] Constructional details [1] 13(f) Practical modification: some sort of ‘hook’ or ‘bracket’ for 4 cable to wrap around [0 – 2] Position for device on back or base [1] Constructional details [1] 13(g) Explanation can include: not all plastics can be recycled, 3 Accept any valid points. discarded plastic products litter the planet, plastic takes a Reward several points made or one or two expanded points. long time to decompose, polluting the land and oceans, negative effects on wildlife, overflowing landfill The manufacture of plastics can give off harmful gases into the atmosphere

This question in 0445/31 May/June 2025

9 Shape memory alloy (SMA) is a smart material. Complete the statement by adding the word that applies to shape memory alloy (SMA). moisture weight heat light Shape memory alloy (SMA) is a smart material that reacts to … [1]

1 marks

Mark scheme: 9 Heat 1

This question in 0445/32 May/June 2025

10 Fig. 10.1 shows two children’s toy trucks. Truck A is made from plastic. Truck B is made of wood. A B Fig. 10.1 (a) Give two reasons why children might prefer to play with the plastic truck rather than the wooden truck. 1 … 2 … [2] (b) Give one reason why the materials used to make truck B could be considered to be more sustainable than those used to make truck A. … [1] (c) State the method of manufacture for the plastic truck A. … [1]

4 marks

Mark scheme: 10(a) Reasons: bright colours, more intricate shapes, lighter to 2 Accept any valid reasons e.g.: child preferences handle, smoother, no splinters Do not accept ‘more attractive’ [2  1] 10(b) Reasons include: 1 Wood used can be replaced with replanted trees. Wood used to make products can be reprocessed to produce manufactured boards Oil used to produce plastic is a finite source. 10(c) Injection moulding, 3D printing 1

This question in 0445/32 May/June 2025

11 Fig. 11.1 shows a design for a rack to hold whiteboard marker pens and a board rubber. The rack is made from 4 mm thick acrylic. slot for board rubber 60 × 30 Ø20 holes for marker pens 300 80 60 Fig. 11.1 (a) Give two properties of acrylic that make it suitable for the rack. 1 … 2 … [2] (b) Give two items of research that the designer of the rack would need to consider. 1 … 2 … [2] (c) Modelling can be very useful when designing and making a product. Modelling can be done using card or by using a computer program. Give one benefit of using: (i) card modelling … … [1] (ii) a computer program … … [1] (d) Fig. 11.2 shows the development (net) of the rack. centres for Ø20 holes waste 60 slot for board rubber 60 × 30 80 60 300 Fig. 11.2 (i) Name two tools or items of equipment that could be used to mark out the centres for the Ø20 holes. 1 … 2 … [2] (ii) The slot for the board rubber will be cut out by hand. Use sketches and notes to show how the waste could be removed and the cut edges made flat and smooth. Name all the tools and equipment used. [5] (e) A batch of ten racks will be produced in a school workshop. Use sketches and notes to show a jig that would allow the holes to be drilled accurately. Name the material used to make the jig. [5] (f) When drilling acrylic sheet there is a danger that the drill bit could snag and cause the sheet to snap. Use sketches and notes to show how holes could be drilled safely and accurately without damaging the acrylic sheet. [3] (g) Use sketches and notes to show how the acrylic sheet could be bent to form the shape of the rack. Give details of all the equipment used. [4]

25 marks

Mark scheme: 11(a) Properties include: attractive, variety of colours, self- 2 Accept any valid properties finishing, easily shaped, easy to work, easy to clean, lightweight to carry, water resistant, durable [2  1] 11(b) 2 items: size of markers and board rubber, number of 2 Accept any valid items of research markers, location, ease of access 11(c)(i) Card modelling: quick, accessible, cheap, no waste of 1 Accept any valid benefits expensive materials 11(c)(ii) Computer program: ease of editing, transfer to CNC 1 Accept any valid benefits machine, send images electronically, create 3D model, accuracy 11(d)(i) Chinagraph pencil, felt tip marker pen, scriber, odd leg 2 calipers [2  1] 11(d)(ii) Hole/s drilled in acrylic [1] 5 Accepted saws: coping, Hegner/scroll, abra, piercing Saw blade inserted [1] Waste sawn out [1] Correctly named saw [1] Cut edges filed [1] 11(e) Template with holes drilled + 1 side + 1 edge located [3] 5 Template with holes drilled = 1 Suitable material for jig named [1] Template with holes drilled + 1 side = 2 Additional explanatory notes [1] 11(f) Sacrificial board underneath [1] 3 Accept references to pilot holes, drill speed, use of hole saw Some type of clamp [1] Added notes to describe method [1] 11(g) Heat acrylic [1] 4 Do not accept oven to heat the acrylic Method of heating acrylic named: strip heater, line bender, heat gun [1] Use of some type of former or line bender [1] Bend to shape and retain while cooling [1]

