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Topical›Design and Technology 0445›Topic 4›Systems & Control – Structures›Paper 3

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

4.2· 497 questions · 4140 marks · 4968 min · 2017–2025· Structured questions

Every Cambridge IGCSE Design and Technology Paper 3 question on systems & control – structures, laid out as 725 A4 pages with the mark scheme below. Nothing is left out. Free to read, no account.

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Question 1: Complete the table below by naming each of the tools or items of equipment used to hold wood. Name Name Name Name [4]Question 2: Fig. 2 shows three boards that will be glued together to make a solid wood table top. 150 150 1 150 2 3 Fig. 2 (a) Give one reason why it w…1 / 725
Question 3: Complete the table by naming the correct metal from the list below to match each description. mild steel cast iron copper stainless steel b…Question 4: Fig. 3 shows the end of a length of wood. Draw on Fig. 3 to show a chamfered edge and a bevelled edge. chamfered edge bevelled edge Fig. 3 …Question 5: Fig. 4 shows a tee square made from two pieces of acrylic. joint Fig. 4 Name a suitable method of joining the two pieces of acrylic togethe…2 / 725
Question 6: Fig. 5 shows a method of joining two wooden boards. Fig. 5 Name the method of joining. ....................................................…Question 7: Fig. 6 shows a modelling knife. The metal body of the knife is made in two parts that are screwed together. body Fig. 6 (a) Name a process …3 / 725
Question 8: Fig. 7 shows views of a child’s table and a parts list. A B A B A B A table shown with top removed Number Part Length × Width × Thickness M…4 / 725
Question 8 (continued)5 / 725
Question 8 (continued)6 / 725
Question 8 (continued)7 / 725
Question 9: Fig. 11 shows views of a cycle rack that could be fixed to the wall of a garage or shed. wooden back 200 × 40 × 15 A A pivot sheet metal su…8 / 725
Question 9 (continued)9 / 725
Question 9 (continued)10 / 725
Question 9 (continued)11 / 725
Question 10: 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…12 / 725
Question 10 (continued)13 / 725
Question 10 (continued)Question 11: Fig. 1 shows two pieces of hardwood that have been glued together. Fig. 1 From the list below circle the type of glue that would provide th…14 / 725
Question 12: Complete the drawing below to show odd leg calipers. [2]Question 13: Fig. 2 shows the end of a length of wood. Draw on Fig. 2 to show a groove and a rebate. Fig. 2 [2]Question 14: Fig. 3 shows four items used to fasten materials together. A B C D Fig. 3 Name each of the items A, B, C and D shown in Fig. 3. A .........…15 / 725
Question 15: Fig. 4 shows three layers of a sheet of plywood. 1 2 3 Fig. 4 Complete Fig. 4 by drawing the grain direction on layers 2 and 3 to show how …Question 16: Fig. 5 shows a manufactured board. Fig. 5 (a) Name the manufactured board. ................................................................…16 / 725
Question 17: Fig. 6 shows a mild steel bracket for a hanging basket. 200 300 brace Fig. 6 (a) State a suitable thickness of mild steel strip for the bra…Question 18: Fig. 7 shows a toast rack made from metal. base Fig. 7 (a) (i) Name a suitable ferrous metal for the toast rack. ..........................…17 / 725
Question 19: Fig. 8 shows views of an artist’s drawing board. storage unit: 1.5 thick plastic ledge: 10×10 hardwood support: Ø8 metal rod board: 15 thic…18 / 725
Question 19 (continued)19 / 725
Question 19 (continued)20 / 725
Question 20: Fig. 10 shows a bird feeder made from wood and plastic. roof: 4 thick clear acrylic end: 12 thick plywood base: 12 thick plywood 200 200 12…21 / 725
Question 20 (continued)22 / 725
Question 20 (continued)23 / 725
Question 20 (continued)24 / 725
Question 21: Fig. 15 shows views of a computer desk manufactured as flat-pack for self-assembly. The end frames, back rail and supports are made from ha…25 / 725
Question 21 (continued)26 / 725
Question 21 (continued)27 / 725
Question 22: Complete the table below by naming each of the tools or items of equipment used to hold wood. Name Name Name Name [4]Question 23: Fig. 2 shows three boards that will be glued together to make a solid wood table top. 150 150 1 150 2 3 Fig. 2 (a) Give one reason why it w…28 / 725
Question 24: Complete the table by naming the correct metal from the list below to match each description. mild steel cast iron copper stainless steel b…Question 25: Fig. 3 shows the end of a length of wood. Draw on Fig. 3 to show a chamfered edge and a bevelled edge. chamfered edge bevelled edge Fig. 3 …Question 26: Fig. 4 shows a tee square made from two pieces of acrylic. joint Fig. 4 Name a suitable method of joining the two pieces of acrylic togethe…29 / 725
Question 27: Fig. 5 shows a method of joining two wooden boards. Fig. 5 Name the method of joining. ....................................................…Question 28: Fig. 6 shows a modelling knife. The metal body of the knife is made in two parts that are screwed together. body Fig. 6 (a) Name a process …30 / 725
Question 29: Fig. 7 shows views of a child’s table and a parts list. A B A B A B A table shown with top removed Number Part Length × Width × Thickness M…31 / 725
Question 29 (continued)32 / 725
Question 29 (continued)33 / 725
Question 29 (continued)34 / 725
Question 30: Fig. 11 shows views of a cycle rack that could be fixed to the wall of a garage or shed. wooden back 200 × 40 × 15 A A pivot sheet metal su…35 / 725
Question 30 (continued)36 / 725
Question 30 (continued)37 / 725
Question 30 (continued)38 / 725
Question 31: 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…39 / 725
Question 31 (continued)40 / 725
Question 31 (continued)Question 32: Fig. 1 shows a child’s scooter. Fig. 1 Describe three ways in which the designer has considered the child’s safety in the design of a scoot…41 / 725
Question 33: Complete the drawing below to show a tenon saw. [2]Question 34: Fig. 4 shows a washing-up liquid bottle made from plastic and a symbol that can be seen on the bottle. 1 PET Fig. 4 (a) Name the plastic. .…42 / 725
Question 35: Complete the drawing below to show a stopped housing joint. [3]Question 36: Fig. 5 shows a house number plate made from brass, a non-ferrous alloy. Fig. 5 Explain the term ‘non-ferrous alloy’. ......................…Question 37: The table below shows two fastening devices. Complete the table by naming each fastening device and stating how each would be tightened. Fa…43 / 725
Question 38: Fig. 7 shows two bookends. The bookends could be made from plastic or metal. One bookend has two storage strips where pens and pencils coul…44 / 725
Question 38 (continued)45 / 725
Question 38 (continued)46 / 725
Question 38 (continued)47 / 725
Question 39: Fig. 10 shows a sign that will be located in a school corridor to give directions to a Design and Technology display. The sign is made from…48 / 725
Question 39 (continued)49 / 725
Question 39 (continued)50 / 725
Question 40: Fig. 12 shows a wooden stool and a parts list. The stool is designed for a person to stand on. platform Number Part Length × width × thickn…51 / 725
Question 40 (continued)52 / 725
Question 40 (continued)Question 41: Fig. 2 shows a try square being used to test an edge for squareness. try square 5 mm thick steel 12 mm thick pine Fig. 2 Give the correct n…Question 42: Fig. 3 shows a block joint. Fig. 3 Add to Fig. 3 to show how the block joint could be strengthened. [2]53 / 725
Question 43: Fig. 4 shows views of a smart phone desk stand. Fig. 4 (a) Name a suitable non-ferrous metal that could be used to make the stand. ........…Question 44: Fig. 5 shows views of a basic frame construction in wood. 800 sides 50 × 25 500 Fig. 5 Add sketches and notes to Fig. 5 to show two ways of…Question 45: Complete the table by selecting the correct material from the list below to match each description. ash plywood blockboard MDF oak Material…54 / 725
Question 46: Fig. 6 shows acrylic sheet bent to shape. base Fig. 6 Add sketches and notes to Fig. 6 to show how the bent shape of the acrylic could be h…Question 47: Complete the drawing below to show an exploded view of a corner bridle joint. [3]55 / 725
Question 48: Fig. 9 shows an incomplete design for a floor standing bathroom storage unit made mainly from softwood. The storage unit will be batch prod…56 / 725
Question 48 (continued)57 / 725
Question 48 (continued)58 / 725
Question 49: Fig. 11 shows views of a wall-mounted coat rack. Coats are hung on the front pegs and coat hangers can be hooked over the pegs behind the f…59 / 725
Question 49 (continued)60 / 725
Question 49 (continued)Question 50: Fig. 13 shows a toy racing car made from softwood. Ten identical cars will be made in a school workshop. spoiler body 150 × 40 × 40 rear wh…61 / 725
Question 50 (continued)62 / 725
Question 50 (continued)Question 51: Fig. 1 shows a door bolt made from steel for use in a bathroom. The bolt has a chrome finish. Fig. 1 Give two benefits of a chrome finish f…63 / 725
Question 52: Fig. 2 shows an incomplete leg fastening used to join a leg to the rails of a table. Fig. 2 Add to Fig. 2 to show how the leg fastening cou…Question 53: Complete the table below by adding the correct name from the list. forstner countersink flat twist centre Drill Name [3]64 / 725
Question 54: Fig. 3 shows a skateboard. The deck is made by gluing thin layers of wood together. Fig. 3 (a) Give the correct term for ‘thin layers of wo…Question 55: Fig. 4 shows a handle made from metal. Fig. 4 Add sketches and notes to Fig. 4 to show a modification to the handle that would make it easi…Question 56: Fig. 5 shows a canoe. Fig. 5 Name two composite materials that could be used to make the canoe. 1 .........................................…65 / 725
Question 57: Fig. 6 shows a piece of steel that has cracked due to work hardening during bending. Fig. 6 Explain what is meant by the term ‘work hardeni…66 / 725
Question 58: Fig. 9 shows a child’s desk organiser made from 4 mm thick acrylic. The desk organiser will store paints, brushes, marker pens, crayons and…67 / 725
Question 58 (continued)68 / 725
Question 58 (continued)69 / 725
Question 58 (continued)70 / 725
Question 59: 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 …71 / 725
Question 59 (continued)72 / 725
Question 59 (continued)73 / 725
Question 59 (continued)74 / 725
Question 60: Fig. 16 shows a card model for a safety glasses holder. The holder could be made from wood or metal. The safety glasses holder will be wall…75 / 725
Question 60 (continued)76 / 725
Question 60 (continued)77 / 725
Question 61: Fig. 2 shows a try square being used to test an edge for squareness. try square 5 mm thick steel 12 mm thick pine Fig. 2 Give the correct n…Question 62: Fig. 3 shows a block joint. Fig. 3 Add to Fig. 3 to show how the block joint could be strengthened. [2]78 / 725
Question 63: Fig. 4 shows views of a smart phone desk stand. Fig. 4 (a) Name a suitable non-ferrous metal that could be used to make the stand. ........…Question 64: Fig. 5 shows views of a basic frame construction in wood. 800 sides 50 × 25 500 Fig. 5 Add sketches and notes to Fig. 5 to show two ways of…Question 65: Complete the table by selecting the correct material from the list below to match each description. ash plywood blockboard MDF oak Material…79 / 725
Question 66: Fig. 6 shows acrylic sheet bent to shape. base Fig. 6 Add sketches and notes to Fig. 6 to show how the bent shape of the acrylic could be h…Question 67: Complete the drawing below to show an exploded view of a corner bridle joint. [3]80 / 725
Question 68: Fig. 9 shows an incomplete design for a floor standing bathroom storage unit made mainly from softwood. The storage unit will be batch prod…81 / 725
Question 68 (continued)82 / 725
Question 68 (continued)83 / 725
Question 69: Fig. 11 shows views of a wall-mounted coat rack. Coats are hung on the front pegs and coat hangers can be hooked over the pegs behind the f…84 / 725
Question 69 (continued)85 / 725
Question 69 (continued)Question 70: Fig. 13 shows a toy racing car made from softwood. Ten identical cars will be made in a school workshop. spoiler body 150 × 40 × 40 rear wh…86 / 725
Question 70 (continued)87 / 725
Question 70 (continued)Question 71: Name the two standard metal sections shown below. ......................................... ...............................................…88 / 725
Question 72: (a) Name the type of tools shown in Fig. 1. Fig. 1 ........................................................................................…Question 73: Fig. 2 shows three different holes drilled before woodscrews can be used to join the two pieces of wood. Each hole has a different purpose.…89 / 725
Question 74: Complete the table below by naming a different material that matches each of the descriptions. Material Description hard plastic, wide rang…Question 75: Fig. 3 shows an incomplete drawing of a marking gauge. Fig. 3 Complete the drawing of the marking gauge by adding: (a) the thumbscrew; (b) …90 / 725
Question 76: Fig. 5 shows two sit-on toys used by children. Toy A is made from wood and toy B from plastic. A B Fig. 5 Describe one benefit to the user …Question 77: Fig. 6 shows a wooden frame construction, a hardboard corner plate and a corrugated fastener. A 80 B 80 hardboard corner plate 15 25 corrug…91 / 725
Question 78: Fig. 9 shows a storage unit. A printer will be placed on top of the unit, which will be positioned under a desk. The unit has shelves that …92 / 725
Question 78 (continued)93 / 725
Question 78 (continued)94 / 725
Question 78 (continued)95 / 725
Question 79: Fig. 11 shows a headphone stand made from 5 thick acrylic. The headphone stand has two main parts: a base and a support. support headphones…96 / 725
Question 79 (continued)97 / 725
Question 79 (continued)98 / 725
Question 79 (continued)99 / 725
Question 80: Fig. 15 shows two designs of shelf units. Both designs are manufactured and sold as self-assembly products. Design A Design B hardwood shel…100 / 725
Question 80 (continued)101 / 725
Question 80 (continued)102 / 725
Question 81: Fig. 1 shows a length of wood marked to the required width. waste edge A side 300 12 Fig. 1 (a) Name a tool, other than a pencil and steel …Question 82: Complete the table below by naming each tool and describing a specific use for each. Tool Name Use [4]103 / 725
Question 83: Fig. 3 shows two pieces of wood that will be joined together using a biscuit joint. B A Fig. 3 Draw on Fig. 3 to show how two biscuits coul…Question 84: Fig. 6 shows a pair of shin pads used by hockey players. The shin pads are made from a composite material. Fig. 6 (a) Name one composite ma…104 / 725
Question 85: Fig. 7 shows part of a leg and rail of a table and a knock-down (KD) fitting. rail rail leg leg Fig. 7 Draw on Fig. 7 to show how the knock…Question 86: Fig. 9 shows views of a toothbrush holder made from 4 mm thick acrylic. 20 support A 100 20 130 180 90 70 end view with end removed Fig. 9 …105 / 725
Question 86 (continued)106 / 725
Question 86 (continued)107 / 725
Question 86 (continued)108 / 725
Question 87: 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 …109 / 725
Question 87 (continued)110 / 725
Question 87 (continued)111 / 725
Question 87 (continued)112 / 725
Question 87 (continued)Question 88: Fig. 16 shows a wall-mounted adjustable shelving system. metal support rods Ø8 shelves 700 × 300 × 15 uprights 1200 × 50 × 25 Fig. 16 (a) N…113 / 725
Question 88 (continued)114 / 725
Question 88 (continued)115 / 725
Question 88 (continued)Question 89: Name the two standard metal sections shown below. ......................................... ...............................................…Question 90: (a) Name the type of tools shown in Fig. 1. Fig. 1 ........................................................................................…116 / 725
Question 91: Fig. 2 shows three different holes drilled before woodscrews can be used to join the two pieces of wood. Each hole has a different purpose.…Question 92: Complete the table below by naming a different material that matches each of the descriptions. Material Description hard plastic, wide rang…Question 93: Fig. 3 shows an incomplete drawing of a marking gauge. Fig. 3 Complete the drawing of the marking gauge by adding: (a) the thumbscrew; (b) …117 / 725
Question 94: Fig. 5 shows two sit-on toys used by children. Toy A is made from wood and toy B from plastic. A B Fig. 5 Describe one benefit to the user …Question 95: Fig. 6 shows a wooden frame construction, a hardboard corner plate and a corrugated fastener. A 80 B 80 hardboard corner plate 15 25 corrug…118 / 725
Question 96: Fig. 9 shows a storage unit. A printer will be placed on top of the unit, which will be positioned under a desk. The unit has shelves that …119 / 725
Question 96 (continued)120 / 725
Question 96 (continued)121 / 725
Question 96 (continued)122 / 725
Question 97: Fig. 11 shows a headphone stand made from 5 thick acrylic. The headphone stand has two main parts: a base and a support. support headphones…123 / 725
Question 97 (continued)124 / 725
Question 97 (continued)125 / 725
Question 97 (continued)126 / 725
Question 98: Fig. 15 shows two designs of shelf units. Both designs are manufactured and sold as self-assembly products. Design A Design B hardwood shel…127 / 725
Question 98 (continued)128 / 725
Question 98 (continued)129 / 725
Question 99: Fig. 1 shows two different methods of filing metal. cross filing draw filing Fig. 1 Describe the purpose of each method of filing. Cross fi…Question 100: Complete the drawing below to show an exploded view of a stopped housing joint. [3]130 / 725
Question 101: Fig. 2 shows a small dish made from plastic. The dish has been vacuum formed. Fig. 2 (a) The former used to vacuum form the dish could be m…Question 102: Fig. 3 shows two electric drills. plastic body aluminium alloy casing rechargeable battery mains cable Drill A Drill B Fig. 3 (a) Name the …131 / 725
Question 103: Fig. 4 shows a kitchen roll holder made from acrylic. kitchen roll Fig. 4 Explain how the designer has used the flexible property of acryli…Question 104: Fig. 5 shows a basic design for a desk tidy made in a school workshop. The desk tidy is made from 4 mm thick acrylic. Fig. 5 Use sketches a…132 / 725
Question 105: Fig. 6 shows part of a garden tool rack. Fig. 6 (a) Indicate clearly on Fig. 6 one example of ‘short grain’. [1] (b) Explain why ‘short gra…Question 106: Fig. 7 shows a round tube that will be joined to a metal strip made from mild steel. tube Ø20 strip 20 × 3 Fig. 7 Add sketches and notes to…133 / 725
Question 107: Fig. 8 shows two different wall brackets. 180 230 bracket A fabricated from softwood bracket B moulded plastic Fig. 8 (a) Describe one qual…134 / 725
Question 108: Fig. 9 shows views of a child’s counting toy. When the discs are stacked on the rod, the collar slides down on top of the discs to show the…135 / 725
Question 108 (continued)136 / 725
Question 108 (continued)137 / 725
Question 109: Fig. 12 shows an incomplete design for a reading lamp to be made in a school workshop. The arms, base and supports are made from hardwood. …138 / 725
Question 109 (continued)139 / 725
Question 109 (continued)140 / 725
Question 109 (continued)141 / 725
Question 110: Fig. 17 shows views of a children’s play table. The height of the table can be adjusted by means of sleeves that fit over the ends of the l…142 / 725
Question 110 (continued)143 / 725
Question 110 (continued)144 / 725
Question 111: Complete the table by stating the manufacturing process used to make each product. Product Manufacturing process metal model toy vehicle pl…Question 112: Fig. 2 shows a length of veneered chipboard marked out, ready to be cut into four pieces. 200 1000 15 mm thick 10 mm waste Fig. 2 (a) Give …145 / 725
Question 113: Name the three standard metal sections shown below. ...................................... ..................................... ..........…Question 114: Complete the drawing below to show a finger (comb) joint. [3]Question 115: Composite materials are made by combining materials with different properties to make a material with more useful properties. Name two comp…146 / 725
Question 116: Fig. 3 shows hardwood strips being glued together to make a chopping board. chopping board scrap wood cramp Fig. 3 (a) Name the type of cra…Question 117: Fig. 4 shows a toast rack made from stainless steel. Fig. 4 Give two reasons why stainless steel is a suitable material for a toast rack. 1…147 / 725
Question 118: Fig. 5 shows a wooden chair. legs 30 × 30 Fig. 5 Use sketches and notes to show how the chair could be modified so that it can be linked, s…148 / 725
Question 119: 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 th…149 / 725
Question 119 (continued)150 / 725
Question 119 (continued)151 / 725
Question 119 (continued)152 / 725
Question 120: 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 …153 / 725
Question 120 (continued)154 / 725
Question 120 (continued)Question 121: Fig. 13 shows a child’s ride-on toy made mainly from wood. A Ø8 axles Ø100 wooden wheel B Fig. 13 (a) Fig. 14 shows details of part A and t…155 / 725
Question 121 (continued)156 / 725
Question 121 (continued)157 / 725
Question 121 (continued)158 / 725
Question 122: Fig. 1 shows two different methods of filing metal. cross filing draw filing Fig. 1 Describe the purpose of each method of filing. Cross fi…Question 123: Complete the drawing below to show an exploded view of a stopped housing joint. [3]159 / 725
Question 124: Fig. 2 shows a small dish made from plastic. The dish has been vacuum formed. Fig. 2 (a) The former used to vacuum form the dish could be m…Question 125: Fig. 3 shows two electric drills. plastic body aluminium alloy casing rechargeable battery mains cable Drill A Drill B Fig. 3 (a) Name the …160 / 725
Question 126: Fig. 4 shows a kitchen roll holder made from acrylic. kitchen roll Fig. 4 Explain how the designer has used the flexible property of acryli…Question 127: Fig. 5 shows a basic design for a desk tidy made in a school workshop. The desk tidy is made from 4 mm thick acrylic. Fig. 5 Use sketches a…161 / 725