This question in 0445/32 May/June 2025

2 Fig. 2.1 shows two products, lengths of tube and a washing-up bowl, made from plastic. tubes washing-up bowl Fig. 2.1 Name a specific process that could be used to manufacture: (a) the tubes … [1] (b) the washing-up bowl. … [1]

2 marks

This question in 0445/33 May/June 2025

4 Fig. 4.1 shows two tools, A and B, being used on the end of a round metal rod. A B metal rod Fig. 4.1 Name tools A and B. A … B … [2]

2 marks

Mark scheme: 4 A scriber 2 B centre square, centre finder [2  1]

This question in 0445/33 May/June 2025

6 Fig. 6.1 shows a handle made from polymorph. Polymorph is a thermoplastic supplied as granules. Fig. 6.1 Describe how the granules are used to make the finished handle. … … … … [2]

2 marks

Mark scheme: 6 Polymorph is immersed in hot water, 2 Do not reward ‘moulded by hand’ on its own Material becomes soft and is moulded by hand [2  1]

This question in 0445/33 May/June 2025

8 Fig. 8.1 shows a baby’s feeding spoon. Fig. 8.1 Explain the benefit of applying thermochromic pigment to the baby’s feeding spoon. … … … [2]

2 marks

Mark scheme: 8 Benefit: the baby will not burn their tongue or mouth [1] 2 Because the spoon will change colour [1]

This question in 0445/31 Oct/Nov 2025

11 Fig. 11.1 shows a child’s toy bus made mainly from 12 mm thick plywood. window dowel joint 200 400 160 Fig. 11.1 (a) State three specification points a designer would have considered when designing the toy bus. The toy bus must: 1 … 2 … 3 … [3] (b) Table 11.1 shows three tools that could be used when cutting out the shape of the windows. Complete Table 11.1 by naming each tool and giving a description of how each tool could be used to cut out the shape of the windows. Table 11.1 Tools Name of tool Description of use [6] (c) Dowel joints are used to join the main parts of the toy bus. Fig. 11.2 shows a length of dowel that could be used. plywood side dowel Ø6 Fig. 11.2 Add sketches and notes to Fig. 11.2 to show how the dowel could be prepared so that: • it is made easier to enter the hole in the plywood side • there is space for the adhesive. [2] (d) Fig. 11.3 shows a length of hardwood that has been ‘turned’ on a woodturning lathe to produce the four wheels for the toy bus. 200 Ø65 12 mm thick Fig. 11.3 Use sketches and notes to show a design for a jig that could be used when sawing off each of the wheels 12 mm thick. Name the materials used for the jig and state two important sizes. [5] (e) Use sketches and notes to show how the two front wheels could be attached to the sides of the toy bus securely and allowed to rotate freely. Give details of all materials, constructions and fittings used and state one important dimension. [4] (f) Use sketches and notes to show a modification to the toy bus to allow a child to pull it along. Give details of any materials and fittings used. [3] (g) Many children’s toys are made from wood-based materials or from plastic. Give one reason why consumers may prefer: wood-based toys … plastic toys. … [2]

25 marks

Mark scheme: 11(a) 3 specification points: safe in use, no sharp edges, finger 3 Accept any valid specification points traps, non-toxic finish, well-built to withstand misuse, sturdy, Do not accept weather resistant, lightweight durable, easy to move around, attractive, aesthetically pleasing [3  1] 11(b) (Twist) drill [1] 6 Description of use MUST relate to the window used to drill holes for saw blade [1] otherwise 0 Coping saw [1] If tool is incorrect, description of use can be marked as blade inserted through hole and refitted to remove shape [1] correct File [1] used to make sawn edges flat/smooth [1] 11(c) Ends of dowel tapered to assist entry [1] 2 Saw-cuts along the length of dowel or across the ends [1] 11(d) Hardwood held securely while sawn [1] 5 Ignore saw blade and material thicknesses 12mm thickness can be sawn without need for marking out [1] Suitable material for jig [1] 2 sizes [2  1] 11(e) Axle fitted to wheels [1] 4 If wheel rotates on axle, method of retention must be shown Axle through side of bus or supported under bus [1] for 1 mark If axle is rotates through side of bus, hole must be larger to Free rotation: washer, bearing, larger diameter hole [1] gain mark for ‘Free rotation’ Award maximum 2 marks for ‘stub’ axle, or screws that are Dimension [1] fitted to ONE side of bus only 11(f) Practical modification [1] 3 Reward modification and additional notes only if shown on Fitted to front of bus [1] back of bus Additional notes [1] 11(g) Reason for wood-based toys: hardwearing, 2 Accept any valid reasons for both types of toy durable, ‘solid’ [1] Do not accept wooden toys are ‘non-toxic’ and plastic toys are ‘cheap’ Reason for plastic toys: appealing colours, more details Only accept wooden toys are attractive if reference is made possible, waterproof, can be cleaned and washed, to ‘grain features’ lightweight [1]

This question in 0445/31 Oct/Nov 2025

12 Fig. 12.1 shows a stand used to display a model yacht. The stand is made from 5 mm thick acrylic. 120 60 20 250 15 25 Fig. 12.1 (a) Acrylic is a thermoplastic. Give one advantage of making the display stand from a thermoplastic rather than a thermosetting plastic. … [1] (b) When working with acrylic the surfaces can become scratched easily. State one way by which scratches could be prevented. … [1] (c) The edges of the acrylic will be self-finished. Explain what is meant by the term ‘self-finished’. … … … [2] (d) Fig. 12.2 shows the development (net) of the display stand. waste bend line 20 190 15 25 85 420 Fig. 12.2 (i) Give one reason why a chinagraph pencil would be used to mark out the bend lines rather than a scriber. … [1] (ii) Use sketches and notes to show how the waste acrylic could be cut out and the sawn edges made flat and smooth. Show how the acrylic could be held securely. Name all the tools and equipment used. [6] (e) Use sketches and notes to show how the ends of the display stand could be bent to shape. Name all the tools and equipment used. [4] (f) Fig. 12.3 shows a different design of display stand made from 6 mm thick MDF. The display stand could be made in a school workshop. The sides and ends slot together. 70 240 140 Fig. 12.3 Fig. 12.4 shows a CAD drawing of one of the sides and one of the ends. The school has a CNC machine that could be used to cut out the sides and ends. waste slots 6 mm wide 70 50 280 140 Fig. 12.4 Complete Table 12.1 to describe how the sides and ends could be cut out using a CNC machine. Table 12.1 Stage Description of process 1 File of CAD drawing saved 2 3 4 5 [4] (g) Fig. 12.5 shows the parts of the display stand before they are assembled. The sides and ends are assembled without the use of an adhesive. Fig. 12.5 Give two benefits to consumers of purchasing products that can be assembled without the use of an adhesive. 1 … 2 … [2] (h) When designing a product it is important to consider the impact of the materials used on the environment. Explain why the use of MDF could be considered more environmentally friendly than using acrylic for the display stand. … … … … … … [4]

25 marks

Mark scheme: 12(a) Ability of thermoplastics to be reheated and reshaped 1 12(b) Retain paper/plastic backing sheet. Apply a separate 1 backing sheet. 12(c) A material that has a surface prepared for 2 final appearance [1] Needing no further treatment [1] 12(d)(i) Scriber produces a permanent mark that cannot be erased 1 whereas a chinagraph pencil can be erased 12(d)(i) Sawing process: 6 Appropriate saws: Hegner, scroll, coping, tenon Name of saw [1] Reward ‘holding securely’ when using Hegner type saws Method of holding work piece [1] without reference Sketch showing process [1] Do not accept jig saw Edge finishing process: Edge filed [1] Method of holding work piece [1] Use of ‘wet and dry paper’ and/or polishing mop [1] 12(e) Method of heating: strip heater, line bender, hot air gun [1] 4 Do not accept oven Some type of former to enable acrylic to be bent to shape [1] Method of retention [1] Accuracy of technical details [1] 12(f) Stages: transfer/download data to CNC machine, place MDF 4 Accept any valid stages on bed of machine, set tool parameters, computer ‘print’, ‘run’ [4  1] 12(g) Generally cheaper than pre-assembled products, personal 2 Do not accept ‘faster’ satisfaction, can be taken apart to repair or for storage, less space when stored, can be assembled by non-expert [2  1] 12(h) MDF is made from waste materials which has little or no 4 Accept any valid issues impact on existing resources, biodegradable [0 – 2] Acrylic is made from oil which is a finite resource, non- biodegradable [0 – 2]