Question 128: Fig. 6 shows part of a garden tool rack. Fig. 6 (a) Indicate clearly on Fig. 6 one example of ‘short grain’. [1] (b) Explain why ‘short gra…Question 129: Fig. 7 shows a round tube that will be joined to a metal strip made from mild steel. tube Ø20 strip 20 × 3 Fig. 7 Add sketches and notes to…162 / 725
Question 130: Fig. 8 shows two different wall brackets. 180 230 bracket A fabricated from softwood bracket B moulded plastic Fig. 8 (a) Describe one qual…163 / 725
Question 131: Fig. 9 shows views of a child’s counting toy. When the discs are stacked on the rod, the collar slides down on top of the discs to show the…164 / 725
Question 131 (continued)165 / 725
Question 131 (continued)166 / 725
Question 132: Fig. 12 shows an incomplete design for a reading lamp to be made in a school workshop. The arms, base and supports are made from hardwood. …167 / 725
Question 132 (continued)168 / 725
Question 132 (continued)169 / 725
Question 132 (continued)170 / 725
Question 133: Fig. 17 shows views of a children’s play table. The height of the table can be adjusted by means of sleeves that fit over the ends of the l…171 / 725
Question 133 (continued)172 / 725
Question 133 (continued)173 / 725
Question 134: Fig. 1 shows a block of metal marked out ready to be drilled. B A C Fig. 1 Name the marking out tool used to mark line A. .................…Question 135: Fig. 2 shows two basic designs for kitchen roll holders. wall-mounted freestanding Fig. 2 Give two reasons why consumers may prefer to buy …174 / 725
Question 136: Fig. 3 shows timber being seasoned in a kiln. outlet inlet valve valve steam pipes heating pipes timber stacked on trolley Fig. 3 (a) Expla…Question 137: A Ø10 hole will be drilled in a sheet of 4 mm thick acrylic. Fig. 4 shows part of a drilling machine used to drill the hole. Add to Fig. 4 …175 / 725
Question 138: Fig. 5 shows the end grain of a piece of hardwood being planed. The wood is planed from each end to the centre, as shown by the arrows, to …Question 139: Circle from the lists below one material that is: (a) from a sustainable source acrylic stainless steel oak nylon [1] (b) biodegradeable. p…176 / 725
Question 140: Fig. 6 shows a computer desk. mild steel tube 20 × 20 × 2 A 500 Fig. 6 Use sketches and notes to show how the corner joint at A could be st…177 / 725
Question 141: Fig. 7 shows two small wooden tables. Both tables are the same overall size. Table A is made by laminating. Table B is made by fabrication.…178 / 725
Question 142: Fig. 8 shows views of a planter box and stand. The planter box is made from 12 mm thick marine plywood and the stand from Ø12 mild steel tu…179 / 725
Question 142 (continued)180 / 725
Question 142 (continued)181 / 725
Question 142 (continued)182 / 725
Question 143: Fig. 12 shows views of an incomplete design for a toy helicopter made from 6 mm thick plywood. B dowel rotor blade C A C Fig. 12 (a) Give t…183 / 725
Question 143 (continued)184 / 725
Question 143 (continued)185 / 725
Question 144: Fig. 16 shows a ladder plant stand. rung 40 × 25 side rail 50 × 25 plant pot ladder height 1300 ladder width 400 foot Fig. 16 (a) Name and …186 / 725
Question 144 (continued)187 / 725
Question 144 (continued)Question 145: Fig. 1 shows a block of metal marked out ready to be drilled. B A C Fig. 1 Name the marking out tool used to mark line A. .................…188 / 725
Question 146: Fig. 2 shows two basic designs for kitchen roll holders. wall-mounted freestanding Fig. 2 Give two reasons why consumers may prefer to buy …Question 147: Fig. 3 shows timber being seasoned in a kiln. outlet inlet valve valve steam pipes heating pipes timber stacked on trolley Fig. 3 (a) Expla…189 / 725
Question 148: A Ø10 hole will be drilled in a sheet of 4 mm thick acrylic. Fig. 4 shows part of a drilling machine used to drill the hole. Add to Fig. 4 …Question 149: Fig. 5 shows the end grain of a piece of hardwood being planed. The wood is planed from each end to the centre, as shown by the arrows, to …Question 150: Circle from the lists below one material that is: (a) from a sustainable source acrylic stainless steel oak nylon [1] (b) biodegradeable. p…190 / 725
Question 151: Fig. 6 shows a computer desk. mild steel tube 20 × 20 × 2 A 500 Fig. 6 Use sketches and notes to show how the corner joint at A could be st…191 / 725
Question 152: Fig. 7 shows two small wooden tables. Both tables are the same overall size. Table A is made by laminating. Table B is made by fabrication.…192 / 725
Question 153: Fig. 8 shows views of a planter box and stand. The planter box is made from 12 mm thick marine plywood and the stand from Ø12 mild steel tu…193 / 725
Question 153 (continued)194 / 725
Question 153 (continued)195 / 725
Question 153 (continued)196 / 725
Question 154: Fig. 12 shows views of an incomplete design for a toy helicopter made from 6 mm thick plywood. B dowel rotor blade C A C Fig. 12 (a) Give t…197 / 725
Question 154 (continued)198 / 725
Question 154 (continued)199 / 725
Question 155: Fig. 16 shows a ladder plant stand. rung 40 × 25 side rail 50 × 25 plant pot ladder height 1300 ladder width 400 foot Fig. 16 (a) Name and …200 / 725
Question 155 (continued)201 / 725
Question 155 (continued)Question 156: Fig. 1 shows a cycle helmet. The outer and inner shells are made from different plastics. outer shell inner shell Fig. 1 Give two propertie…202 / 725
Question 157: Fig. 3 shows two pieces of wood being glued together. Fig. 3 Draw on Fig. 3 to show how the glued joint could be strengthened by dovetail n…Question 158: Fig. 4 shows a saucepan. handle saucepan body Fig. 4 (a) Name a thermosetting plastic that could be used for the handle. ..................…203 / 725
Question 159: Fig. 5 shows three pre-drilled holes to take a screw. 1 1 ......................................................... 2 .....................…Question 160: Fig. 6 shows a board made from hardwood. The board needs to be seasoned. Fig. 6 Draw on Fig. 6 to show what could happen to the shape of th…Question 161: Fig. 7 shows a wheelbarrow. The mild steel body of the wheelbarrow is galvanised. body Fig. 7 (a) State what is meant by the term ‘galvanis…204 / 725
Question 162: Fig. 11 shows an incomplete metal bracket used to support a net on a table-tennis table. net bracket threaded hole threaded rod Fig. 11 (a)…205 / 725
Question 163: 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 …206 / 725
Question 163 (continued)207 / 725
Question 163 (continued)208 / 725
Question 163 (continued)209 / 725
Question 163 (continued)210 / 725
Question 164: Fig. 17 shows a basic design for a toothbrush holder made from 4 mm thick acrylic. Ø15 100 Ø8 100 100 Fig. 17 (a) Give two specification po…211 / 725
Question 164 (continued)212 / 725
Question 164 (continued)213 / 725
Question 164 (continued)Question 165: Fig. 20 shows a wall-mounted cycle rack made from 19 mm thick manufactured board. back 330 side 250 350 de Fig. 20 (a) Give two advantages …214 / 725
Question 165 (continued)215 / 725
Question 165 (continued)Question 166: Give two pieces of information required when buying woodscrews. 1 .........................................................................…Question 167: A list of materials is given below. brass CFRP copper polycarbonate stainless steel Select from the list one material that is: (a) an alloy…216 / 725
Question 168: Complete the drawing below to show an exploded view of a corner halving joint. [3]Question 169: Complete Table 4.1 by naming a suitable material for each product. Table 4.1 Product Suitable material plastic chair metal water pipe fitti…217 / 725
Question 170: Fig. 7.1 shows the end of a mild steel strip marked out, ready to be shaped. waste 25 70 3 mm thick Fig. 7.1 Name the hand tool used to: (a…Question 171: Fig. 9.1 shows a box made from softwood. The box will have a base made from 4 mm thick manufactured board. 15 mm thick 400 220 Fig. 9.1 Use…218 / 725
Question 172: 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 …219 / 725
Question 172 (continued)220 / 725
Question 172 (continued)221 / 725
Question 172 (continued)222 / 725
Question 172 (continued)223 / 725
Question 173: Fig. 12.1 shows an incomplete design for a storage box made from wood. 6 mm thick partitions lifts out 50 15 mm thick sides A 80 360 180 Fi…224 / 725
Question 173 (continued)225 / 725
Question 173 (continued)226 / 725
Question 173 (continued)227 / 725
Question 174: Fig. 13.1 shows wind chimes that will be batch produced in a school workshop. All the production methods require speed and accuracy. top pi…228 / 725
Question 174 (continued)229 / 725
Question 174 (continued)Question 175: Fig. 2.1 shows a drawer made from hardwood. Sketch a suitable joint, other than a butt joint, that could be used at corner A. A Fig. 2.1 [3]230 / 725
Question 176: Complete Table 3.1 by naming a suitable material for each product. Table 3.1 Product Suitable material wooden building blocks metal toothbr…Question 177: Fig. 4.1 shows details of a shelf bracket and a length of softwood from which the bracket is made. 250 300 25 × 25 Fig. 4.1 State three pro…231 / 725
Question 178: Fig. 5.1 shows a garden table made from plastic and the top of one of the removable table legs. The legs are fastened to the underside of t…Question 179: Fig. 7.1 shows views of a bracket made from 3 mm thick aluminium. 30 × 30 Fig. 7.1 Describe how the square holes 30 × 30 could be produced …232 / 725
Question 180: Fig. 8.1 shows a draining rack used for drying crockery and cutlery. The draining rack is made from steel and has a plastic coated finish. …233 / 725
Question 181: Fig. 10.1 shows views of a desk tidy made from 3 mm thick MDF. The front, back and base fit into slots in the ends. 160 slots in end 130 Fi…234 / 725
Question 182: Fig. 11.1 shows views of an incomplete design for a key rack made from hardwood. The front of the key rack can swing open and closed as sho…235 / 725
Question 182 (continued)236 / 725
Question 182 (continued)237 / 725
Question 183: Fig. 12.1 shows an incomplete design for a rack to store items of equipment used for cycle maintenance. Three trays will be supported insid…238 / 725
Question 183 (continued)239 / 725
Question 183 (continued)240 / 725
Question 183 (continued)241 / 725
Question 184: Fig. 13.1 shows a small table to be made in a school workshop. 700 500 table top: manufactured board 400 legs: solid wood Fig. 13.1 (a) (i)…242 / 725
Question 184 (continued)243 / 725
Question 184 (continued)244 / 725
Question 185: Give two pieces of information required when buying woodscrews. 1 .........................................................................…Question 186: A list of materials is given below. brass CFRP copper polycarbonate stainless steel Select from the list one material that is: (a) an alloy…Question 187: Complete the drawing below to show an exploded view of a corner halving joint. [3]245 / 725
Question 188: Complete Table 4.1 by naming a suitable material for each product. Table 4.1 Product Suitable material plastic chair metal water pipe fitti…Question 189: Fig. 7.1 shows the end of a mild steel strip marked out, ready to be shaped. waste 25 70 3 mm thick Fig. 7.1 Name the hand tool used to: (a…246 / 725
Question 190: Fig. 9.1 shows a box made from softwood. The box will have a base made from 4 mm thick manufactured board. 15 mm thick 400 220 Fig. 9.1 Use…247 / 725
Question 191: 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 …248 / 725
Question 191 (continued)249 / 725
Question 191 (continued)250 / 725
Question 191 (continued)251 / 725
Question 191 (continued)252 / 725
Question 192: Fig. 12.1 shows an incomplete design for a storage box made from wood. 6 mm thick partitions lifts out 50 15 mm thick sides A 80 360 180 Fi…253 / 725
Question 192 (continued)254 / 725
Question 192 (continued)255 / 725
Question 192 (continued)256 / 725
Question 193: Fig. 13.1 shows wind chimes that will be batch produced in a school workshop. All the production methods require speed and accuracy. top pi…257 / 725
Question 193 (continued)258 / 725
Question 193 (continued)Question 194: Fig. 2.1 shows part of a jig used when bending metal. The base and pegs are made from mild steel. The pegs will be brazed into the base. pe…259 / 725
Question 195: Fig. 3.1 shows views of a mortise and tenon joint. Add sketches and notes to Fig. 3.1 to show how the joint could be strengthened. Fig. 3.1…Question 196: Fig. 4.1 shows a wall-mounted bench used outdoors. 800 Fig. 4.1 Explain how anthropometric data would be used to decide the height at which…Question 197: (a) Explain what is meant by the term ‘alloy’. ............................................................................................…260 / 725
Question 198: Fig. 6.1 shows the back of a hardwood gate. post positions for hinges A Fig. 6.1 (a) State the purpose of part A. .........................…Question 199: Fig. 7.1 shows a notelet holder made from plastic. Fig. 7.1 Explain why the use of plastic to make products has an impact on the environmen…261 / 725
Question 200: Fig. 8.1 shows views of an incomplete design for a photograph frame. 1 mm thick mild steel 3 mm thick hardboard front back Fig. 8.1 Use ske…Question 201: Fig. 9.1 shows a mild steel rod that will be joined to a mild steel base by means of a screw thread. rod base Fig. 9.1 Name the tool that w…262 / 725
Question 202: Fig. 11.1 shows a balance that will be used by young children. The balance will be made in a school workshop. arm arrow support weights pan…263 / 725
Question 202 (continued)264 / 725
Question 202 (continued)265 / 725
Question 202 (continued)266 / 725
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Question 202 (continued)268 / 725
Question 203: 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 har…269 / 725
Question 203 (continued)270 / 725
Question 203 (continued)271 / 725
Question 203 (continued)272 / 725
Question 204: Fig. 13.1 shows a plant holder and the brackets that will support it on a wall. The sides and ends of the plant holder are made from 15 mm …273 / 725
Question 204 (continued)274 / 725
Question 204 (continued)275 / 725
Question 205: Fig. 1.1 shows two standard timber sections, A and B. 50 × 25 50 × 50 A B Fig. 1.1 Give the correct name for each of the standard timber se…Question 206: Fig. 2.1 shows part of a length of Ø20 aluminium tube that will be cut into 50 mm long pieces. Fig. 2.1 Complete Table 2.1 by naming one to…276 / 725
Question 207: Fig. 3.1 shows a former that will be used when vacuum forming plastic. Fig. 3.1 State two features of the former that will ensure that the …Question 208: Fig. 4.1 shows a nameplate used in a garden centre. The nameplate is made from mild steel. card label to be attached here 200 Golden Rose 1…277 / 725
Question 209: Complete Table 6.1 by naming a suitable specific material for each product. Table 6.1 Product Suitable specific material body of metalwork …Question 210: Complete Table 8.1 by naming a suitable finish, other than paint, for each of the products made from metal. Table 8.1 Product Suitable fini…278 / 725
Question 211: Fig. 9.1 shows details of a knock-down (KD) fitting. 40 barrel Ø10 Ø6 allen screw Fig. 9.1 Fig. 9.2 shows the corner of a small wooden box.…279 / 725
Question 212: Fig. 11.1 shows views of a small table made from 15 mm thick plywood. The table top has been removed to show details of the frame and legs.…280 / 725
Question 212 (continued)281 / 725
Question 212 (continued)282 / 725
Question 212 (continued)283 / 725
Question 212 (continued)284 / 725
Question 213: 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 stan…285 / 725
Question 213 (continued)286 / 725
Question 213 (continued)287 / 725
Question 213 (continued)288 / 725
Question 214: Fig. 13.1 shows a table lamp that could be made in a school workshop. base 2 mm thick brass Ø15 brass tube hardwood legs Fig. 13.1 (a) The …289 / 725
Question 214 (continued)290 / 725
Question 214 (continued)291 / 725
Question 215: Fig. 1.1 shows a workshop operation where there is a danger of damaging the material. two pieces of 20 mm thick softwood Fig. 1.1 State the…Question 216: Fig. 2.1 shows a photograph holder and two hardwood stands. photograph holder slot 35 hardwood stand 110 Fig. 2.1 Complete Table 2.1 by sta…Question 217: Complete the statement below by adding the correct term from the list. soft flexible hard corrosion resistant Steel that contains a high am…292 / 725
Question 218: Draw on Fig. 4.1 to show an exploded view of a tee-halving joint. Fig. 4.1 [3]Question 219: Fig. 6.1 shows two lengths of 5 mm thick mild steel strip with pre-drilled holes. Fig. 6.1 Name different types of fastening that could be …293 / 725
Question 220: Fig. 9.1 shows two lengths of softwood, A and B. Draw on A to show a rebate. Draw on B to show a groove. A B Fig. 9.1 [4]294 / 725
Question 221: Fig. 11.1 shows a table made from oak with a detachable magazine rack made from acrylic. 500 750 top rail 40 × 20 500 leg 40 × 20 magazine …295 / 725
Question 221 (continued)296 / 725
Question 221 (continued)297 / 725
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Question 221 (continued)299 / 725
Question 221 (continued)300 / 725
Question 222: Fig. 12.1 shows a storage unit with adjustable shelves that will be used in a bathroom. The storage unit is made from acrylic and could be …301 / 725
Question 222 (continued)302 / 725
Question 222 (continued)303 / 725
Question 222 (continued)Question 223: 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 t…304 / 725
Question 223 (continued)305 / 725
Question 223 (continued)306 / 725
Question 224: Draw on Fig. 1.1 to show the construction of blockboard. Fig. 1.1 [4]Question 225: Complete the statement below by adding the correct term from the list. manufactured composite pure hardened Carbon fibre reinforced plastic…Question 226: Fig. 3.1 shows a solid wood board that has warped. Fig. 3.1 Give two reasons why the solid wood board has warped. 1 .......................…307 / 725
Question 227: Fig. 5.1 shows a surface plate and scribing block. scribing block surface plate Fig. 5.1 Give two reasons why the surface plate and scribin…Question 228: (a) Complete the statement below by adding the correct term from the list. polystyrene polypropylene polythene polyester Glass-reinforced p…308 / 725
Question 229: Fig. 7.1 shows an incomplete drawing of a hasp and staple fitting. Fig. 7.1 Add sketches and notes to Fig. 7.1 to complete the drawing of t…Question 230: Fig. 8.1 shows a chair leg made from a length of hardwood 100 mm wide × 20 mm thick. The chair leg has been formed by steam bending. Fig. 8…309 / 725
Question 231: Fig. 9.1 shows a workshop operation where there is a danger of damaging the material. line to be sawn 4 mm thick acrylic Fig. 9.1 State the…Question 232: Fig. 10.1 shows a wooden mould used to vacuum form a small tray. Fig. 10.1 (a) Give two advantages of making the mould from MDF rather than…310 / 725
Question 233: Fig. 11.1 shows details of an incomplete design for an adjustable mirror made mainly from acrylic. Parts of the adjustable mirror will be b…311 / 725
Question 233 (continued)312 / 725
Question 233 (continued)313 / 725
Question 233 (continued)314 / 725
Question 234: Fig. 12.1 shows a folding stool made from hardwood with a fabric seat. The stool will be used outdoors. position for coach bolt A rail Fig.…315 / 725
Question 234 (continued)316 / 725
Question 234 (continued)317 / 725
Question 234 (continued)318 / 725
Question 234 (continued)319 / 725
Question 235: Fig. 13.1 shows a nesting box made from 15 mm thick softwood. A batch of twenty nesting boxes is to be made in a school workshop. back roof…320 / 725
Question 235 (continued)321 / 725
Question 235 (continued)322 / 725
Question 236: Fig. 1.1 shows a method of joining two lengths of hardwood. An adhesive is used. slot Fig. 1.1 (a) State the method of joining shown in Fig…Question 237: There are three main stages to be carried out to produce a high quality finish to the edges of acrylic sheet. Fig. 2.1 shows the first stag…Question 238: Circle from the list of materials below one material that can be anodised. copper steel lead aluminium [1]323 / 725
Question 239: Fig. 5.1 shows two items of equipment, A and B, used when marking out metal. B A Fig. 5.1 Name the items of equipment A and B in Fig. 5.1. …Question 240: Fig. 6.1 shows a chair. The curved parts of the chair have been produced by steam bending. Fig. 6.1 Give two benefits of using steam bendin…324 / 725
Question 241: Fig. 7.1 shows a design for a wall-mounted leaflet holder. Fig. 7.1 Add sketches and notes to Fig. 7.1 to show a modification to the design…Question 242: Fig. 8.1 shows a car body shell made from carbon fibre reinforced plastic (CFRP). Fig. 8.1 Give two advantages of making the car body shell…325 / 725
Question 243: Fig. 9.1 shows two serving trays. Tray A is made from moulded thermosetting plastic. Tray B is made from hardwood. A B thermosetting plasti…Question 244: 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 p…326 / 725
Question 244 (continued)327 / 725
Question 244 (continued)328 / 725
Question 244 (continued)329 / 725
Question 244 (continued)330 / 725
Question 245: Fig. 12.1 shows an incomplete design for a desk tidy. The trays are made from vacuum formed plastic and can rotate as shown. tray Ø80 × 10 …331 / 725
Question 245 (continued)332 / 725
Question 245 (continued)333 / 725
Question 246: Fig. 13.1 shows details of a ‘floating’ shelf. • The shelf bracket is screwed to the wall. • The shelf slides onto the bracket, hiding it f…334 / 725
Question 246 (continued)335 / 725
Question 246 (continued)Question 247: Circle from the list of materials below one metal that can be hardened. lead zinc high carbon steel cast iron [1]336 / 725
Question 248: Fig. 3.1 shows two pieces of hardwood that are to be joined by means of a KD (Knock-Down) fitting. Fig. 3.1 Add sketches and notes to Fig. …Question 249: Fig. 5.1 shows an item of equipment used to hold components when drilling holes. handle Fig. 5.1 (a) Give the correct name for the item of …337 / 725
Question 250: Fig. 6.1 shows a hardwood bracket. The bracket has been fabricated using hardwood. 160 Fig. 6.1 (a) State what is meant by the term ‘fabric…338 / 725
Question 251: Fig. 8.1 shows a leaflet holder made from 3 mm thick acrylic. 200 150 Fig. 8.1 Complete Table 8.1 by describing what each of the tools or i…339 / 725
Question 252: Fig. 10.1 shows the underside of a table top. The table top is made by gluing together three hardwood boards. positions for screws slot bat…340 / 725
Question 253: Fig. 11.1 shows an incomplete design for a step stool made from oak. platform 20 mm thick through housing joint area A step 20 mm thick leg…341 / 725
Question 253 (continued)342 / 725
Question 253 (continued)343 / 725
Question 253 (continued)344 / 725
Question 254: 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…345 / 725
Question 254 (continued)346 / 725
Question 254 (continued)347 / 725
Question 254 (continued)348 / 725
Question 255: Fig. 13.1 shows an incomplete design for a jewellery stand made from mahogany and brass. Ø30 mahogany bar brass cap Ø15 brass tube base: 15…349 / 725
Question 255 (continued)350 / 725
Question 255 (continued)351 / 725
Question 256: Fig. 1.1 shows a method of joining two lengths of hardwood. An adhesive is used. slot Fig. 1.1 (a) State the method of joining shown in Fig…Question 257: There are three main stages to be carried out to produce a high quality finish to the edges of acrylic sheet. Fig. 2.1 shows the first stag…Question 258: Circle from the list of materials below one material that can be anodised. copper steel lead aluminium [1]352 / 725
Question 259: Fig. 5.1 shows two items of equipment, A and B, used when marking out metal. B A Fig. 5.1 Name the items of equipment A and B in Fig. 5.1. …Question 260: Fig. 6.1 shows a chair. The curved parts of the chair have been produced by steam bending. Fig. 6.1 Give two benefits of using steam bendin…353 / 725
Question 261: Fig. 7.1 shows a design for a wall-mounted leaflet holder. Fig. 7.1 Add sketches and notes to Fig. 7.1 to show a modification to the design…Question 262: Fig. 8.1 shows a car body shell made from carbon fibre reinforced plastic (CFRP). Fig. 8.1 Give two advantages of making the car body shell…354 / 725
Question 263: Fig. 9.1 shows two serving trays. Tray A is made from moulded thermosetting plastic. Tray B is made from hardwood. A B thermosetting plasti…Question 264: 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 p…355 / 725
Question 264 (continued)356 / 725
Question 264 (continued)357 / 725
Question 264 (continued)358 / 725
Question 264 (continued)359 / 725
Question 265: Fig. 12.1 shows an incomplete design for a desk tidy. The trays are made from vacuum formed plastic and can rotate as shown. tray Ø80 × 10 …360 / 725
Question 265 (continued)361 / 725
Question 265 (continued)362 / 725
Question 266: Fig. 13.1 shows details of a ‘floating’ shelf. • The shelf bracket is screwed to the wall. • The shelf slides onto the bracket, hiding it f…363 / 725
Question 266 (continued)364 / 725
Question 266 (continued)365 / 725
Question 267: Fig. 1.1 shows a screw. Fig. 1.1 Give three additional items of information required when ordering 200 of the screws shown in Fig. 1.1. 1 N…Question 268: Fig. 2.1 shows two pieces of softwood glued together. Fig. 2.1 (a) Name the type of joint shown in Fig. 2.1. ..............................…366 / 725
Question 269: Fig. 3.1 shows three different types of ‘square’, A, B and C, that could be used when marking out and testing. A B C Fig. 3.1 Give the corr…Question 270: Fig. 4.1 shows a sundial that could be made in a school workshop. triangular plate (gnomon) 3 mm thick brass face of sundial 2 mm thick bra…367 / 725
Question 271: Fig. 5.1 shows a slot marked out on sheet material. A hole has been drilled to allow a saw blade to be inserted to cut out the slot. 10 mm …Question 272: Fig. 6.1 shows plastic tableware for outdoor use. The tableware is made from melamine formaldehyde. Fig. 6.1 Give two reasons why melamine …Question 273: A list of materials is given below. acrylic redwood polystyrene carbon steel Circle from the list one material that is from a sustainable s…368 / 725
Question 274: Fig. 8.1 shows two tools, A and B, that are used to mark lines parallel to the edges of materials. edge of wood edge of metal strip marked …Question 275: Fig. 9.1 shows a storage unit for three remote controls. The storage unit has two sides, a base and four partitions made from 5 mm thick MD…369 / 725
Question 276: Fig. 11.1 shows views of a table that will be assembled by customers. The parts of the table are joined by means of knock-down (KD) fitting…370 / 725
Question 276 (continued)371 / 725
Question 276 (continued)372 / 725
Question 276 (continued)373 / 725
Question 277: Fig. 12.1 shows details of a desktop toy. The suspended weight can be made to swing forwards and backwards around a central pivot. Ø90 cent…374 / 725
Question 277 (continued)375 / 725
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Question 277 (continued)377 / 725
Question 277 (continued)Question 278: Fig. 13.1 shows an incomplete design for a wind gauge that could be made in a school workshop. The cups and arms rotate when the wind blows…378 / 725
Question 278 (continued)379 / 725
Question 278 (continued)380 / 725
Question 279: Fig. 1.1 shows a wooden stand for a mobile phone. Fig. 1.1 State two different processes that could be used to form the shape of the mobile…Question 280: Fig. 2.1 shows two pieces of hardwood prepared to take a countersunk head screw. pilot hole Fig. 2.1 Sketch onto Fig. 2.1 to show: (a) a co…381 / 725
Question 281: Products such as chisels and screwdrivers, made from high carbon steel, can be ‘hardened’. Hardening makes the metal very brittle. Complete…Question 282: Fig. 6.1 shows a type of sandwich packaging. Fig. 6.1 (a) Name a suitable plastic from which the packaging could be made. .................…382 / 725
Question 283: Fig. 7.1 shows a knock-down (KD) fitting. Fig. 7.1 (a) Name the type of knock-down (KD) fitting shown in Fig. 7.1. ........................…383 / 725
Question 284: Fig. 8.1 shows two camping stools, A and B. Stool A is made from oak and stool B is made from aluminium tube with a canvas seat. A B Fig. 8…Question 285: Fig. 9.1 shows the end of a length of softwood with a rebate marked out. rebate 20 70 Fig. 9.1 (a) Name a power tool that could be used to …384 / 725
Question 286: Fig. 10.1 shows an incomplete design for a trophy made from 1 mm thick brass. The trophy requires a wooden base to make it stable. T & AWAR…385 / 725
Question 287: Fig. 11.1 shows views and details of a garden lantern. The lantern has a plastic candle with a flickering bulb that imitates a real flame. …386 / 725
Question 287 (continued)387 / 725
Question 287 (continued)388 / 725
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Question 287 (continued)390 / 725
Question 288: 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…391 / 725
Question 288 (continued)392 / 725
Question 288 (continued)393 / 725
Question 288 (continued)394 / 725
Question 288 (continued)395 / 725
Question 288 (continued)Question 289: Fig. 2.1 shows two pieces of softwood that will be joined using panel pins. Fig. 2.1 (a) Add sketches to Fig. 2.1 to show how the two piece…396 / 725
Question 290: Fig. 3.1 shows a workshop process. Fig. 3.1 (a) Name the process shown in Fig. 3.1. .......................................................…397 / 725
Question 291: Fig. 6.1 shows a cabinet door. The door has a panel that is fitted inside the hardwood frame. 4 mm thick manufactured board panel hardwood …398 / 725
Question 292: Fig. 8.1 shows a cycle helmet. inner cushioned lining outer shell Fig. 8.1 A list of plastics is given below. nylon polycarbonate polypropy…Question 293: A list of metals is given below. cast iron aluminium stainless steel duralumin copper Select from the list one metal that is a: (a) ferrous…399 / 725
Question 294: 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…400 / 725
Question 294 (continued)401 / 725
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Question 294 (continued)403 / 725
Question 295: 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) S…404 / 725
Question 295 (continued)405 / 725
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Question 295 (continued)408 / 725
Question 296: Fig. 13.1 shows an incomplete design for a wall-mounted shelf unit for a bathroom. The end frames are made from softwood. The shelves are m…409 / 725
Question 296 (continued)410 / 725
Question 296 (continued)411 / 725
Question 297: Fig. 1.1 shows a set of steps used in a swimming pool. support rail step Fig. 1.1 Give the name of: (a) a suitable specific metal that coul…Question 298: Fig. 3.1 shows a card model of an adjustable lamp mechanism. paper fasteners card base Fig. 3.1 Give two benefits of making a card model wh…412 / 725
Question 299: A list of materials is given below. ABS aluminium polypropylene brass mild steel melamine formaldehyde Select, from the list, one material …Question 300: Fig. 6.1 shows a battery that has been ‘blister packaged’. e5gr mAh567B 650 CCD Fig. 6.1 (a) State two benefits of blister packaging produc…413 / 725
Question 301: Fig. 7.1 shows two pieces of hardwood that will be joined by means of a dowel joint. Ø9 20 70 Fig. 7.1 Use sketches and notes to show a des…Question 302: Fig. 8.1 shows a length of 20 × 20 square tube and a length of Ø10 rod. tube Ø10 rod Fig. 8.1 State a method of joining the rod to the tube…414 / 725
Question 303: Fig. 9.1 shows a wooden drawer and the top of a desk. 15 mm thick desk top drawer slides in and out 12 mm thick side Fig. 9.1 Use sketches …415 / 725
Question 304: Fig. 11.1 shows a small table made from hardwood. The table top has been removed to show details of the legs and rails. table top Ø450 × 20…416 / 725
Question 304 (continued)417 / 725
Question 304 (continued)418 / 725
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Question 304 (continued)420 / 725
Question 305: Fig. 12.1 shows a book stand that will be used to display books in a school library. The book stand is made from 5 mm thick acrylic and a b…421 / 725
Question 305 (continued)422 / 725
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Question 305 (continued)424 / 725
Question 306: Fig. 13.1 shows an incomplete design for a table football game. players handle end rod side base A goal area Fig. 13.1 (a) Table 13.1 shows…425 / 725
Question 306 (continued)426 / 725
Question 306 (continued)427 / 725
Question 307: Fig. 1.1 shows three fastenings, A, B and C, used to join materials. A B C Fig. 1.1 Name an appropriate tool for use with each fastening. A…Question 308: Fig. 2.1 shows part of a table top with an area to be cut out so that a container can fit inside. 150 200 waste wood to be removed 18 mm th…428 / 725
Question 309: Fig. 3.1 shows a set of hardwood skittles that have been made using a woodturning lathe. Fig. 3.1 (a) State one benefit of using a close-gr…Question 310: Fig. 4.1 shows a cycle rack used in a public park. The wooden posts are made from oak and the metal tubes from mild steel. Fig. 4.1 (a) Giv…429 / 725
Question 311: Fig. 6.1 shows an incomplete drawing of a mortise and tenon joint. mortise Fig. 6.1 Complete Fig. 6.1 to show a tenon that would fit into t…Question 312: Fig. 7.1 shows a yoghurt pot with a plastic foldable spoon attached to the inside of the lid of the pot. Fig. 7.1 (a) Give one benefit to c…430 / 725
Question 313: Fig. 8.1 shows a barbecue made from 1.5 mm thick mild steel sheet. 250 500 300 Fig. 8.1 Use sketches and notes to show a modification to th…431 / 725
Question 314: 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 th…432 / 725
Question 315: Fig. 10.1 shows a picnic table made from recycled plastic. Fig. 10.1 Give two benefits of using recycled plastic for the picnic table rathe…433 / 725
Question 316: Fig. 11.1 shows an incomplete design for a cabinet with a drawer. The cabinet is made from 18 mm thick veneered chipboard and designed as f…434 / 725
Question 316 (continued)435 / 725
Question 316 (continued)436 / 725
Question 316 (continued)437 / 725
Question 317: 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 ac…438 / 725
Question 317 (continued)439 / 725
Question 317 (continued)440 / 725
Question 317 (continued)441 / 725
Question 317 (continued)442 / 725
Question 318: Fig. 13.1 shows a jewellery stand made in a school workshop. The jewellery stand could be delivered to customers as flat pack for self-asse…443 / 725
Question 318 (continued)444 / 725
Question 318 (continued)Question 319: Fig. 2.1 shows views of a butt joint using softwood 60 mm wide × 15 mm thick. Fig. 2.1 Add sketches and notes to Fig. 2.1 to show how the b…445 / 725
Question 320: Fig. 4.1 shows a hardwood block with a line measured and marked out 100 mm from the datum face. 100 datum face Fig. 4.1 Describe the purpos…Question 321: Select the plastic from the list below that corresponds to the description. expanded polystyrene PVC nylon polyester resin phenol formaldeh…446 / 725
Question 322: Fig. 6.1 shows an incomplete design for a bracket made from 3 mm thick mild steel strip that will be fixed to a wall. weight is applied 150…447 / 725
Question 323: Fig. 7.1 shows a hardwood rail, 40 × 25, with a recess cut out, ready to take a butt hinge. Fig. 7.1 Fig. 7.2 Add sketches to Fig. 7.2 to s…Question 324: Fig. 8.1 shows two components, A and B, that have been produced by different manufacturing processes. Component A is made of plastic. Compo…448 / 725
Question 325: Fig. 10.1 shows a sheet of 4 mm thick hardboard. 400 300 Fig. 10.1 Use sketches and notes to show how a softwood frame could be joined to t…449 / 725
Question 326: Fig. 11.1 shows an incomplete design for a sweet dispenser. The sweet dispenser is made from 5 mm thick MDF with a clear plastic window. Th…450 / 725
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Question 326 (continued)453 / 725
Question 327: Fig. 12.1 shows an incomplete design for an adjustable stand to support a tablet. The stand is made of 4 mm thick acrylic and could be made…454 / 725
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Question 327 (continued)457 / 725
Question 328: Fig. 13.1 shows a desk organiser made from hardwood. partitions 10 mm thick ends 12 mm thick A 140 B 280 space at B 122 wide × 30 high × 10…458 / 725
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Question 328 (continued)460 / 725
Question 329: Fig. 2.1 shows a shaped piece of hardwood. A B Fig. 2.1 State from the list below the correct name for the types of grain labelled at A and…Question 330: Fig. 4.1 shows one part, the yoke, of a two-piece former that is used to produce the press formed moulding. yoke press formed moulding plug…Question 331: Circle from the list below one metal that is a pure metal. mild steel brass stainless steel aluminium [1]461 / 725
Question 332: Fig. 6.1 shows the back of a shelf unit and details of two keyhole plates that will be used when fitting the shelf unit to a wall. keyhole …462 / 725
Question 333: Fig. 7.1 shows a table number stand used in a cafe and a development (net) of the stand. 7 7 7 Fig. 7.1 (a) Name a suitable non-ferrous met…Question 334: Fig. 8.1 shows a through housing joint marked out on a length of hardwood. 30 waste 20 80 Fig. 8.1 Complete Table 8.1 by describing the pro…463 / 725
Question 335: Circle from the list below one material that is biodegradable. polystyrene hardboard tin nylon copper [1]Question 336: Fig. 11.1 shows an incomplete design for a guitar stand. protective padding A leg support rubber cap foot Fig. 11.1 Table 11.1 shows a part…464 / 725
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Question 337: Fig. 12.1 shows views of an incomplete design for a coin box used by children. The coin box is made mainly from MDF. Coins are placed in th…469 / 725
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Question 338: Fig. 13.1 shows a bird feeder made of 5 mm thick clear acrylic. The bird feeder has an outer case made from one length of acrylic folded an…474 / 725
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Question 338 (continued)476 / 725
Question 339: Fig. 1.1 shows a chair that can be used when camping. Fig. 1.1 State three specification points a designer would need to consider when desi…Question 340: Fig. 2.1 shows two parts, A and B, of an incomplete tee bridle joint. A B Fig. 2.1 Draw on part B in Fig. 2.1 to show the other part of the…477 / 725
Question 341: Fig. 3.1 shows a piece of sheet metal that will be folded to shape using a rawhide mallet. rawhide mallet sheet metal A engineer’s vice Fig…Question 342: Fig. 4.1 shows a watering can made of plastic. ribs Fig. 4.1 (a) Name a suitable plastic for the watering can. ............................…478 / 725
Question 343: Fig. 5.1 shows two different types of leg construction, A and B, for a small table made of hardwood. legs 40 × 40 400 A B Fig. 5.1 (a) Stat…479 / 725
Question 344: Fig. 6.1 shows a mountain bike. Fig. 6.1 Identify three ways the designer of the mountain bike has considered anthropometric data. 1 ......…Question 345: Fig. 7.1 shows views of a coat rack with adjustable sliders. The coat rack and the sliders are made of plastic and are produced by differen…480 / 725
Question 346: Select from the list below the material that corresponds to the description. MDF parana pine beech blockboard ash Hardwood, close-grained, …Question 347: 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 ma…481 / 725
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Question 347 (continued)486 / 725
Question 348: Fig. 12.1 shows an incomplete design for a small table. The tabletop is made of hardwood. The frames are made from mild steel rectangular t…487 / 725
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Question 348 (continued)491 / 725
Question 349: 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 sch…492 / 725
Question 349 (continued)493 / 725
Question 349 (continued)Question 350: Fig. 2.1 shows a length of wood being planed in two directions, A and B. grain A B Fig. 2.1 (a) State the name of the plane shown in Fig. 2…494 / 725
Question 351: Fig. 3.1 shows details of a tabletop that will be fastened to the rails of a small table. MDF tabletop 18 thick hardwood rail 40 × 15 Fig. …Question 352: Fig. 6.1 shows the centre for a drilled hole marked out on 6 mm thick metal. tool A lines showing the centre for a drilled hole Fig. 6.1 (a…495 / 725
Question 353: Fig. 7.1 shows two pieces of 5 mm thick acrylic that will be joined together. Fig. 7.1 (a) Name a suitable adhesive that could be used to j…Question 354: Fig. 8.1 shows two pieces of brass that will be soldered on a brazing hearth using a blow torch. firebricks flame brass pieces gas and air …496 / 725
Question 355: Fig. 10.1 shows a basic design for a wall-mounted shelf made from 10 mm thick MDF. 200 600 150 Fig. 10.1 (a) Use sketches and notes to show…497 / 725
Question 356: Fig. 11.1 shows views of an incomplete design for a desktop box easel. The outer frames of the box and lid are made of 15 mm thick hardwood…498 / 725
Question 356 (continued)499 / 725
Question 356 (continued)500 / 725
Question 356 (continued)501 / 725
Question 357: Fig. 12.1 shows an incomplete design for a tape dispenser made mainly from 1.6 mm thick mild steel sheet. The tape dispenser could be made …502 / 725
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Question 357 (continued)506 / 725
Question 358: Fig. 13.1 shows views of a design for a novelty photograph holder made of 4 mm thick acrylic in the shape of a t-shirt. The t-shirt has a c…507 / 725
Question 358 (continued)508 / 725
Question 358 (continued)Question 359: Fig. 1.1 shows a garden wheelbarrow. polypropylene tray mild steel frame Fig. 1.1 Identify three design features that would help the consum…509 / 725
Question 360: Fig. 2.1 shows exploded views of a finger (comb) joint marked out and cut out. waste marked out cut out Fig. 2.1 Name two different saws th…Question 361: Fig. 3.1 shows two parts of a shelving system. The upright is screwed to a wall and the bracket slots into the upright to support a wooden …510 / 725
Question 362: Fig. 4.1 shows a sink unit made from stainless steel. Fig. 4.1 (a) State one property of stainless steel that makes it suitable for the sin…Question 363: Fig. 5.1 shows a gate fixed to a wall. The frame of the gate has started to collapse. A sides of gate 80mm wide × 30mm thick Fig. 5.1 (a) N…511 / 725
Question 364: Fig. 6.1 shows two pieces of 5 mm thick mild steel, A and B. file to line 40 file to line 65 A B Fig. 6.1 Name a specific file that could b…Question 365: Fig. 7.1 shows an exploded view of a hand-held torch showing the different parts. glass plastic steel plastic lens reflector spring body pl…512 / 725
Question 366: Fig. 8.1 shows legs of a small table that have been produced by laminating veneers. clamping blocks base board laminates Fig. 8.1 Add sketc…Question 367: Select from the list below the metal that corresponds to the description. mild steel brass lead cast iron copper (a) Pure metal, good condu…513 / 725
Question 368: 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 la…514 / 725
Question 368 (continued)515 / 725
Question 368 (continued)516 / 725
Question 368 (continued)517 / 725
Question 369: A Design and Technology student has been asked by a local nursery to design a chair suitable for children aged 3–4 years old. A prototype o…518 / 725
Question 369 (continued)519 / 725
Question 369 (continued)520 / 725
Question 369 (continued)521 / 725
Question 370: Fig. 13.1 shows views of an adjustable table lamp made of acrylic. Ø5 lampshade Ø120 × 150 bracket 4 mm thick Ø5 tilts stem Ø20 × 300 base …522 / 725
Question 370 (continued)523 / 725
Question 370 (continued)Question 371: Fig. 2.1 shows a length of wood being planed in two directions, A and B. grain A B Fig. 2.1 (a) State the name of the plane shown in Fig. 2…524 / 725
Question 372: Fig. 3.1 shows details of a tabletop that will be fastened to the rails of a small table. MDF tabletop 18 thick hardwood rail 40 × 15 Fig. …Question 373: Fig. 6.1 shows the centre for a drilled hole marked out on 6 mm thick metal. tool A lines showing the centre for a drilled hole Fig. 6.1 (a…525 / 725