This question in 0445/31 Oct/Nov 2025

6 Fig. 6.1 shows a tool being used to measure the diameter of a metal rod. Fig. 6.1 (a) Name the tool shown in Fig. 6.1. … [1] (b) Use sketches and notes to show how the actual measurement made by the tool would be read. [2]

3 marks

Mark scheme: 6(a) Outside / external calipers 1 Do not accept ‘caliper’ 6(b) Sketch shows ‘tip’ of caliper [1] positioned against end of 2 Award 1 mark for ‘tips’ of caliper shown along the rule but steel rule [1] not at the end

This question in 0445/32 Oct/Nov 2025

9 Fig. 9.1 shows a rechargeable wind-up radio. Fig. 9.1 Describe two ways in which the designer has considered ergonomics in the design of the wind-up radio. 1 … … 2 … … [4]

4 marks

Mark scheme: 9 Examples of ergonomic features: 4 Does the answer demonstrate an understanding of shaped handle [1] is comfortable to grip [1] ‘ergonomics’? curved shape [1] is comfortable to carry [1] lightweight design [1] makes it comfortable to carry [1] cranked handle [1] makes it easier to turn [1]

This question in 0445/32 Oct/Nov 2025

4 Fig. 4.1 shows a spray bottle with parts made from two different plastics. head bottle Fig. 4.1 Name a suitable plastic that could be used to make: (a) the head … [1] (b) the bottle. … [1]

2 marks

Mark scheme: 4(a) Polypropylene, PP 1 4(b) HDPE, PET, polyethelene 1 Do not accept polythene, LDPE

This question in 0445/33 Oct/Nov 2025

8 Fig. 8.1 shows a baby’s feeding spoon. Fig. 8.1 Explain the benefit of applying thermochromic pigment to the baby’s feeding spoon. … … … [2]

2 marks

Mark scheme: 8 Benefit: the baby will not burn their tongue or mouth [1] 2 Because the spoon will change colour [1]

This question in 0445/33 Oct/Nov 2025

12 Fig. 12.1 shows a stand used to display a model yacht. The stand is made from 5 mm thick acrylic. 120 60 20 250 15 25 Fig. 12.1 (a) Acrylic is a thermoplastic. Give one advantage of making the display stand from a thermoplastic rather than a thermosetting plastic. … [1] (b) When working with acrylic the surfaces can become scratched easily. State one way by which scratches could be prevented. … [1] (c) The edges of the acrylic will be self-finished. Explain what is meant by the term ‘self-finished’. … … … [2] (d) Fig. 12.2 shows the development (net) of the display stand. waste bend line 20 190 15 25 85 420 Fig. 12.2 (i) Give one reason why a chinagraph pencil would be used to mark out the bend lines rather than a scriber. … [1] (ii) Use sketches and notes to show how the waste acrylic could be cut out and the sawn edges made flat and smooth. Show how the acrylic could be held securely. Name all the tools and equipment used. [6] (e) Use sketches and notes to show how the ends of the display stand could be bent to shape. Name all the tools and equipment used. [4] (f) Fig. 12.3 shows a different design of display stand made from 6 mm thick MDF. The display stand could be made in a school workshop. The sides and ends slot together. 70 240 140 Fig. 12.3 Fig. 12.4 shows a CAD drawing of one of the sides and one of the ends. The school has a CNC machine that could be used to cut out the sides and ends. waste slots 6 mm wide 70 50 280 140 Fig. 12.4 Complete Table 12.1 to describe how the sides and ends could be cut out using a CNC machine. Table 12.1 Stage Description of process 1 File of CAD drawing saved 2 3 4 5 [4] (g) Fig. 12.5 shows the parts of the display stand before they are assembled. The sides and ends are assembled without the use of an adhesive. Fig. 12.5 Give two benefits to consumers of purchasing products that can be assembled without the use of an adhesive. 1 … 2 … [2] (h) When designing a product it is important to consider the impact of the materials used on the environment. Explain why the use of MDF could be considered more environmentally friendly than using acrylic for the display stand. … … … … … … [4]