Question 374: Fig. 7.1 shows two pieces of 5 mm thick acrylic that will be joined together. Fig. 7.1 (a) Name a suitable adhesive that could be used to j…Question 375: Fig. 8.1 shows two pieces of brass that will be soldered on a brazing hearth using a blow torch. firebricks flame brass pieces gas and air …526 / 725
Question 376: Fig. 10.1 shows a basic design for a wall-mounted shelf made from 10 mm thick MDF. 200 600 150 Fig. 10.1 (a) Use sketches and notes to show…527 / 725
Question 377: Fig. 11.1 shows views of an incomplete design for a desktop box easel. The outer frames of the box and lid are made of 15 mm thick hardwood…528 / 725
Question 377 (continued)529 / 725
Question 377 (continued)530 / 725
Question 377 (continued)531 / 725
Question 378: Fig. 12.1 shows an incomplete design for a tape dispenser made mainly from 1.6 mm thick mild steel sheet. The tape dispenser could be made …532 / 725
Question 378 (continued)533 / 725
Question 378 (continued)534 / 725
Question 378 (continued)535 / 725
Question 378 (continued)536 / 725
Question 379: Fig. 13.1 shows views of a design for a novelty photograph holder made of 4 mm thick acrylic in the shape of a t-shirt. The t-shirt has a c…537 / 725
Question 379 (continued)538 / 725
Question 379 (continued)Question 380: Fig. 1.1 shows a tennis racket made from carbon fibre reinforced plastic (CFRP). Fig. 1.1 State two properties of carbon fibre reinforced p…539 / 725
Question 381: Fig. 3.1 shows the outline shape and a development (net) for a tray made from 1.5 mm mild steel sheet. 120 Fig. 3.1 (a) Add flaps to the de…Question 382: Fig. 4.1 shows two parts, A and B, of an incomplete housing joint. A B Fig. 4.1 Draw on part B in Fig. 4.1 to show the other part of the ho…540 / 725
Question 383: Fig. 6.1 shows a length of brass that is to be heated to a dull red colour. 120 5 mm thick 20 Fig. 6.1 Complete the following sentences. (a…Question 384: Fig. 7.1 shows a paint pot holder made of wood. manufactured board holes Ø50 softwood 40 240 140 Fig. 7.1 Use sketches and notes to show ho…541 / 725
Question 385: Table 8.1 gives detailed stages of a process that could be carried out on steel. Table 8.1 Stage Process 1 Heat up steel to dull red 2 Dip …Question 386: Fig. 9.1 shows views of a small box made of hardwood. The hardwood base has been glued and screwed to the sides of the box. base screw base…542 / 725
Question 387: Fig. 11.1 shows views of an incomplete design for a teaching aid that could be used to teach children addition and subtraction. The case is…543 / 725
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Question 387 (continued)545 / 725
Question 387 (continued)546 / 725
Question 387 (continued)547 / 725
Question 388: 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…548 / 725
Question 388 (continued)549 / 725
Question 388 (continued)550 / 725
Question 388 (continued)551 / 725
Question 389: Fig. 13.1 shows views of an incomplete design for an adjustable tray that could be used by a person sitting up in bed. The tray can be used…552 / 725
Question 389 (continued)553 / 725
Question 389 (continued)554 / 725
Question 390: Fig. 1.1 shows parts A and B of an incomplete drawing of a twin mortise and tenon joint. A B Fig. 1.1 Draw on part B in Fig. 1.1 to show th…Question 391: Fig. 2.1 shows a label from the front of a box of steel bolts. M10 × 50 A B C Fig. 2.1 State what is meant by each item of information labe…555 / 725
Question 392: CFRP and GRP are examples of composite materials. Complete the names of the composite materials. (a) C………………………………... Fibre Reinforced Plas…Question 393: Fig. 7.1 shows a copper dish being beaten into shape. When the copper is beaten it becomes ‘work hardened’. A Fig. 7.1 (a) Complete the sen…556 / 725
Question 394: Fig. 11.1 shows a portable toolbox made of softwood. handle tray lifts out hinge hinged side 400 600 200 end Fig. 11.1 (a) Name a suitable …557 / 725
Question 394 (continued)558 / 725
Question 394 (continued)559 / 725
Question 394 (continued)560 / 725
Question 394 (continued)561 / 725
Question 395: Fig. 12.1 shows an incomplete design for a desk that could be made in a school workshop. The materials list gives details of the materials …562 / 725
Question 395 (continued)563 / 725
Question 395 (continued)564 / 725
Question 395 (continued)565 / 725
Question 395 (continued)566 / 725
Question 395 (continued)567 / 725
Question 396: Fig. 13.1 shows views of a desk tidy that will be batch produced in a school workshop. The desk tidy is made from acrylic. Ø40 acrylic tube…568 / 725
Question 396 (continued)569 / 725
Question 396 (continued)570 / 725
Question 397: Fig. 1.1 shows a small table. The tabletop could be made from plywood or chipboard. tabletop Fig. 1.1 Give two advantages of using plywood …Question 398: Fig. 2.1 shows an incomplete drawing of two pieces of metal being riveted together. hammer head rivet Fig. 2.1 (a) Name the type of hammer …571 / 725
Question 399: Fig. 3.1 shows details of a length of 8 mm thick hardwood that has been bent to shape. 8 mm thick 80 160 500 Fig. 3.1 Use sketches and note…Question 400: Fig. 4.1 shows a menu stand made from acrylic. MENU Fig. 4.1 Explain how the designer has used the flexible property of acrylic in the desi…572 / 725
Question 401: Explain the term ‘alloy’. .................................................................................................................…Question 402: Fig. 6.1 shows a wooden box with a ‘lift-off’ lid. 10 mm thick 10 mm thick 80 200 120 Fig. 6.1 Use sketches and notes to show a modificatio…573 / 725
Question 403: Fig. 9.1 shows three wood screws, A, B and C, with different types of head. A B C Fig. 9.1 Name the type of head for each of the wood screw…Question 404: Fig. 10.1 shows a piercing saw that will be used to cut out the curved shape in a piece of 1 mm thick brass sheet. brass sheet Fig. 10.1 Us…574 / 725
Question 405: Fig. 11.1 shows views of an incomplete design for a trophy. The trophy has three main parts made from the following materials: • front part…575 / 725
Question 405 (continued)576 / 725
Question 405 (continued)577 / 725
Question 405 (continued)578 / 725
Question 406: Fig. 12.1 shows an incomplete design for a bird feeder made from 1.5 mm thick mild steel sheet. 30 150 perch base Fig. 12.1 (a) Mild steel …579 / 725
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Question 406 (continued)583 / 725
Question 407: Fig. 13.1 shows a design for a stand for a hot melt glue gun. The stand is made from plywood and a batch of 12 stands will be produced in a…584 / 725
Question 407 (continued)585 / 725
Question 407 (continued)586 / 725
Question 408: Fig. 1.1 shows the label from a box of wood screws. B A 5.0 x 40mm 5.0 x 40mm 200 200 C Fig. 1.1 State what is meant by each item labelled …Question 409: Fig. 3.1 shows a block of softwood 20 mm thick. Fig. 3.1 Draw a groove on the softwood block shown in Fig. 3.1. [2]587 / 725
Question 410: Fig. 4.1 shows a mobile phone holder made from aluminium. Fig. 4.1 Identify three design features of the mobile phone holder shown in Fig. …588 / 725
Question 411: Fig. 5.1 shows a sign holder made from 1.5 mm thick mild steel sheet. 15 80 120 20 Fig. 5.1 Use sketches and notes to show how a batch of t…589 / 725
Question 412: Fig. 6.1 shows a split pattern made of wood. The split pattern will be used to make an aluminium handle for a hacksaw. Fig. 6.1 Name the pr…Question 413: Fig. 7.1 shows a dish that has been shaped from thin copper sheet and a process that is carried out during its manufacture. Fig. 7.1 (a) Na…590 / 725
Question 414: Fig. 9.1 shows two lengths of softwood glued together. 40 × 40 Fig. 9.1 Add sketches and notes to Fig. 9.1 to show how the joint could be s…591 / 725
Question 415: 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…592 / 725
Question 415 (continued)593 / 725
Question 415 (continued)594 / 725
Question 415 (continued)595 / 725
Question 415 (continued)596 / 725
Question 416: Fig. 12.1 shows views of an incomplete design for a freestanding clock made from acrylic. The clock mechanism and the clock hands have been…597 / 725
Question 416 (continued)598 / 725
Question 416 (continued)599 / 725
Question 416 (continued)600 / 725
Question 417: Fig. 13.1 shows a photo frame made of hardwood supported on a stand made from mild steel. frame 30 × 15 hardwood stand 5 × 5 mild steel 210…601 / 725
Question 417 (continued)602 / 725
Question 417 (continued)603 / 725
Question 418: Carbon fibre reinforced plastic (CFRP) is used to build many different aircraft parts. State two benefits of using carbon fibre reinforced …Question 419: Fig. 2.1 shows pipes used for plumbing being joined together. blowtorch metal pipe Fig. 2.1 (a) Name the metal used for the pipes. ........…Question 420: Fig. 3.1 shows a through mortise and tenon joint. Fig. 3.1 Add sketches and notes to Fig. 3.1 to show how the joint could be prevented from…604 / 725
Question 421: Fig. 4.1 shows three products made of different materials. mild steel wheelbarrow body silver pendant brass tap Fig. 4.1 State a suitable d…Question 422: Fig. 5.1 shows 4 mm thick acrylic sheet that has been shaped. 130 40 Fig. 5.1 Use sketches and notes to show how the curved shape could be …605 / 725
Question 423: Fig. 7.1 shows part of a length of mild steel square tube and an engineer’s vice. A hacksaw will be used to cut the tube to make a 90° bend…Question 424: Fig. 8.1 shows a body shell for a car made from glass reinforced plastic (GRP). Fig. 8.1 Explain what is meant by the term ‘glass reinforce…606 / 725
Question 425: Fig. 10.1 shows two hardwood stools, A and B. Stool A has been fabricated and stool B has been made by steam bending. A B Fig. 10.1 Explain…607 / 725
Question 426: 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 w…608 / 725
Question 426 (continued)609 / 725
Question 426 (continued)610 / 725
Question 426 (continued)611 / 725
Question 427: Fig. 12.1 shows an incomplete design for a coat hook used by children. The coat hook is made from 2 mm thick mild steel sheet. Fig. 12.1 (a…612 / 725
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Question 427 (continued)616 / 725
Question 428: Fig. 13.1 shows an incomplete design for a case to store and carry a selection of artist’s materials and equipment. lid 4 mm thick manufact…617 / 725
Question 428 (continued)618 / 725
Question 428 (continued)619 / 725
Question 429: Fig. 1.1 shows the label from a box of wood screws. B A 5.0 x 40mm 5.0 x 40mm 200 200 C Fig. 1.1 State what is meant by each item labelled …Question 430: Fig. 3.1 shows a block of softwood 20 mm thick. Fig. 3.1 Draw a groove on the softwood block shown in Fig. 3.1. [2]620 / 725
Question 431: Fig. 4.1 shows a mobile phone holder made from aluminium. Fig. 4.1 Identify three design features of the mobile phone holder shown in Fig. …621 / 725
Question 432: Fig. 5.1 shows a sign holder made from 1.5 mm thick mild steel sheet. 15 80 120 20 Fig. 5.1 Use sketches and notes to show how a batch of t…622 / 725
Question 433: Fig. 6.1 shows a split pattern made of wood. The split pattern will be used to make an aluminium handle for a hacksaw. Fig. 6.1 Name the pr…Question 434: Fig. 7.1 shows a dish that has been shaped from thin copper sheet and a process that is carried out during its manufacture. Fig. 7.1 (a) Na…623 / 725
Question 435: Fig. 9.1 shows two lengths of softwood glued together. 40 × 40 Fig. 9.1 Add sketches and notes to Fig. 9.1 to show how the joint could be s…624 / 725
Question 436: 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…625 / 725
Question 436 (continued)626 / 725
Question 436 (continued)627 / 725
Question 436 (continued)628 / 725
Question 436 (continued)629 / 725
Question 437: Fig. 12.1 shows views of an incomplete design for a freestanding clock made from acrylic. The clock mechanism and the clock hands have been…630 / 725
Question 437 (continued)631 / 725
Question 437 (continued)632 / 725
Question 437 (continued)633 / 725
Question 438: Fig. 13.1 shows a photo frame made of hardwood supported on a stand made from mild steel. frame 30 × 15 hardwood stand 5 × 5 mild steel 210…634 / 725
Question 438 (continued)635 / 725
Question 438 (continued)636 / 725
Question 439: Fig. 1.1 shows timber being seasoned naturally in the open air. roof to protect from sun and rain timber boards battens brick piers Fig. 1.…Question 440: Fig. 3.1 shows strips of hardwood glued and clamped together to make a chopping board. chopping board hardwood strips scrap wood cramp Fig.…637 / 725
Question 441: Fig. 5.1 shows a basic design for a letter rack made from 4 mm thick acrylic. 50 70 200 60 Fig. 5.1 (a) Draw a former that could be used wh…638 / 725
Question 442: Complete Fig. 7.1 to show a tee halving joint. Fig. 7.1 [3]Question 443: Fig. 10.1 shows two office chairs, A and B. A B Fig. 10.1 Identify one design feature on each chair. Chair A ..............................…639 / 725
Question 444: Fig. 11.1 shows a drill rack that will be attached to the pillar of a pillar drill. The drill rack is made from 15 mm thick plywood. collar…640 / 725
Question 444 (continued)641 / 725
Question 444 (continued)642 / 725
Question 444 (continued)643 / 725
Question 445: Fig. 12.1 shows a child’s xylophone that could be made in a school workshop. bar 50 peg support stand 400 110 Fig. 12.1 (a) The stand is ma…644 / 725
Question 445 (continued)645 / 725
Question 445 (continued)646 / 725
Question 445 (continued)647 / 725
Question 446: Fig. 2.1 shows parts of two wooden boards that will be joined using a tongue and groove joint. Fig. 2.1 Complete Fig. 2.1 to show a tongue …Question 447: Fig. 4.1 shows three hardwood boards glued together to make a table top. 140 A B C Fig. 4.1 (a) Draw the end grain on boards B and C. [2] (…648 / 725
Question 448: Fig. 5.1 shows a bucket made from a thermoplastic. Fig. 5.1 (a) Name a suitable thermoplastic for the bucket. .............................…Question 449: Fig. 6.1 shows the end grain of hardwood being planed. When planing end grain there is a danger that it could split. split Fig. 6.1 Use ske…649 / 725
Question 450: Fig. 7.1 shows a strip of metal that has been work hardened. cracks Fig. 7.1 Explain what is meant by the term ‘work hardened’. ...........…Question 451: Complete Fig. 8.1 to show an exploded view of a stopped housing joint. Fig. 8.1 [3]650 / 725
Question 452: 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 b…651 / 725
Question 452 (continued)652 / 725
Question 452 (continued)653 / 725
Question 452 (continued)654 / 725
Question 453: Fig. 12.1 shows a design for a holder to contain salt and pepper shakers. A batch of 12 holders will be produced for use in a local café. h…655 / 725
Question 453 (continued)656 / 725
Question 453 (continued)657 / 725
Question 453 (continued)658 / 725
Question 454: Fig. 13.1 shows views of a desk made of wood. desktop drawer A end frame overall dimensions length 900 height 750 width 480 desk with top r…659 / 725
Question 454 (continued)660 / 725
Question 454 (continued)661 / 725
Question 455: Fig. 1.1 shows timber being seasoned naturally in the open air. roof to protect from sun and rain timber boards battens brick piers Fig. 1.…Question 456: Fig. 3.1 shows strips of hardwood glued and clamped together to make a chopping board. chopping board hardwood strips scrap wood cramp Fig.…662 / 725
Question 457: Fig. 5.1 shows a basic design for a letter rack made from 4 mm thick acrylic. 50 70 200 60 Fig. 5.1 (a) Draw a former that could be used wh…663 / 725
Question 458: Complete Fig. 7.1 to show a tee halving joint. Fig. 7.1 [3]Question 459: Fig. 9.1 shows details of a jig used when bending a brass strip to shape. brass strip steel peg Ø6 base 18 mm thick Fig. 9.1 Add sketches a…664 / 725
Question 460: Fig. 10.1 shows two office chairs, A and B. A B Fig. 10.1 Identify one design feature on each chair. Chair A ..............................…665 / 725
Question 461: Fig. 11.1 shows a drill rack that will be attached to the pillar of a pillar drill. The drill rack is made from 15 mm thick plywood. collar…666 / 725
Question 461 (continued)667 / 725
Question 461 (continued)668 / 725
Question 461 (continued)669 / 725
Question 462: Fig. 12.1 shows a child’s xylophone that could be made in a school workshop. bar 50 peg support stand 400 110 Fig. 12.1 (a) The stand is ma…670 / 725
Question 462 (continued)671 / 725
Question 462 (continued)672 / 725
Question 462 (continued)673 / 725
Question 463: 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…674 / 725
Question 463 (continued)675 / 725
Question 463 (continued)676 / 725
Question 464: Fig. 1.1 shows two methods of seasoning wood. Method A is kiln seasoning. Method B is open-air seasoning. outlet valve inlet valve steam pi…Question 465: Complete Fig. 2.1 to show the construction of blockboard. 18 mm thick Fig. 2.1 [2]677 / 725
Question 466: Fig. 3.1 shows a tool used to mark a circle on metal surfaces. tip Fig. 3.1 (a) Name the tool shown in Fig. 3.1. ..........................…Question 467: 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 …678 / 725
Question 468: Fig. 5.1 shows a hardwood block with line A marked across the grain and lines B marked along the grain. B A Fig. 5.1 (a) Name the type of g…Question 469: Fig. 6.1 shows an office chair. Fig. 6.1 Give three ways in which anthropometric data has been used in the design of the office chair. 1 ..…679 / 725
Question 470: Fig. 7.1 shows a table number made from 1.5 mm thick aluminium sheet, for use in a local café. bend line 60 12 12 30 25 Fig. 7.1 Use sketch…680 / 725
Question 471: Fig. 9.1 shows two wooden boards that are to be joined together by means of a biscuit joint. Fig. 9.1 Complete Fig. 9.1 to show how two bis…Question 472: Fig. 10.1 shows an item of equipment that can be used to join pieces of metal permanently. Fig. 10.1 (a) Name the item of equipment shown i…681 / 725
Question 473: 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 specificat…682 / 725
Question 473 (continued)683 / 725
Question 473 (continued)684 / 725
Question 473 (continued)685 / 725
Question 474: 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…686 / 725
Question 474 (continued)687 / 725
Question 474 (continued)688 / 725
Question 474 (continued)689 / 725
Question 474 (continued)690 / 725
Question 475: 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. …691 / 725
Question 475 (continued)692 / 725
Question 476: Fig. 1.1 shows a solid wood board A, and the same board B, after it has warped. A B Fig. 1.1 Give two reasons why the solid wood board coul…Question 477: Fig. 2.1 shows a saucepan. The body is made from ferrous metal. The handle is made from thermosetting plastic. handle body Fig. 2.1 (a) Nam…Question 478: Name the process that uses all the following materials. gel coat release agent polyester resin ............................................…693 / 725
Question 479: Fig. 4.1 shows two wooden boards that will be joined together by means of a half-lap joint. Fig. 4.1 Complete Fig. 4.1 to show a half-lap j…Question 480: Fig. 5.1 shows a toy fire engine. Fig. 5.1 Name a process that could be used to manufacture the toy fire engine when made from: (a) zinc ba…694 / 725
Question 481: Fig. 7.1 shows the casing of a television remote control made from moulded plastic. Fig. 7.1 Give two quality control checks that could be …Question 482: Fig. 8.1 shows views of a bracket made from 1.6 mm thick mild steel sheet. 60 30 bend lines 20 60 20 Fig. 8.1 Use sketches and notes to sho…695 / 725
Question 483: Fig. 10.1 shows a length of hardwood that needs to be planed. The hardwood is only 6 mm thick and could not be held securely in a woodworke…696 / 725
Question 484: Fig. 11.1 shows an incomplete design for scales and weights that could be used by children. A parts list gives details of the materials use…697 / 725
Question 484 (continued)698 / 725
Question 484 (continued)699 / 725
Question 484 (continued)700 / 725
Question 484 (continued)701 / 725
Question 484 (continued)702 / 725
Question 485: Fig. 12.1 shows a holder to store a gaming controller and a headset. The holder is made from MDF. neck upright 6 mm thick support 6 mm thic…703 / 725
Question 485 (continued)704 / 725
Question 485 (continued)705 / 725
Question 485 (continued)706 / 725
Question 486: Fig. 13.1 shows an incomplete design for a wall-mounted adjustable shelving unit. end frame shelf rod 500 700 180 Fig. 13.1 Parts List Numb…707 / 725
Question 486 (continued)708 / 725
Question 486 (continued)709 / 725
Question 487: Fig. 1.1 shows two methods of seasoning wood. Method A is kiln seasoning. Method B is open-air seasoning. outlet valve inlet valve steam pi…Question 488: Complete Fig. 2.1 to show the construction of blockboard. 18 mm thick Fig. 2.1 [2]710 / 725
Question 489: Fig. 3.1 shows a tool used to mark a circle on metal surfaces. tip Fig. 3.1 (a) Name the tool shown in Fig. 3.1. ..........................…Question 490: Fig. 5.1 shows a hardwood block with line A marked across the grain and lines B marked along the grain. B A Fig. 5.1 (a) Name the type of g…711 / 725
Question 491: Fig. 6.1 shows an office chair. Fig. 6.1 Give three ways in which anthropometric data has been used in the design of the office chair. 1 ..…712 / 725
Question 492: Fig. 7.1 shows a table number made from 1.5 mm thick aluminium sheet, for use in a local café. bend line 60 12 12 30 25 Fig. 7.1 Use sketch…713 / 725
Question 493: Fig. 9.1 shows two wooden boards that are to be joined together by means of a biscuit joint. Fig. 9.1 Complete Fig. 9.1 to show how two bis…Question 494: Fig. 10.1 shows an item of equipment that can be used to join pieces of metal permanently. Fig. 10.1 (a) Name the item of equipment shown i…714 / 725
Question 495: 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 specificat…715 / 725
Question 495 (continued)716 / 725
Question 495 (continued)717 / 725
Question 495 (continued)718 / 725
Question 496: 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…719 / 725
Question 496 (continued)720 / 725
Question 496 (continued)721 / 725
Question 496 (continued)722 / 725
Question 496 (continued)723 / 725
Question 497: 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. …724 / 725
Question 497 (continued)725 / 725

Mark scheme497 answers

Answers below. Sit the paper first if you are practising.

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Design and Technology 0445 · Systems & Control – Structures — Paper 3

IGCSE · topical answer key — answer key (teacher use)

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Another paper, or another topic

Paper
Paper 3497 questionsPaper 4168 questions

All of Topic 4 →

Questions as text

Q1 · Complete the table below by naming each of the tools or items of equipment used to hold… 0445/31 May/June 2017

1 Complete the table below by naming each of the tools or items of equipment used to hold wood. Name Name Name Name [4]

4 marks

Mark scheme: Question Answer Marks 1 bench hook G cramp vice bench stop 4×1 4

This question in 0445/31 May/June 2017

Q2 · Three boards that will be glued together to make a solid wood table top 0445/31 May/June 2017

4 Fig. 2 shows three boards that will be glued together to make a solid wood table top. 150 150 1 150 2 3 Fig. 2 (a) Give one reason why it would be necessary to join three boards together to make a solid wood table top. … [1] (b) Complete Fig. 2 by drawing the end grain on boards 2 and 3 so that the table top would remain stable. [2] (c) Name the type of cramps that would be used when gluing the boards together. … [1]

4 marks

Mark scheme: 4(a) solid wood boards not available in required width 1 4(b) end grain inverted on 2. 1 2 end grain on 3 should match that shown on 1 1 4(c) sash, F cramps 1

This question in 0445/31 May/June 2017

Q3 · Complete the table by naming the correct metal from the list below to match each… 0445/31 May/June 2017

5 Complete the table by naming the correct metal from the list below to match each description. mild steel cast iron copper stainless steel brass aluminium Metal Description hard, tough, used to make sink units hard, brittle, used to make metalwork vices lightweight, resists corrosion, used to make aircraft bodies [3]

3 marks

Mark scheme: 5 stainless steel cast iron aluminium 3×1 3

This question in 0445/31 May/June 2017

Q4 · The end of a length of wood 0445/31 May/June 2017

6 Fig. 3 shows the end of a length of wood. Draw on Fig. 3 to show a chamfered edge and a bevelled edge. chamfered edge bevelled edge Fig. 3 [2]

2 marks

Mark scheme: 6 Completed drawing of chamfer 1 2 Completed drawing of bevel 1

This question in 0445/31 May/June 2017

Q5 · A tee square made from two pieces of acrylic 0445/31 May/June 2017

7 Fig. 4 shows a tee square made from two pieces of acrylic. joint Fig. 4 Name a suitable method of joining the two pieces of acrylic together: (a) temporarily; … (b) permanently. … [2]

2 marks

Mark scheme: 7(a) screws, nuts and bolts 1 1 7(b) acrylic cement, plastic welding [not welding], rivet 1 1

This question in 0445/31 May/June 2017

Q6 · A method of joining two wooden boards 0445/31 May/June 2017

8 Fig. 5 shows a method of joining two wooden boards. Fig. 5 Name the method of joining. … [1]

1 marks

Mark scheme: 8 tongue and groove 1

This question in 0445/31 May/June 2017

Question 7 0445/31 May/June 2017

9 Fig. 6 shows a modelling knife. The metal body of the knife is made in two parts that are screwed together. body Fig. 6 (a) Name a process that could be used to produce the two parts for the body of the knife. … [1] (b) Name a metal that could be used to make the body of the knife. … [1]

2 marks

Mark scheme: 9(a) casting, die casting 1 9(b) aluminium, zinc 1

This question in 0445/31 May/June 2017

Q8 · Views of a child’s table and a parts list 0445/31 May/June 2017

11 Fig. 7 shows views of a child’s table and a parts list. A B A B A B A table shown with top removed Number Part Length × Width × Thickness Material Required leg 4 450 × 60 × 15 softwood end rail A 4 470 × 60 × 15 softwood long rail B 3 740 × 60 × 15 softwood table top 1 840 × 540 × 19 manufactured board Fig. 7 (a) (i) Name a suitable softwood and manufactured board for parts of the table shown in the parts list. Softwood … Manufactured board … [2] (ii) The legs and rails are all 60 wide × 15 thick. Give one benefit to a manufacturer of using materials that are the same width and thickness. … [1] (b) Give two ways in which the table top could be made more hardwearing for use by children. 1 … 2 … [2] (c) The table top will be attached to the rails by means of screws. Fig. 8 shows part of the table with the positions for two screw holes marked out. centre for screw hole Fig. 8 (i) Use a sketch and notes to show how the holes could be drilled so that the screw head would be hidden. [3] (ii) Use sketches and notes to show how a knock-down (KD) fitting could be used to attach the table top to the rails. [3] (d) The rails and the legs will be joined using dowel joints. A drilling jig is needed when drilling the holes for the dowel. (i) Give two benefits of using a drilling jig when drilling the holes for the dowel. 1 … 2 … [2] (ii) Fig. 9 shows an exploded view of a dowel joint between a rail and a leg. rail leg Fig. 9 Use sketches and notes to show a drilling jig that could be used when drilling holes in the ends of the rails. [4] (e) A container is required to store pens, pencils and other small items of equipment. Fig. 10 shows the area where the container will fit into the table top. area to be removed 250 × 120 Fig. 10 (i) Use sketches and notes to show how the area could be removed and the edges made smooth. [4] (ii) Use sketches and notes to show a design for a container that could fit into the area cut out. Include details of materials and constructions used. [4]

25 marks

Mark scheme: 11(a)(i) Softwood: pine, red deal, whitewood, parana pine, yew 1 2 Manufactured board: plywood, chipboard, blockboard, MDF 1 11(a)(ii) Benefit: more efficient use of materials, quicker manufacture, 1 less waste, can be produced more cheaply 11(b) Two ways of making top durable: apply hardwearing finish: polyurethane 2 varnish, lacquer or paint, apply plastic laminate 2×1 11(c)(i) Counterbored hole: 3 diameter for screw head 1 diameter for screw shank 1 appropriate depths 1 Countersink = 1–2 max 11(c)(ii) Use of recognised KD fitting 1 3 Correct position 1 Technical accuracy 1 11(d)(i) Two benefits: speed, repetitive accuracy, no need for preparatory marking 2 could keep drill vertical 2×1 11(d)(ii) jig located against end of rail in one direction 1 4 jig located against end of rail in two directions 1 holes positioned correctly 1 additional explanatory notes 1 11(e)(i) drill hole in area to be removed 1 4 insert saw blade [vibro saw] router 1 use of file 1 glasspaper to smooth edges 1 Do not reward marking out stage 11(e)(ii) practical idea 1 4 some form of lipping to prevent container falling through top 1 materials and constructions used 0–2

This question in 0445/31 May/June 2017

Q9 · Views of a cycle rack that could be fixed to the wall of a garage or shed 0445/31 May/June 2017

12 Fig. 11 shows views of a cycle rack that could be fixed to the wall of a garage or shed. wooden back 200 × 40 × 15 A A pivot sheet metal support 280 × 75 × 1.5 Fig. 11 (a) Give two items of research a designer would need to consider when designing a cycle rack. 1 … 2 … [2] (b) Sketch and name a suitable method of joining parts A to the back shown in Fig. 11. [4] (c) Fig. 12 shows details of the sheet metal support. 280 20 270 35 75 Fig. 12 An outline of the sheet of metal used to make the support is shown below. (i) Draw on the outline the development (net) for the support. not to scale [4] (ii) Give two advantages of making the support for the cycle rack from non-ferrous metal rather than ferrous metal. 1 … 2 … [2] (d) To make the support, the slot will be cut out and the metal will be bent to shape. (i) Use sketches and notes to show how the slot could be cut out and the edges made smooth. [4] (ii) Use sketches and notes to show how the sheet metal could be bent to shape. [3] (e) Fig. 13 shows views of the back and support. The support will be pivoted between parts A and will fold down when not in use. A wall A folds down Fig. 13 Use sketches and notes to show how the support could be locked in a horizontal position as shown in Fig. 13. [3] (f) Fig. 14 shows a cycle helmet that is to be stored on the cycle rack. Use sketches and notes to show a modification to any part of the cycle rack so that the helmet could be stored. Fig. 14 [3]

25 marks

Mark scheme: 12(a) Two items include: various dimensions of cycle; e.g. diameter of seat post, 2 distance from wall, height off ground, parts of bike to be supported, consumer research Accept any genuine item. 2×1 12(b) Suitable joint: dowel, housing, M and T named 1 4 Accuracy of completed joint drawn 0–3 Butt joint pinned and glued maximum 3 marks 12(c)(i) 4 2 bend lines 2×1 1 slot 1 2 shaped ends 1 12(c)(ii) Two advantages: non-ferrous metal does not rust, easier to bend to shape 2 2×1 12(d)(i) drill hole/s for slot diameter/use of round file 1 4 use of tin snips, shears to remove waste 1 use of file/emery cloth/wet and dry paper to smooth edges 1 technical accuracy 1 Do not reward marking out stage 12(d)(ii) sheet metal held between folding bars, scrap wood 1 3 secured in vice 1 use of mallet, hammer and scrap wood to bend to shape 1 12(e) Method of locking: some form of nut and bolt [principle], bolt/rod 0–2 3 details of type of head method of tightening 0–1 12(f) Method includes the use of pins or slots into which the straps 3 could be hooked over/through Award 0–3 dependent upon accuracy of a practical modification 0–3

This question in 0445/31 May/June 2017

Q10 · An incomplete design for a toy lorry 0445/31 May/June 2017

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.

This question in 0445/31 May/June 2017

Q11 · Two pieces of hardwood that have been glued together 0445/32 May/June 2017

1 Fig. 1 shows two pieces of hardwood that have been glued together. Fig. 1 From the list below circle the type of glue that would provide the strongest joint. contact adhesive hot melt glue gun PVA [1]

1 marks

Mark scheme: Question Answer Marks 1 PVA 1

This question in 0445/32 May/June 2017

Q12 · Complete the drawing below to show odd leg calipers 0445/32 May/June 2017

2 Complete the drawing below to show odd leg calipers. [2]

2 marks

Mark scheme: 2 Point = 1 mark 2 ‘Step’ = 1 mark

This question in 0445/32 May/June 2017

Q13 · The end of a length of wood 0445/32 May/June 2017

4 Fig. 2 shows the end of a length of wood. Draw on Fig. 2 to show a groove and a rebate. Fig. 2 [2]

2 marks

Mark scheme: 4 Award 1 mark for each correctly drawn groove and rebate 2

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Q14 · Four items used to fasten materials together 0445/32 May/June 2017

5 Fig. 3 shows four items used to fasten materials together. A B C D Fig. 3 Name each of the items A, B, C and D shown in Fig. 3. A … B … C … D … [4]

4 marks

Mark scheme: 5 A nut and bolt 4 B [pop] rivet C screw D nail Accept incorrectly named screw or nail. Not cut tack.

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Q15 · Three layers of a sheet of plywood 0445/32 May/June 2017

6 Fig. 4 shows three layers of a sheet of plywood. 1 2 3 Fig. 4 Complete Fig. 4 by drawing the grain direction on layers 2 and 3 to show how plywood is constructed. [1]

1 marks

Mark scheme: 6 Completed drawing showing grain at 90° to previous layers 1

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Question 16 0445/32 May/June 2017

8 Fig. 5 shows a manufactured board. Fig. 5 (a) Name the manufactured board. … [1] (b) Describe briefly how the manufactured board shown in Fig. 5 is made. … … … [2] (c) The manufactured board shown in Fig. 5 is widely used in the production of mass-produced furniture. From the list below circle the most important benefit of using this manufactured board. weight appearance cost strength [1]

4 marks

Mark scheme: 8(a) Chipboard 1 8(b) Very small particles of scrap/wood chips 1 2 With an adhesive 1 Not sawdust. Ignore references to recycled wood 8(c) Cost 1

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Q17 · A mild steel bracket for a hanging basket 0445/32 May/June 2017

9 Fig. 6 shows a mild steel bracket for a hanging basket. 200 300 brace Fig. 6 (a) State a suitable thickness of mild steel strip for the bracket. … [1] (b) Give two methods of joining the brace to the bracket permanently. 1 … 2 … [2]

3 marks

Mark scheme: 9(a) 1.5–3 mm. Do not accept ranges of thicknesses. 1 9(b) Two methods of permanent joining: brazing [soldering], welding, riveting 2 Not pop rivets, epoxy resin

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Q18 · A toast rack made from metal 0445/32 May/June 2017

10 Fig. 7 shows a toast rack made from metal. base Fig. 7 (a) (i) Name a suitable ferrous metal for the toast rack. … (ii) Name a suitable non-ferrous metal for the toast rack. … [2] (b) Give two reasons why a base has been fitted to the toast rack. 1 …

4 marks

Mark scheme: 10(a)(i) Stainless steel, mild steel 1 10(a)(ii) Aluminium, brass, copper 1 10(b) Base fitted: to collect crumbs, add rigidity to rack, stability 2 Prevent scratches to surfaces, pick up more easily Not wider surface area. Section B

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Q19 · Views of an artist’s drawing board 0445/32 May/June 2017

11 Fig. 8 shows views of an artist’s drawing board. storage unit: 1.5 thick plastic ledge: 10×10 hardwood support: Ø8 metal rod board: 15 thick manufactured board Fig. 8 (a) Describe two good design features of the artist’s drawing board. 1 … 2 … [2] (b) Complete the parts list below by naming a specific material for each of the parts of the drawing board. Number Part Length × Width × Thickness Specific material Required board 1 650 × 450 × 15 storage unit 1 300 × 100 × 1.5 ledge 1 400 × 10 × 10 support 1 750 × Ø8 [4] (c) (i) Name a portable power saw that could be used to cut out the shape of the drawing board from a large sheet of manufactured board. … [1] (ii) Give one safety precaution, other than wearing eye protection, that must be taken when using portable power tools. … [1] (d) The storage unit that will fit into the drawing board is produced by vacuum forming. (i) Describe two important features of the design of the former used to vacuum form the storage unit. 1 … 2 … [2] (ii) Explain why it is important to heat the plastic to the correct temperature when vacuum forming. … … [2] (e) Fig. 9 shows the ends of the support fixed into hardwood blocks. hardwood blocks glued to underside of board Fig. 9 (i) Explain why the designer has used hardwood blocks for the ends of the support to fit into rather than drilling holes directly into the drawing board. … … … [2] (ii) The support will be made by bending one length of Ø8 metal rod to shape. Use sketches and notes to show how the Ø8 metal rod could be bent to shape. Name the tools and equipment used. [3] (f) Use sketches and notes to show a different method of supporting the drawing board to that shown in Fig. 8. Include details of all materials and constructions used. [6] (g) Give two benefits of using a portable power sander to prepare the surface of the drawing board before a finish is applied. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) Two good design features include: angled for comfort [ergonomics], storage 2 unit useful, ledge prevents pens/pencils/paper sliding off, rounded corners for safety 11(b) Board plywood, faced chipboard only, MDF, 1 4 Blockboard, Laminboard, not chipboard Storage unit PVC, ABS, HIPS, acrylic polystyrene 1 Ledge accept any suitable named hardwood 1 Support mild steel, stainless steel, aluminium, not steel 1 11(c)(i) Power saw: jig saw, circular saw 1 11(c)(ii) No trailing leads, no loose clothing, long hair tied back, work secured, 1 face mask, safety of hands, ear defenders Not goggles, gloves 11(d)(i) Two features of mould design: draft angle, rounded edges/corners, no 2 undercuts Not vent holes 11(d)(ii) If the plastic is overheated = 1 it will melt = 1 2 If the plastic is not hot enough = 1 it will not form to the mould = 1 Plastic can be moulded to the shape of the former = 1 Plastic is made soft = 1 11(e)(i) The drawing board is only 15mm thick and the metal rod would not be secure 2 or the holes would wear and the support work loose. Additional blocks provide a thicker material to provide deeper holes Makes more stable/stronger Hole will be visible 11(e)(ii) Metal rod bent: 3 Held in vice or clamped to a bench 1 Vice, former or anvil around which the rod can be bent 1 Method of force hammer and scrap wood or mallet 1 Not hammer on its own 11(f) Practical method: 6 Angled 1 Stable and secure 0–2 Named materials 1 Constructions 0–2 Total redesign of board = max 3 11(g) Portable sander benefits: faster than by hand, more even pressure 2 exerted. Produces a smooth surface, removes marks and scratches.