25 marks

Mark scheme: 12(a) Ability of thermoplastics to be reheated and reshaped 1 12(b) Retain paper/plastic backing sheet. Apply a separate 1 backing sheet. 12(c) A material that has a surface prepared for 2 final appearance [1] Needing no further treatment [1] 12(d) Scriber produces a permanent mark that cannot be erased 1 whereas a chinagraph pencil can be erased 12(d) Sawing process: 6 Appropriate saws: Hegner, scroll, coping, tenon Name of saw [1] Reward ‘holding securely’ when using Hegner type saws Method of holding work piece [1] without reference Sketch showing process [1] Do not accept jig saw Edge finishing process: Edge filed [1] Method of holding work piece [1] Use of ‘wet and dry paper’ and/or polishing mop [1] 12(e) Method of heating: strip heater, line bender, hot air gun [1] 4 Do not accept oven Some type of former to enable acrylic to be bent to shape [1] Method of retention [1] Accuracy of technical details [1] 12(f) Stages: transfer/download data to CNC machine, place MDF 4 Accept any valid stages on bed of machine, set tool parameters, computer ‘print’, ‘run’ [4  1] 12(g) Generally cheaper than pre-assembled products, personal 2 Do not accept ‘faster’ satisfaction, can be taken apart to repair or for storage, less space when stored, can be assembled by non-expert [2  1] 12(h) MDF is made from waste materials which has little or no 4 Accept any valid issues impact on existing resources, biodegradable [0 – 2] Acrylic is made from oil which is a finite resource, non- biodegradable [0 – 2]

This question in 0445/33 Oct/Nov 2025

13 Fig. 13.1 shows a menu stand that has been produced by a D&T student for use in a local café. A batch of ten menu stands will be produced. menu support Ø5 brass rod base 20 mm thick oak 35 260 60 Fig. 13.1 (a) Give three specification points that the student would have considered when designing the menu stand. The menu stand must: 1 … 2 … 3 … [3] (b) Two Ø5 holes will be drilled in the base before it is shaped. Use sketches and notes to show a jig that could be used to mark out the positions of the holes accurately when making a batch of ten menu stands. Name the material from which the jig could be made. [4] (c) Fig. 13.2 shows a chamfer marked out on the base of the menu stand and the completed chamfer after the waste wood has been planed off. chamfer marked out chamfer Fig. 13.2 (i) Give the name of a plane that could be used to produce the chamfer. (ii) Use sketches and notes to show how the base could be held securely while the chamfer is planed. [3] (d) (i) The brass used for the rod is a non-ferrous metal. Give the meaning of the term non-ferrous metal. … [1] (ii) The brass rod needs to be made softer so that it could be bent to shape more easily. State the name of the process that is used to make the brass softer. … [1]

13 marks

Mark scheme: 13(a) 3 specification points: menu card dimensions, method of 3 Accept any valid specification points changing menu card, exact location, size of table surface, Do not accept references to writing on menu, lightweight café décor/style, stable in use, attractive, aesthetically pleasing, durable, easy to manufacture [3  1] 13(b) Template with holes drilled [1] + 1 side [1] + 4 Template with holes drilled = 1 1 edge located [1] Template with holes drilled + 1 side = 2 Suitable material for jig named [1] 13(c)(i) Block, jack, smoothing planes 1 13(c)(ii) Methods: 3 Award 0–2 dependent on technical accuracy Wood held secure in vice or with cramps [0 – 2] Wood could be held in a vice between its sides or held Additional notes [1] between its edges 13(d)(i) Metals that do not contain iron 1 13(d)(ii) Annealing 1 13(e) Jig design: EITHER a flat board with locating pegs/pins OR 4 bent around a shaped former held in a vice or held with cramps [0 – 2] Held securely in place [1] Method of force [1] 13(f)(i) White/French polish, Danish/Teak oil, wax, olive oil 1 Do not accept varnish, oil [on its own] 13(f)(ii) Lacquer 1 13(g) 2 parts of epoxy resin: resin + hardener [1] 2 Equal parts mixed together [1] 13(h) Menu stand A is the more economical to produce [1] 4 Reward any valid justified points Reasons to support choice should expand on fewer materials, types of construction and processes involved to batch produce Supportive reasons [3  1]

This question in 0445/33 Oct/Nov 2025