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Q20 · A bird feeder made from wood and plastic 0445/32 May/June 2017

12 Fig. 10 shows a bird feeder made from wood and plastic. roof: 4 thick clear acrylic end: 12 thick plywood base: 12 thick plywood 200 200 120 Fig. 10 (a) Give two reasons why acrylic is a good choice of material for the roof of the bird feeder. 1 … 2 … [2] (b) Fig. 11 shows a tool that could be used to produce the Ø50 holes in the base of the bird feeder. Fig. 11 Name the tool shown in Fig. 11. … [1] (c) Fig. 12 shows one end of the bird feeder marked out ready to be cut to shape. outside curve inside curve Fig. 12 (i) Name a machine saw that could be used to cut out the shape. … [1] (ii) Name a tool that could be used to finish the inside curve. … [1] (iii) Give one safety precaution you would take when using a disc sander to finish the outside curve. … [1] (d) Use sketches and notes to show how the base and ends could be joined together permanently. [3] (e) Fig. 13 shows the roof of the bird feeder marked out on a sheet of acrylic. roof shape 500 400 Fig. 13 (i) Name two ways of marking lines on the surface of acrylic. 1 … 2 … [2] (ii) When sawing acrylic there is a possibility that it could crack. Describe how this could be prevented. … … … [2] (f) Use sketches and notes to show how the curved shape of the roof could be produced. [4] (g) Two plastic bowls are needed to fit into the holes in the base of the bird feeder. Fig. 14 shows the former that will be used to vacuum form the plastic bowls. Fig. 14 (i) Describe two features of the design of the former that will allow the plastic bowls to be released from the former when vacuum formed. 1 … 2 … [2] (ii) Use sketches and notes to show how one plastic bowl could be produced by vacuum forming. [6]

25 marks

Mark scheme: 12(a) Two reasons include: easily formed, self-coloured, durable outdoors, 2 waterproof, easily cleaned, corrosion resistant, windproof Not self-finishing. 12(b) Hole saw 1 12(c)(i) Hegner saw or equivalent, scroll saw, band saw, jig saw 1 12(c)(ii) Half-round file, round [rat tail] file, spokeshave, scraper, bobbin sander 1 12(c)(iii) Safety glasses, goggles, eye protection, no loose clothing, long hair tied 1 back, finger safety 12(d) Sketch showing: butt joint glued and pinned/screwed, dowel, half-lap, 3 dovetail, finger, biscuit Award use of adhesive 1 Technical accuracy of joint 0–2 Not mitre joint, hot glue gun 12(e)(i) Two items of equipment: chinagraph pencil, marker pen, wax pencil, 2 crayon, pencil on protective paper, felt-tip pen. Not scriber 12(e)(ii) lower acrylic in vice, support behind acrylic while sawing, fine tooth blade, 2 speed of sawing, clamping/securing acrylic. Award 1 mark for 1 point and 1 mark for additional description OR Award 2 marks for 2 separate points. 12(f) Method of shaping roof: 3 stages: 3 4 Heat plastic in oven, hot air ‘gun’ use of former over which to shape acrylic Method of retention Technical accuracy of stages/equipment used 0–1 12(g)(i) Two features of mould include draft angle, smooth surfaces, radiused 2 edges/corners, no undercuts 12(g)(ii) Vacuum forming process involves numerous stages: 6 Position mould on platen, clamp plastic to machine, heat plastic, test for flexibility, lift platen into plastic, turn on blower to suck out air, lower platen, leave to cool, trim edges of plastic, finish edges appropriately Award 1 mark for 6 specific stages

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Q21 · Views of a computer desk manufactured as flat-pack for self-assembly 0445/32 May/June 2017

13 Fig. 15 shows views of a computer desk manufactured as flat-pack for self-assembly. The end frames, back rail and supports are made from hardwood. A 750 drawer support back rail 25×25 75×20 end frame 25×25 1000 500 Fig. 15 (a) The computer desk top will be made from manufactured board. (i) Name a suitable manufactured board for the desk top. … [1] (ii) Give a reason for your choice of manufactured board. … [1] (b) (i) Sketch and name a permanent joint that could be used at corner A in Fig. 15. [4] (ii) Fig. 16 shows an exploded view of a support and an end frame. Use sketches and notes to show how the support could be joined to the end frame using a temporary fixing in the space below. support 25×25 end frame Fig. 16 [3] (c) The hardwood parts of the computer desk will be finished with polyurethane varnish. (i) Describe how each of the items listed below could be used to prepare the surfaces of the hardwood parts before a polyurethane varnish finish is applied. Medium grade glasspaper … Fine grade glasspaper … Damp cloth … Cork block … [4] (ii) Give two reasons why polyurethane varnish is a suitable finish for the computer desk. 1 … 2 … [2] (d) Explain how the designer has decided on the measurements of: (i) the length and width of the computer desktop; … (ii) the height of the computer desk top above the ground. … [2] (e) Fig. 17 shows details of a drawer that will be supported below the computer desk top. sides 15 thick 50 600 250 Fig. 17 Use sketches and notes to show how the drawer could be supported below the computer desk top and made to slide in and out as shown in Fig. 15. Include details of materials, constructions and two important sizes. [6] (f) Many items of furniture are designed for self-assembly. Give two drawbacks of self-assembly furniture. 1 …

23 marks

Mark scheme: 13(a) MDF, plywood, chipboard, blockboard, laminboard 1 13(a)(ii) Reason for choice: durable, hardwearing, stable, references to recycled 1 materials, cheaper than...[qualified], MDF [only] low risk of splinters Not cheap. 13(b)(i) Suitable joint: mortise and tenon, dowel, bridle named 1 4 Technical accuracy of joining method 0–3 Not butt joint, screwed joint, mitre joint Must be in correct orientation/proportion for maximum marks 13(b)(ii) Support joined using screws/KD fitting/nuts and bolts, brackets 1 3 technical accuracy of details provided 0–2 13(c)(i) Medium grade glasspaper: used to clean hardwood and remove small 4 scratches and marks 1 Fine grade glasspaper: used after medium grade to produce an even smoother finish 1 Progression through 2 grades of glasspaper Damp cloth: used to remove dust following glasspapering 1 Cork block: used to wrap glasspaper around to provide more even pressure 1 13(c)(ii) Polyurethane varnish is hardwearing, tough, easily cleaned, stain resistant, 2 durable, gives protection, attractive/aesthetic, waterproof/resistant. 13(d)(i) Length of computer desk top dependent on items to be positioned on the top, 1 anthropometric measurements 13(d)(ii) Height of desk dependent on seat height of user 1 13(e) Drawer supported under desk top and made to slide in and out 6 Use of runners, rebates or grooves for drawer to run on and be supported 0–2 Award 0–2 for practical idea Joined to supports = 1 mark Two important sizes 0–2 Details of materials and constructions used 0–2 13(f) Two drawbacks: some methods of construction may not be as durable, parts 2 sometimes missing, limited consumer skill, difficult instructions, tools not available. References to strength of materials and/or constructions must be qualified otherwise 0 marks.

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Q22 · Complete the table below by naming each of the tools or items of equipment used to hold… 0445/33 May/June 2017

1 Complete the table below by naming each of the tools or items of equipment used to hold wood. Name Name Name Name [4]

4 marks

Mark scheme: Question Answer Marks 1 bench hook G cramp vice bench stop 4×1 4

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Q23 · Three boards that will be glued together to make a solid wood table top 0445/33 May/June 2017

4 Fig. 2 shows three boards that will be glued together to make a solid wood table top. 150 150 1 150 2 3 Fig. 2 (a) Give one reason why it would be necessary to join three boards together to make a solid wood table top. … [1] (b) Complete Fig. 2 by drawing the end grain on boards 2 and 3 so that the table top would remain stable. [2] (c) Name the type of cramps that would be used when gluing the boards together. … [1]

4 marks

Mark scheme: 4(a) solid wood boards not available in required width 1 4(b) end grain inverted on 2. 1 2 end grain on 3 should match that shown on 1 1 4(c) sash, F cramps 1

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Q24 · Complete the table by naming the correct metal from the list below to match each… 0445/33 May/June 2017

5 Complete the table by naming the correct metal from the list below to match each description. mild steel cast iron copper stainless steel brass aluminium Metal Description hard, tough, used to make sink units hard, brittle, used to make metalwork vices lightweight, resists corrosion, used to make aircraft bodies [3]

3 marks

Mark scheme: 5 stainless steel cast iron aluminium 3×1 3

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Q25 · The end of a length of wood 0445/33 May/June 2017

6 Fig. 3 shows the end of a length of wood. Draw on Fig. 3 to show a chamfered edge and a bevelled edge. chamfered edge bevelled edge Fig. 3 [2]

2 marks

Mark scheme: 6 Completed drawing of chamfer 1 2 Completed drawing of bevel 1

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Q26 · A tee square made from two pieces of acrylic 0445/33 May/June 2017

7 Fig. 4 shows a tee square made from two pieces of acrylic. joint Fig. 4 Name a suitable method of joining the two pieces of acrylic together: (a) temporarily; … (b) permanently. … [2]

2 marks

Mark scheme: 7(a) screws, nuts and bolts 1 1 7(b) acrylic cement, plastic welding [not welding], rivet 1 1

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Q27 · A method of joining two wooden boards 0445/33 May/June 2017

8 Fig. 5 shows a method of joining two wooden boards. Fig. 5 Name the method of joining. … [1]

1 marks

Mark scheme: 8 tongue and groove 1

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Question 28 0445/33 May/June 2017

9 Fig. 6 shows a modelling knife. The metal body of the knife is made in two parts that are screwed together. body Fig. 6 (a) Name a process that could be used to produce the two parts for the body of the knife. … [1] (b) Name a metal that could be used to make the body of the knife. … [1]

2 marks

Mark scheme: 9(a) casting, die casting 1 9(b) aluminium, zinc 1

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Q29 · Views of a child’s table and a parts list 0445/33 May/June 2017

11 Fig. 7 shows views of a child’s table and a parts list. A B A B A B A table shown with top removed Number Part Length × Width × Thickness Material Required leg 4 450 × 60 × 15 softwood end rail A 4 470 × 60 × 15 softwood long rail B 3 740 × 60 × 15 softwood table top 1 840 × 540 × 19 manufactured board Fig. 7 (a) (i) Name a suitable softwood and manufactured board for parts of the table shown in the parts list. Softwood … Manufactured board … [2] (ii) The legs and rails are all 60 wide × 15 thick. Give one benefit to a manufacturer of using materials that are the same width and thickness. … [1] (b) Give two ways in which the table top could be made more hardwearing for use by children. 1 … 2 … [2] (c) The table top will be attached to the rails by means of screws. Fig. 8 shows part of the table with the positions for two screw holes marked out. centre for screw hole Fig. 8 (i) Use a sketch and notes to show how the holes could be drilled so that the screw head would be hidden. [3] (ii) Use sketches and notes to show how a knock-down (KD) fitting could be used to attach the table top to the rails. [3] (d) The rails and the legs will be joined using dowel joints. A drilling jig is needed when drilling the holes for the dowel. (i) Give two benefits of using a drilling jig when drilling the holes for the dowel. 1 … 2 … [2] (ii) Fig. 9 shows an exploded view of a dowel joint between a rail and a leg. rail leg Fig. 9 Use sketches and notes to show a drilling jig that could be used when drilling holes in the ends of the rails. [4] (e) A container is required to store pens, pencils and other small items of equipment. Fig. 10 shows the area where the container will fit into the table top. area to be removed 250 × 120 Fig. 10 (i) Use sketches and notes to show how the area could be removed and the edges made smooth. [4] (ii) Use sketches and notes to show a design for a container that could fit into the area cut out. Include details of materials and constructions used. [4]

25 marks

Mark scheme: 11(a)(i) Softwood: pine, red deal, whitewood, parana pine, yew 1 2 Manufactured board: plywood, chipboard, blockboard, MDF 1 11(a)(ii) Benefit: more efficient use of materials, quicker manufacture, 1 less waste, can be produced more cheaply 11(b) Two ways of making top durable: apply hardwearing finish: polyurethane 2 varnish, lacquer or paint, apply plastic laminate 2×1 11(c)(i) Counterbored hole: 3 diameter for screw head 1 diameter for screw shank 1 appropriate depths 1 Countersink = 1–2 max 11(c)(ii) Use of recognised KD fitting 1 3 Correct position 1 Technical accuracy 1 11(d)(i) Two benefits: speed, repetitive accuracy, no need for preparatory marking 2 could keep drill vertical 2×1 11(d)(ii) jig located against end of rail in one direction 1 4 jig located against end of rail in two directions 1 holes positioned correctly 1 additional explanatory notes 1 11(e)(i) drill hole in area to be removed 1 4 insert saw blade [vibro saw] router 1 use of file 1 glasspaper to smooth edges 1 Do not reward marking out stage 11(e)(ii) practical idea 1 4 some form of lipping to prevent container falling through top 1 materials and constructions used 0–2

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Q30 · Views of a cycle rack that could be fixed to the wall of a garage or shed 0445/33 May/June 2017

12 Fig. 11 shows views of a cycle rack that could be fixed to the wall of a garage or shed. wooden back 200 × 40 × 15 A A pivot sheet metal support 280 × 75 × 1.5 Fig. 11 (a) Give two items of research a designer would need to consider when designing a cycle rack. 1 … 2 … [2] (b) Sketch and name a suitable method of joining parts A to the back shown in Fig. 11. [4] (c) Fig. 12 shows details of the sheet metal support. 280 20 270 35 75 Fig. 12 An outline of the sheet of metal used to make the support is shown below. (i) Draw on the outline the development (net) for the support. not to scale [4] (ii) Give two advantages of making the support for the cycle rack from non-ferrous metal rather than ferrous metal. 1 … 2 … [2] (d) To make the support, the slot will be cut out and the metal will be bent to shape. (i) Use sketches and notes to show how the slot could be cut out and the edges made smooth. [4] (ii) Use sketches and notes to show how the sheet metal could be bent to shape. [3] (e) Fig. 13 shows views of the back and support. The support will be pivoted between parts A and will fold down when not in use. A wall A folds down Fig. 13 Use sketches and notes to show how the support could be locked in a horizontal position as shown in Fig. 13. [3] (f) Fig. 14 shows a cycle helmet that is to be stored on the cycle rack. Use sketches and notes to show a modification to any part of the cycle rack so that the helmet could be stored. Fig. 14 [3]

25 marks

Mark scheme: 12(a) Two items include: various dimensions of cycle; e.g. diameter of seat post, 2 distance from wall, height off ground, parts of bike to be supported, consumer research Accept any genuine item. 2×1 12(b) Suitable joint: dowel, housing, M and T named 1 4 Accuracy of completed joint drawn 0–3 Butt joint pinned and glued maximum 3 marks 12(c)(i) 4 2 bend lines 2×1 1 slot 1 2 shaped ends 1 12(c)(ii) Two advantages: non-ferrous metal does not rust, easier to bend to shape 2 2×1 12(d)(i) drill hole/s for slot diameter/use of round file 1 4 use of tin snips, shears to remove waste 1 use of file/emery cloth/wet and dry paper to smooth edges 1 technical accuracy 1 Do not reward marking out stage 12(d)(ii) sheet metal held between folding bars, scrap wood 1 3 secured in vice 1 use of mallet, hammer and scrap wood to bend to shape 1 12(e) Method of locking: some form of nut and bolt [principle], bolt/rod 0–2 3 details of type of head method of tightening 0–1 12(f) Method includes the use of pins or slots into which the straps 3 could be hooked over/through Award 0–3 dependent upon accuracy of a practical modification 0–3

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Q31 · An incomplete design for a toy lorry 0445/33 May/June 2017

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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Question 32 0445/31 Oct/Nov 2017

1 Fig. 1 shows a child’s scooter. Fig. 1 Describe three ways in which the designer has considered the child’s safety in the design of a scooter. 1 … 2 … 3 … [3]

3 marks

Mark scheme: Question Answer Marks 1 Three safety features: hardwearing materials, strong joints, no sharp 3 corners/edges, no ‘trapping’ places, appropriate sizes for key parts- handlebars, footrest, brake, grips on handlebars, footrest. Accept any sensible safety feature. 3×1

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Q33 · Complete the drawing below to show a tenon saw 0445/31 Oct/Nov 2017

3 Complete the drawing below to show a tenon saw. [2]

2 marks

Mark scheme: 3 Award 0–2 dependent on technical accuracy 2 Award 1 mark for shape of blade. Award 1 mark for back drawn.

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Q34 · A washing-up liquid bottle made from plastic and a symbol that can be seen on the bottle 0445/31 Oct/Nov 2017

6 Fig. 4 shows a washing-up liquid bottle made from plastic and a symbol that can be seen on the bottle. 1 PET Fig. 4 (a) Name the plastic. … [1] (b) Describe one problem for the environment when using products made from plastic. … [1]

2 marks

Mark scheme: 6(a) Polyethylene, polythene, polyether terephthalate 1 6(b) plastics are non-biodegradable, some plastics cannot be recycled [easily] 1 give off toxic fumes when burnt, pollution, decompose extremely slowly

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Q35 · Complete the drawing below to show a stopped housing joint 0445/31 Oct/Nov 2017

7 Complete the drawing below to show a stopped housing joint. [3]

3 marks

Mark scheme: 7 Award 0–3 dependent on technical accuracy 3

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Q36 · A house number plate made from brass, a non-ferrous alloy 0445/31 Oct/Nov 2017

8 Fig. 5 shows a house number plate made from brass, a non-ferrous alloy. Fig. 5 Explain the term ‘non-ferrous alloy’. … … [2]

2 marks

Mark scheme: 8 Non-ferrous is a metal that does not contain iron 1 2 Alloy is a mixture of two or more pure metals 1

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Q37 · The table below shows two fastening devices 0445/31 Oct/Nov 2017

10 The table below shows two fastening devices. Complete the table by naming each fastening device and stating how each would be tightened. Fastening device Name Method of tightening [4]

4 marks

Mark scheme: 10 Fastening device: nut [hexagonal] [lock] 1 4 Method of tightening: spanner, wrench, socket 1 Fastening device: wing nut 1 Method of tightening: fingers 1

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Question 38 0445/31 Oct/Nov 2017

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

This question in 0445/31 Oct/Nov 2017

Q39 · A sign that will be located in a school corridor to give directions to a Design and… 0445/31 Oct/Nov 2017

12 Fig. 10 shows a sign that will be located in a school corridor to give directions to a Design and Technology display. The sign is made from 15 thick hardwood and can be made to be wall-mounted or freestanding. Technology Display& Design Fig. 10 (a) Fig. 11 shows the sign marked out ready to be cut to shape. 600 waste C 140 A B Fig. 11 (i) Name an attractive hardwood for the sign. … [1] (ii) For each of the areas A, B and C, name a different tool that could be used to remove the waste. A … B … C … [3] (iii) Describe how the surfaces of the sign could be prepared to take an applied finish. … … … [2] (iv) Name a suitable finish and describe how it could be applied to achieve a high quality finished surface. Suitable finish … [1] How to achieve a high quality finished surface. … … … [2] (b) Use sketches and notes to show how the sign could be fixed to a wall. Your method of fixing must not be seen on the front of the sign. Include all named materials and methods of construction. [5] (c) Use sketches and notes to show how the sign could be freestanding and supported at a height of 1.5 metres above the ground. Your design must include: • a stable base; • a method of joining the sign to the support; • two important sizes. Include all named materials and methods of construction. [8] (d) The sign and lettering could be produced using Computer-Aided-Design, [CAD]. Describe how CAD could be used to design the words ‘Design & Technology Display’. … … … … [3]

25 marks

Mark scheme: 12(a)(i) Wide variety of hardwoods available for choice. 1 Award 1 mark for any recognised hardwood that could be used for the sign. 12(a)(ii) A variety of saws could be used to cut out each area A B C 3 Award 1 mark for a different appropriately named saw for each area including: Hegner, vibro, band, jig, tenon, coping saws. 12(a)(iii) Use of glasspaper, different grade/s, cork block, cloth to remove dust. 2 Award 0–2 dependent details provided. 12(a)(iv) Suitable finish: [polyurethane] varnish, shellac, wax, lacquer, various 1 oils/stains How to achieve a high quality finish: brush strokes along the grain, no 2 runs or drips, brush not overloaded. For oils: use of cotton wad, appropriate amount of oil onto wad, appropriate action onto surface of wood. 0–2 12(b) Some form of bracket attached to the back of the clock with provision for 5 fixing to wall. Alternative method: plate with keyhole slot. Not visible from front 1 Award 0–2 dependent upon accuracy of practical idea. 0–2 Materials and constructions 0–2 12(c) Stand with stable base [solid or legs] Practical idea. 0–2 8 Method of joining sign to stand 0–2 Two important sizes 2×1 Named materials and constructions: 0–2 12(d) CAD used to model different font styles, size and spacing, colour. 3 CAD allows for on-screen modelling, trialling before manufacture. Award 0–3 for any practical knowledge of using CAD.

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Q40 · A wooden stool and a parts list 0445/31 Oct/Nov 2017

13 Fig. 12 shows a wooden stool and a parts list. The stool is designed for a person to stand on. platform Number Part Length × width × thickness end Required platform 1 350 × 250 × 20 end 2 250 × 250 × 20 rail rail 1 300 × 50 × 20 Fig. 12 (a) From the list of materials below, circle a hardwood that would be suitable for making the stool. plywood ash pine cedar [1] (b) The platform for the stool is 250 wide. The widest available hardwood board is only 150 wide. Fig. 13 shows two boards, each 150 wide. uneven sawn edges Fig. 13 Use sketches and notes to show how the two boards, each 150 wide, could be prepared and joined to make the platform for the stool. (c) Sketch and name a method of permanently joining the rail to one end. [4] (d) Fig. 14 shows the shaping to be carried out to one end. waste Fig. 14 Use sketches and notes to show how the waste wood could be removed and the sawn edges made flat and smooth. [3] (e) Fig. 15 shows a bit that could be used to drill the hole in the stool platform. Fig. 15 (i) Name the bit shown in Fig. 15. … [1] (ii) When drilling the wood there is a danger that the wood can split as the drill passes through the wood. Use sketches and notes to show how this could be prevented. [3] (f) Describe how more grip could be applied to the surface of the platform so that a person standing on it would be less likely to slip. … … … [2]

20 marks

Mark scheme: 13(a) ash 1 13(b) Edge/butt joint, tongue and groove, dowel or biscuit joint process 0–1 6 Preparation: wood held in vice, edges planed 0–2 Gluing and clamping 0–2 Technical accuracy 0–1 13(c) Suitable joint: dowel, M&T named 1 4 Award 0–3 dependent on technical accuracy 0–3 13(d) Use of coping saw, Hegner saw or equivalent, band saw 1 3 Use of files/glasspaper to make smooth 1 Technical accuracy: wood held securely, correctly named file 1 13(e)(i) Accept saw tooth or forstner bit 1 13(e)(ii) Wood should be shown on top of scrap wood 1 3 Securely clamped in position 1 Technical accuracy 1 13(f) Application of some form of non-slip material. 2 Award 0–2 dependent on technical quality of description. 13(g)(i) polypropylene 1 13(g)(ii) injection moulding, rotational moulding 1 13(g)(iii) Wooden stool more expensive than plastic stool: 3 More materials used, more constructional process take longer to produce Longer production times means greater costs compared to speed of production of plastic stool. Award 0–3 dependent on quality of explanation and points made.

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Q41 · A try square being used to test an edge for squareness 0445/31 May/June 2018

2 Fig. 2 shows a try square being used to test an edge for squareness. try square 5 mm thick steel 12 mm thick pine Fig. 2 Give the correct name of a specific hand tool that could be used to make the edge square when made from: (a) 5 mm thick steel … [1] (b) 12 mm thick pine … [1]

2 marks

Mark scheme: 2(a) Flat, hand file 1 2(b) Jack, smoothing, try, block plane 1

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Question 42 0445/31 May/June 2018

3 Fig. 3 shows a block joint. Fig. 3 Add to Fig. 3 to show how the block joint could be strengthened. [2]

2 marks

Mark scheme: 3 Pins or screws shown in 2 directions 2 Use of adhesive only 1 2

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Q43 · Views of a smart phone desk stand 0445/31 May/June 2018

4 Fig. 4 shows views of a smart phone desk stand. Fig. 4 (a) Name a suitable non-ferrous metal that could be used to make the stand. … [1] (b) Give one reason for your choice of non-ferrous metal. … [1]

2 marks

Mark scheme: 4(a) Brass, copper, gilding metal, aluminium 1 4(b) Easy to bend, attractive finish, malleable 1

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Q44 · Views of a basic frame construction in wood 0445/31 May/June 2018

5 Fig. 5 shows views of a basic frame construction in wood. 800 sides 50 × 25 500 Fig. 5 Add sketches and notes to Fig. 5 to show two ways of strengthening the frame construction. [4]

4 marks

Mark scheme: 5 1 way: strengthen corners using gusset, metal fasteners 0–2 1 way: insert cross rails 0–2 4

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Q45 · Complete the table by selecting the correct material from the list below to match each… 0445/31 May/June 2018

6 Complete the table by selecting the correct material from the list below to match each description. ash plywood blockboard MDF oak Material Description of material tough, wide-grained hardwood used for tool handles, cricket stumps, hockey sticks manufactured board made by sandwiching strips of softwood between two plies manufactured board made by compressing and gluing wooden fibres together [3]

3 marks

Mark scheme: 6 From the top to bottom: ash blockboard MDF 3

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Q46 · Acrylic sheet bent to shape 0445/31 May/June 2018

7 Fig. 6 shows acrylic sheet bent to shape. base Fig. 6 Add sketches and notes to Fig. 6 to show how the bent shape of the acrylic could be held in position while it cooled. [2]

2 marks

Mark scheme: 7 Retaining strips positioned on the base in front and behind acrylic, use of grooves/housings 2

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Q47 · Complete the drawing below to show an exploded view of a corner bridle joint 0445/31 May/June 2018

9 Complete the drawing below to show an exploded view of a corner bridle joint. [3]

3 marks

Mark scheme: 9 Award 0–3 dependent on technical accuracy 3

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Q48 · An incomplete design for a floor standing bathroom storage unit made mainly from softwood 0445/31 May/June 2018

11 Fig. 9 shows an incomplete design for a floor standing bathroom storage unit made mainly from softwood. The storage unit will be batch produced and the parts delivered to customers for self-assembly. position for handle A B 700 upright C 250 150 Fig. 9 (a) (i) Name a suitable softwood for the storage unit. … [1] (ii) Give one reason why the choice of materials is important when designing products for use in a bathroom. … [1] (b) Fig. 10 shows an exploded view of box A. 50 base 4 mm thick sides 10 mm thick Fig. 10 (i) Sketch and name a suitable construction that could be used at each corner of the box. [4] (ii) Use sketches and notes to show how the base could be fitted inside the box so that the edges of the base cannot be seen. [3] (c) Use sketches and notes to show a design for a handle that could be fitted in the position shown in Fig. 9. [3] (d) Use sketches and notes to design a jig or device that could be used to speed up batch production of one part of the storage unit. State clearly which part of the storage unit is to be batch produced. Part to be batch produced … [5] (e) Each of the boxes will be fitted to the uprights by customers using only screws. Use sketches and notes to show customers how one box will be fitted to an upright. [3] (f) Use sketches and notes to show one functional improvement to the design of the storage unit. [3] (g) Give two reasons why self-assembly products are popular with customers. 1 … 2 … [2]

25 marks

Mark scheme: 11(a)(i) Red deal, pine, parana pine, whitewood, yew 1 11(a)(ii) Materials must not be affected by moisture as a result of steam Materials used to co-ordinate with existing colour scheme/style 1 11(b)(i) Butt joint pinned and glued, finger [comb] joint, dowel, mitre, dovetail, lapped, KD block Award 0–3 dependent on technical accuracy Named joint appropriate 1 4 Question Answer Marks 11(b)(ii) Methods include: groove or rebate [by removal or applied beads] KD block Award 0–3 dependent on technical accuracy 3 11(c) Handle shape 1 Material 1 Construction 1 3 11(d) Accept any appropriate part of the storage unit: e.g. cutting sides to length, positions for holes to attach uprights to boxes. Appropriate part stated 1 Jig or device to speed up batch production: award 0–4 dependent on technical accuracy/additional detailed notes 5 11(e) 2 screws required to join uprights to boxes 2 × 1 Additional details 1 3 11(f) Accept any appropriate functional improvement; e.g. ‘feet’ to raise storage unit off the floor, some form of cleaning holes/slots in base of boxes to assist cleaning, partitions. 3 11(g) Reasons include: satisfaction of constructing the product themselves, generally cheaper than ready-assembled products, some self-assembly products can be disassembled for storage, easier to transport home 2 × 1 2

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Q49 · Views of a wall-mounted coat rack 0445/31 May/June 2018

12 Fig. 11 shows views of a wall-mounted coat rack. Coats are hung on the front pegs and coat hangers can be hooked over the pegs behind the front of the coat rack. bracket 12 × 2 pegs Ø12 900 peg back back 60 × 15 bracket front front 100 × 15 Fig. 11 (a) Name a suitable hardwood for the front and back of the coat rack. … [1] (b) Stainless steel will be used to make the brackets and pegs. Give two reasons for using stainless steel. 1 … 2 … [2] (c) (i) Five holes Ø12 will be drilled in the front and back of the coat rack. Name two bits that could be used to drill the holes. 1 … 2 … [2] (ii) Explain how you could prevent the wood from splintering at the back of the hardwood when holes are drilled. … … … [2] (d) Fig. 12 shows a strip of stainless steel marked out ready to be bent to the shape of the bracket. centres for holes bend lines 60 60 60 15 bracket Fig. 12 (i) Name two marking out tools that could be used to show the bend lines. 1 … 2 … [2] (ii) Explain the purpose of a centre punch when marking the centres of holes to be drilled. … … … [2] (iii) Use sketches and notes to show how the 2 mm thick stainless steel strip could be bent to the shape of the bracket. • Describe the order in which the bends will be made. • Name all the tools and equipment used. . [6] (e) Explain why it is sometimes necessary to anneal metals. … … … … [2] (f) The purpose of the bracket shown in Fig. 11 is to join the front to the back of the coat rack. Use sketches and notes to show a different method using wood-based materials rather than stainless steel. Include the following details: • specific material/s • constructions used • two important sizes. [6]

25 marks

Mark scheme: 12(a) Wide variety of hardwoods available 1 12(b) Extremely hard, attractive appearance, non-corrosive, durable, tough 2 × 1 2 12(c)(i) saw tooth, forstner bit, flat bit, auger, twist drill 2 × 1 2 12(c)(ii) Scrap wood provides support to prevent splintering as the drill/bit emerges Scrap wood protects the surface from drilled holes Clamping is safer as work piece cannot ‘spin’ and snag 2 12(d)(i) Scriber, permanent marker, pencil , marking blue 2 × 1 2 Question Answer Marks 12(d)(ii) Centre punch: provides an indentation to guide the drill 1 Prevents the drill from slipping and damaging work piece 1 2 12(d)(iii) Tools/equipment named/shown: vice, mallet, hammer and scrap wood 0–2 Sketches showing process: Award 0–3 dependent on technical accuracy 0–3 Correct order: 0–1 6 12(e) Metal can become work hardened when it is shaped. Annealing will reduce internal stress and ‘soften’ the metal. 2 × 1 2 12(f) Some form of ‘block’ to act as a spacer 1 Appropriate method of construction joining the front to the back of rack 0–2 Named material/s 1 2 important sizes 2 6

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Q50 · A toy racing car made from softwood 0445/31 May/June 2018

13 Fig. 13 shows a toy racing car made from softwood. Ten identical cars will be made in a school workshop. spoiler body 150 × 40 × 40 rear wheel Ø50 × 15 front wheel Ø40 × 12 Fig. 13 (a) (i) Name a suitable softwood for the toy racing car. … [1] (ii) Give one reason, other than ‘strength’, for your choice of softwood. … [1] (b) The 150 mm long car body will be cut from a length of softwood similar to that shown below. 40 40 Use sketches and notes to show a design for a sawing jig that would enable ten identical car bodies to be cut to length. The sawing jig must: • position the softwood length securely while it is sawn • produce an accurate 150 mm length. [4] (c) The front wheels will be produced by turning between centres on a woodturning lathe. Fig. 14 shows a length of softwood before it is set up on a woodturning lathe. 300 50 50 Fig. 14 (i) Describe two processes that would be carried out to the length of softwood before it is set up on the woodturning lathe. 1 … 2 … [2] (ii) Name a tool that could be used to check the diameter of the wheels when they are turned on the lathe. … [1] (iii) Name two other tools or items of equipment that could be used when turning the wheels. 1 … 2 … [2]

11 marks

Mark scheme: 13(a)(i) Red deal, pine, parana pine, whitewood, yew 1 13(a)(ii) Generally cheaper than hardwood, can be left bare or painted 1 13(b) Softwood positioned/located securely 1 Accurate length can be sawn 1 Technical accuracy 0–2 4 13(c)(i) Diagonals marked, saw cut across one diagonal, circle marked on ends, corners planed off 2 × 1 2 13(c)(ii) Outside calipers, digital calipers 1 13(c)(iii) Scraper, gouge, parting tool, glasspaper and cork block [rubber], chisel, relevant and appropriate PPE 2 × 1 2 13(d) Stub axle or continuous rod 1 Method of retention: nut, ‘cap’, star washer 1 Move freely: clearance holes, use of washers 1 3 Question Answer Marks 13(e)(i) Jack, smoothing, block plane 1 13(e)(ii) Bench stop clearly shown 1 Softwood shown in position against bench stop 0–2 3 13(f)(i) Modifications include: draft angle on sides 0–2 Rounded edges/corners 0–2 4 13(f)(ii) Polystyrene [HIPS], acrylic, ABS 1 13(f)(iii) 2 checks include: plastic clamped securely, correct temperature achieved to soften plastic, blower on long enough to withdraw air 2 × 1 2

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Q51 · A door bolt made from steel for use in a bathroom 0445/32 May/June 2018

1 Fig. 1 shows a door bolt made from steel for use in a bathroom. The bolt has a chrome finish. Fig. 1 Give two benefits of a chrome finish for the door bolt. 1 … 2 … [2]

2 marks

Mark scheme: 1 2

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Q52 · An incomplete leg fastening used to join a leg to the rails of a table 0445/32 May/June 2018

2 Fig. 2 shows an incomplete leg fastening used to join a leg to the rails of a table. Fig. 2 Add to Fig. 2 to show how the leg fastening could be fixed to the leg and the rails. [3]

3 marks

Mark scheme: 2 Screws in left, right and centre = 3. 2 screws in left and 2 screws in right = 3. 1 screw in left and 1 screw in right = 2. 1 screw in centre = 3. 1 screw/bolt in centre with wing nut = 2. 3

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Q53 · Complete the table below by adding the correct name from the list 0445/32 May/June 2018

3 Complete the table below by adding the correct name from the list. forstner countersink flat twist centre Drill Name [3]

3 marks

Mark scheme: 3 countersunk, centre, twist 3 × 1

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Question 54 0445/32 May/June 2018

4 Fig. 3 shows a skateboard. The deck is made by gluing thin layers of wood together. Fig. 3 (a) Give the correct term for ‘thin layers of wood’. … [1] (b) Complete the statement below by adding the correct term from the list. casting machining shaping laminating Gluing thin layers of wood together is known as … [1]

2 marks

Mark scheme: 4(a) Veneers 1 4(b) laminating 1 Question Answer Marks 5 Examples of modifications include: knurling to edge, insertion of shaped piece into top surface of handle, saw cut to provide space for screwdriver blade. Award 1 mark for practical idea. Award 1 mark for notes that expand upon drawing* 2

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Q55 · A handle made from metal 0445/32 May/June 2018

5 Fig. 4 shows a handle made from metal. Fig. 4 Add sketches and notes to Fig. 4 to show a modification to the handle that would make it easier to grip and turn. [2]

2 marks

Mark scheme: 5 Award 1 mark for practical idea. Award 1 mark for notes that expand upon drawing*

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Question 56 0445/32 May/June 2018

6 Fig. 5 shows a canoe. Fig. 5 Name two composite materials that could be used to make the canoe. 1 … 2 … [2]

2 marks

Mark scheme: 6

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Q57 · A piece of steel that has cracked due to work hardening during bending 0445/32 May/June 2018

7 Fig. 6 shows a piece of steel that has cracked due to work hardening during bending. Fig. 6 Explain what is meant by the term ‘work hardening’. … … … [2]

2 marks

Mark scheme: 7 Hammer/hammering stated = 1

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Q58 · A child’s desk organiser made from 4 mm thick acrylic 0445/32 May/June 2018

11 Fig. 9 shows a child’s desk organiser made from 4 mm thick acrylic. The desk organiser will store paints, brushes, marker pens, crayons and similar equipment. Ø60 tube partition base 30 120 120 Fig. 9 (a) Fig. 10 shows the development (net) of the base of the desk organiser as a card template that will be glued to the acrylic. bend lines Fig. 10 (i) Give one advantage of using a template rather than marking the development (net) directly onto the acrylic. … [1] (ii) Use sketches and notes to show how the acrylic development (net) could be cut out by hand. Include the following details: • the method of holding the acrylic • the name of a suitable saw • one precaution that would be taken to prevent damage when sawing [4] (b) Fig. 11 shows a basic former around which the acrylic will be moulded to shape. Fig. 11 Describe how the acrylic could be: • made soft enough to be moulded to shape • held securely while it cools [4] (c) The base of the desk organiser could also be produced by the vacuum forming process. (i) Name a suitable plastic, other than acrylic, that could be vacuum formed. … [1] (ii) Describe two modifications that would need to be made to the former shown in Fig. 11 so that it could be used to vacuum form the base of the desk organiser. 1 … 2 … [2] (iii) Explain why vacuum forming would be a better method of producing the base of the desk organiser if it were to be batch produced. … … … [2] (d) The partitions will be joined permanently to the base and the Ø60 tube using acrylic cement. Describe two safety precautions that must be taken when using acrylic cement. 1 … 2 … [2] (e) Many of the edges of the acrylic will need to be made smooth and highly polished. List three tools or items of equipment that could be used to make the edges smooth and highly polished. 1 … 2 … 3 … [3] (f) To make it easier for children to access the equipment in the desk organiser an additional base is required that will allow the desk organiser to rotate. Children will then be able to turn the desk organiser to select the equipment they need. Use sketches and notes to show how the desk organiser could be made to rotate freely on a base. Include the following details: • specific materials • two important sizes [6]

25 marks

Mark scheme: 11(a)(i) Quicker than having to draw, more accurate, repeated accuracy, no risk of damaging acrylic 1 11(a)(ii) Holding acrylic: vice, clamped down = 1 Named saw; coping, hacksaw, Hegner [or equivalent], band = 1 One precaution: low in vice, well supported, use of scrap wood to protect sides = 1 Technical accuracy: terms used, accuracy of sketches = 1 4 11(b) Acrylic shown above strip heater/line bender, oven 0–2 Method of holding: use of strips/blocks and some form of clamping 0–2 4 11(c)(i) HIPS, polystyrene, ABS 1 11(c)(ii) Draft angle on sides, rounded edges/corners 2 × 1 2 11(c)(iii) Quicker process because the mould can be reused and provides repetitive accuracy, less waste 2 11(d) Well-ventilated area, no naked flames, wearing of PPE [e.g. nose and mouth masks, gloves, goggles], use of barrier cream 2 × 1 2 11(e) File, scraper, various grades of wet and dry [silicon carbide] paper, polishing mop, buffing wheel, polishing compound 3 × 1 3 11(f) Recognised base 1 Constructional details: e.g. how the rod is inserted, grooves routed, some form of rod or ball bearings/marbles in a groove 0–2 Named materials appropriate 1 2 important sizes 2 × 1 6

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Q59 · A guitar stand made from hardwood 0445/32 May/June 2018

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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Q60 · A card model for a safety glasses holder 0445/32 May/June 2018

13 Fig. 16 shows a card model for a safety glasses holder. The holder could be made from wood or metal. The safety glasses holder will be wall-mounted in a school workshop. 100 170 60 Fig. 16 (a) Give two benefits of making a card model of the holder before making it from wood or metal. 1 … 2 … [2] (b) The development (net) of the safety glasses holder will be marked out on a sheet of metal. (i) Name a suitable ferrous metal for the holder. … [1] (ii) Name a suitable non-ferrous metal for the holder. … [1] (iii) The table below shows three marking out tools that could be used to mark out sheet metal. Complete the table by giving the specific name for each tool. Tool Name (iv) Explain why tinsnips would be a more effective tool to cut out the shape of the holder rather than a hacksaw. … … … [2] (c) Fig. 17 shows a safety glasses holder made from plywood. back, front and sides 9 mm thick base 4 mm thick plywood Fig. 17 (i) Plywood is a very stable manufactured board that is unlikely to twist or warp. Use sketches and notes to show the construction of plywood. [3] (ii) Name a different manufactured board that could be used to make the safety glasses holder. … [1] (iii) The parts of the safety glasses holder shown in Fig. 17 will be nailed and glued together. Name a specific type of nail that could be used to join the parts of the holder together. … [1] (iv) State a suitable length for the nail that could be used to join the front to the sides. … [1] (v) Name a suitable adhesive that could be used to glue the parts together. … [1] (vi) State approximately how long the adhesive named in part (v) would take to set. … [1] (d) Choose whether to make the safety glasses holder from metal or plywood. (i) Use sketches and notes to show a modification to the safety glasses holder so that it could be fixed to a wall and easily removed for cleaning. [3]

20 marks

Mark scheme: 13(b)(i) Mild steel, stainless steel 1 13(b)(ii) Aluminium, brass, copper, duralumin 1 13(b)(iii) From the top to bottom: try square, engineers square, odd-legs[calipers], Jenny callipers, scriber 3 × 1 3 13(b)(iv) Hacksaw limited to the depth of the frame, thin sheet can bend = 1 Tinsnips provide more control = 1 2 13(c)(i) 2 layers shown with same grain = 1 3 layers shown with same grain = 2 2 layers shown with alter. grain = 2 3 layers shown with alter. grain = 3 3 13(c)(ii) MDF, chipboard 1 13(c)(iii) Panel pin, round wire, oval nail/brad 1 13(c)(iv) Accept a single number between 15–25 mm 1 13(c)(v) PVA, Cascamite, Synthetic resin, Gorilla glue 1 13(c)(vi) Time must correspond to named adhesive: e.g. PVA 1–4 hours, Gorilla glue 1 hour 1 13(d)(i) 1 hook/bracket/screw = 1 2 screw holes only [no screws shown] = 1 2 screws + 2 holes in back of holder = 2 2 screws and 2 keyholes in back of holder = 3 Added hooks/brackets and screws = 3 Additional notes to expand on drawings = 1 3 Question Answer Marks 13(d)(ii) Lid can be hinged or ‘lift-off’ design. Practical design: 0–2 Constructional details: 0–2 Named materials: 0–1 5

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Q61 · A try square being used to test an edge for squareness 0445/33 May/June 2018

2 Fig. 2 shows a try square being used to test an edge for squareness. try square 5 mm thick steel 12 mm thick pine Fig. 2 Give the correct name of a specific hand tool that could be used to make the edge square when made from: (a) 5 mm thick steel … [1] (b) 12 mm thick pine … [1]

2 marks

Mark scheme: 2(a) Flat, hand file 1 2(b) Jack, smoothing, try, block plane 1

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Question 62 0445/33 May/June 2018

3 Fig. 3 shows a block joint. Fig. 3 Add to Fig. 3 to show how the block joint could be strengthened. [2]

2 marks

Mark scheme: 3 Pins or screws shown in 2 directions 2 Use of adhesive only 1 2

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Q63 · Views of a smart phone desk stand 0445/33 May/June 2018

4 Fig. 4 shows views of a smart phone desk stand. Fig. 4 (a) Name a suitable non-ferrous metal that could be used to make the stand. … [1] (b) Give one reason for your choice of non-ferrous metal. … [1]

2 marks

Mark scheme: 4(a) Brass, copper, gilding metal, aluminium 1 4(b) Easy to bend, attractive finish, malleable 1

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Q64 · Views of a basic frame construction in wood 0445/33 May/June 2018

5 Fig. 5 shows views of a basic frame construction in wood. 800 sides 50 × 25 500 Fig. 5 Add sketches and notes to Fig. 5 to show two ways of strengthening the frame construction. [4]

4 marks

Mark scheme: 5 1 way: strengthen corners using gusset, metal fasteners 0–2 1 way: insert cross rails 0–2 4

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Q65 · Complete the table by selecting the correct material from the list below to match each… 0445/33 May/June 2018

6 Complete the table by selecting the correct material from the list below to match each description. ash plywood blockboard MDF oak Material Description of material tough, wide-grained hardwood used for tool handles, cricket stumps, hockey sticks manufactured board made by sandwiching strips of softwood between two plies manufactured board made by compressing and gluing wooden fibres together [3]

3 marks

Mark scheme: 6 From the top to bottom: ash blockboard MDF 3

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Q66 · Acrylic sheet bent to shape 0445/33 May/June 2018

7 Fig. 6 shows acrylic sheet bent to shape. base Fig. 6 Add sketches and notes to Fig. 6 to show how the bent shape of the acrylic could be held in position while it cooled. [2]

2 marks

Mark scheme: 7 Retaining strips positioned on the base in front and behind acrylic, use of grooves/housings 2

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Q67 · Complete the drawing below to show an exploded view of a corner bridle joint 0445/33 May/June 2018

9 Complete the drawing below to show an exploded view of a corner bridle joint. [3]

3 marks

Mark scheme: 9 Award 0–3 dependent on technical accuracy 3

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Q68 · An incomplete design for a floor standing bathroom storage unit made mainly from softwood 0445/33 May/June 2018

11 Fig. 9 shows an incomplete design for a floor standing bathroom storage unit made mainly from softwood. The storage unit will be batch produced and the parts delivered to customers for self-assembly. position for handle A B 700 upright C 250 150 Fig. 9 (a) (i) Name a suitable softwood for the storage unit. … [1] (ii) Give one reason why the choice of materials is important when designing products for use in a bathroom. … [1] (b) Fig. 10 shows an exploded view of box A. 50 base 4 mm thick sides 10 mm thick Fig. 10 (i) Sketch and name a suitable construction that could be used at each corner of the box. [4] (ii) Use sketches and notes to show how the base could be fitted inside the box so that the edges of the base cannot be seen. [3] (c) Use sketches and notes to show a design for a handle that could be fitted in the position shown in Fig. 9. [3] (d) Use sketches and notes to design a jig or device that could be used to speed up batch production of one part of the storage unit. State clearly which part of the storage unit is to be batch produced. Part to be batch produced … [5] (e) Each of the boxes will be fitted to the uprights by customers using only screws. Use sketches and notes to show customers how one box will be fitted to an upright. [3] (f) Use sketches and notes to show one functional improvement to the design of the storage unit. [3] (g) Give two reasons why self-assembly products are popular with customers. 1 … 2 … [2]

25 marks

Mark scheme: 11(a)(i) Red deal, pine, parana pine, whitewood, yew 1 11(a)(ii) Materials must not be affected by moisture as a result of steam Materials used to co-ordinate with existing colour scheme/style 1 11(b)(i) Butt joint pinned and glued, finger [comb] joint, dowel, mitre, dovetail, lapped, KD block Award 0–3 dependent on technical accuracy Named joint appropriate 1 4 Question Answer Marks 11(b)(ii) Methods include: groove or rebate [by removal or applied beads] KD block Award 0–3 dependent on technical accuracy 3 11(c) Handle shape 1 Material 1 Construction 1 3 11(d) Accept any appropriate part of the storage unit: e.g. cutting sides to length, positions for holes to attach uprights to boxes. Appropriate part stated 1 Jig or device to speed up batch production: award 0–4 dependent on technical accuracy/additional detailed notes 5 11(e) 2 screws required to join uprights to boxes 2 × 1 Additional details 1 3 11(f) Accept any appropriate functional improvement; e.g. ‘feet’ to raise storage unit off the floor, some form of cleaning holes/slots in base of boxes to assist cleaning, partitions. 3 11(g) Reasons include: satisfaction of constructing the product themselves, generally cheaper than ready-assembled products, some self-assembly products can be disassembled for storage, easier to transport home 2 × 1 2

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Q69 · Views of a wall-mounted coat rack 0445/33 May/June 2018

12 Fig. 11 shows views of a wall-mounted coat rack. Coats are hung on the front pegs and coat hangers can be hooked over the pegs behind the front of the coat rack. bracket 12 × 2 pegs Ø12 900 peg back back 60 × 15 bracket front front 100 × 15 Fig. 11 (a) Name a suitable hardwood for the front and back of the coat rack. … [1] (b) Stainless steel will be used to make the brackets and pegs. Give two reasons for using stainless steel. 1 … 2 … [2] (c) (i) Five holes Ø12 will be drilled in the front and back of the coat rack. Name two bits that could be used to drill the holes. 1 … 2 … [2] (ii) Explain how you could prevent the wood from splintering at the back of the hardwood when holes are drilled. … … … [2] (d) Fig. 12 shows a strip of stainless steel marked out ready to be bent to the shape of the bracket. centres for holes bend lines 60 60 60 15 bracket Fig. 12 (i) Name two marking out tools that could be used to show the bend lines. 1 … 2 … [2] (ii) Explain the purpose of a centre punch when marking the centres of holes to be drilled. … … … [2] (iii) Use sketches and notes to show how the 2 mm thick stainless steel strip could be bent to the shape of the bracket. • Describe the order in which the bends will be made. • Name all the tools and equipment used. . [6] (e) Explain why it is sometimes necessary to anneal metals. … … … … [2] (f) The purpose of the bracket shown in Fig. 11 is to join the front to the back of the coat rack. Use sketches and notes to show a different method using wood-based materials rather than stainless steel. Include the following details: • specific material/s • constructions used • two important sizes. [6]

25 marks

Mark scheme: 12(a) Wide variety of hardwoods available 1 12(b) Extremely hard, attractive appearance, non-corrosive, durable, tough 2 × 1 2 12(c)(i) saw tooth, forstner bit, flat bit, auger, twist drill 2 × 1 2 12(c)(ii) Scrap wood provides support to prevent splintering as the drill/bit emerges Scrap wood protects the surface from drilled holes Clamping is safer as work piece cannot ‘spin’ and snag 2 12(d)(i) Scriber, permanent marker, pencil , marking blue 2 × 1 2 Question Answer Marks 12(d)(ii) Centre punch: provides an indentation to guide the drill 1 Prevents the drill from slipping and damaging work piece 1 2 12(d)(iii) Tools/equipment named/shown: vice, mallet, hammer and scrap wood 0–2 Sketches showing process: Award 0–3 dependent on technical accuracy 0–3 Correct order: 0–1 6 12(e) Metal can become work hardened when it is shaped. Annealing will reduce internal stress and ‘soften’ the metal. 2 × 1 2 12(f) Some form of ‘block’ to act as a spacer 1 Appropriate method of construction joining the front to the back of rack 0–2 Named material/s 1 2 important sizes 2 6

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Q70 · A toy racing car made from softwood 0445/33 May/June 2018

13 Fig. 13 shows a toy racing car made from softwood. Ten identical cars will be made in a school workshop. spoiler body 150 × 40 × 40 rear wheel Ø50 × 15 front wheel Ø40 × 12 Fig. 13 (a) (i) Name a suitable softwood for the toy racing car. … [1] (ii) Give one reason, other than ‘strength’, for your choice of softwood. … [1] (b) The 150 mm long car body will be cut from a length of softwood similar to that shown below. 40 40 Use sketches and notes to show a design for a sawing jig that would enable ten identical car bodies to be cut to length. The sawing jig must: • position the softwood length securely while it is sawn • produce an accurate 150 mm length. [4] (c) The front wheels will be produced by turning between centres on a woodturning lathe. Fig. 14 shows a length of softwood before it is set up on a woodturning lathe. 300 50 50 Fig. 14 (i) Describe two processes that would be carried out to the length of softwood before it is set up on the woodturning lathe. 1 … 2 … [2] (ii) Name a tool that could be used to check the diameter of the wheels when they are turned on the lathe. … [1] (iii) Name two other tools or items of equipment that could be used when turning the wheels. 1 … 2 … [2]

11 marks

Mark scheme: 13(a)(i) Red deal, pine, parana pine, whitewood, yew 1 13(a)(ii) Generally cheaper than hardwood, can be left bare or painted 1 13(b) Softwood positioned/located securely 1 Accurate length can be sawn 1 Technical accuracy 0–2 4 13(c)(i) Diagonals marked, saw cut across one diagonal, circle marked on ends, corners planed off 2 × 1 2 13(c)(ii) Outside calipers, digital calipers 1 13(c)(iii) Scraper, gouge, parting tool, glasspaper and cork block [rubber], chisel, relevant and appropriate PPE 2 × 1 2 13(d) Stub axle or continuous rod 1 Method of retention: nut, ‘cap’, star washer 1 Move freely: clearance holes, use of washers 1 3 Question Answer Marks 13(e)(i) Jack, smoothing, block plane 1 13(e)(ii) Bench stop clearly shown 1 Softwood shown in position against bench stop 0–2 3 13(f)(i) Modifications include: draft angle on sides 0–2 Rounded edges/corners 0–2 4 13(f)(ii) Polystyrene [HIPS], acrylic, ABS 1 13(f)(iii) 2 checks include: plastic clamped securely, correct temperature achieved to soften plastic, blower on long enough to withdraw air 2 × 1 2

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Q71 · Name the two standard metal sections shown below 0445/31 Oct/Nov 2018

1 Name the two standard metal sections shown below. … … [2]

2 marks

Mark scheme: 1 Round rod, bar 1 Hexagonal bar 1 2

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Q72 · Name the type of tools shown in Fig 0445/31 Oct/Nov 2018

2 (a) Name the type of tools shown in Fig. 1. Fig. 1 … [1] (b) Give one reason why the tools in Fig. 1 can remove wood quickly and efficiently. … [1]

2 marks

Mark scheme: 2(a) Surform/rasp 1 2(b) The teeth have a ‘cheese grater’ shape, sharp edges, very coarse teeth 1

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Q73 · Three different holes drilled before woodscrews can be used to join the two pieces of wood 0445/31 Oct/Nov 2018

3 Fig. 2 shows three different holes drilled before woodscrews can be used to join the two pieces of wood. Each hole has a different purpose. woodscrew A B C Fig. 2 Name each type of hole, A, B and C. A … B … C … [3]

3 marks

Mark scheme: 3 A countersink 1 B clearance 1 C pilot 1 3

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Q74 · Complete the table below by naming a different material that matches each of the… 0445/31 Oct/Nov 2018

4 Complete the table below by naming a different material that matches each of the descriptions. Material Description hard plastic, wide range of colours, used to make car rear light clusters manufactured board made by gluing layers together at 90° to each other close-grained hardwood used to make mallet heads and children’s toys an alloy of copper and zinc, metal with corrosion resistance, electrical conductivity [4]

4 marks

Mark scheme: 4 Hard plastic: acrylic, polystyrene 1 Manufactured board: plywood 1 Close-grained hardwood: beech, hickory, box, maple, lignum vitae 1 Corrosion resistant metal: brass 1 4

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Q75 · An incomplete drawing of a marking gauge 0445/31 Oct/Nov 2018

5 Fig. 3 shows an incomplete drawing of a marking gauge. Fig. 3 Complete the drawing of the marking gauge by adding: (a) the thumbscrew; (b) the pin or spur. [2]

2 marks

Mark scheme: 5(a) Thumbscrew shown 1 5(b) Pin or spur shown 1 Qu uestion Answer Mar rks

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Q76 · Two sit-on toys used by children 0445/31 Oct/Nov 2018

7 Fig. 5 shows two sit-on toys used by children. Toy A is made from wood and toy B from plastic. A B Fig. 5 Describe one benefit to the user of making a sit-on toy from: wood … plastic … [2]

2 marks

Mark scheme: Qu 7 Wood Plasti uestion d: hard wearing, ic: colour will no stable, solid, no t chip, lightweigh ot easily broken ht, moulded sha apes safe, comfo Answer ortable, water re sistant, easily cl leaned 1 1 Mar 2 rks

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Q77 · A wooden frame construction, a hardboard corner plate and a corrugated fastener 0445/31 Oct/Nov 2018

8 Fig. 6 shows a wooden frame construction, a hardboard corner plate and a corrugated fastener. A 80 B 80 hardboard corner plate 15 25 corrugated fastener Fig. 6 Draw on Fig. 6 to show how the frame construction could be strengthened by means of: (a) the hardboard corner plate at A; [1] (b) the corrugated fastener at B. [1]

2 marks

Mark scheme: Qu 8(a) Hardb 8(b) Metal uestion board corner pla l fastener in corr ate in correct pos rect position sition [not inside e frame] Answer Mar 1 1 rks

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Question 78 0445/31 Oct/Nov 2018

11 Fig. 9 shows a storage unit. A printer will be placed on top of the unit, which will be positioned under a desk. The unit has shelves that will be used to store printer paper. 350 450 top 500 end shelf not all dimensions are given Fig. 9 (a) An incomplete parts list for the storage unit is shown below. Complete the parts list. Number Part Length × width × thickness Material required Top 1 450 × … × 19 Veneered chipboard Shelf 2 … × … × 19 Veneered chipboard End 2 … × 350 × 19 Veneered chipboard [4] (b) Give two advantages of using veneered chipboard rather than solid wood for the storage unit. 1 … 2 … [2] (c) Sketch and name a pre-manufactured component that would enable the storage unit to be moved about easily. [3] (d) Use sketches and notes to show how one shelf could be joined to one end using knock-down (KD) fittings. [4] (e) Fig. 10 shows part of the top of the storage unit. veneered surface Fig. 10 Use sketches and notes to show how a solid wood lipping could be applied to one edge. [3] (f) Use sketches and notes to show a modification to the storage unit so that a quantity of paper clips, pens, pencils and a 300 mm plastic rule could be stored safely. Include details of materials, constructions and fittings used. [5] (g) There is a possibility that the paper stored on the shelves could fall through the back of the unit. Use sketches and notes to show how this could be prevented. Include details of materials, constructions and fittings used. [4]

25 marks

Mark scheme: 11(a) Part Number reqd. Length × width × thickness Material Top 1 450 × 350 × 19 Veneered chipboard Shelf 2 332 – 391 × 300 – 330 × 19 Veneered chipboard End 2 481 – 486 × 350 × 19 Veneered chipboard 4 11(b) Two advantages: cheaper, does not warp/shrink, more readily available, accept environmental advantages, large sheets 2 × 1 2 11(c) Component named: castor, skid 1 Sketch 0–2 dependent on technical accuracy 0–2 3 11(d) KD fitting: corner/modesty block drawn [Accuracy] 0–2 Appropriate number: maximum three under shelf Method of fixing to unit 1 4 11(e) Solid lipping appropriate width and thickness shown 1 Method of fixing: use of adhesive or pin and glue 1 Technical accuracy 1 If iron-on lipping is used award one mark maximum 3 11(f) Practical idea: some form of ‘tidy’ clearly drawn 0–2 Position of modifications clearly shown 1 Details of materials, constructions and fittings 0–2 5 11(g) Method includes addition of a rail, back or ‘tray’: practical idea 0–2 Details of materials, constructions and fittings [screws, dowels, nails and use of an adhesive] 0–2 4

This question in 0445/31 Oct/Nov 2018

Q79 · A headphone stand made from 5 thick acrylic 0445/31 Oct/Nov 2018

12 Fig. 11 shows a headphone stand made from 5 thick acrylic. The headphone stand has two main parts: a base and a support. support headphones base 100 overall height 230 Fig. 11 (a) Give two items of research that would need to be considered when designing the headphone stand. 1 … 2 … [2] (b) Give two reasons why you would make a model of the headphone stand before making it from acrylic. 1 … 2 … [2] (c) Fig. 12 shows the base of the headphone stand made from acrylic. A Fig. 12 (i) Use sketches and notes to show how the bend at A could be formed. [4] (ii) Explain why acrylic can be considered to be a ‘smart’ material. … … … [2] (d) (i) Describe how the support could be joined permanently to the base of the headphone stand using acrylic cement. … … [2] (ii) Give two safety precautions that must be taken when using acrylic cement. 1 … 2 … [2] (e) Fig. 13 shows a different design of headphone stand made from hardwood. support 200 high × 15 thick A base 100 × 100 × 15 Fig. 13 (i) Sketch and name a suitable joint used to join the support to the base at A in Fig. 13. [4] (ii) Fig. 14 shows the shape of the support drawn on paper and glued onto a block of hardwood. Fig. 14 Give the correct term for the paper shape. … [1] (iii) Name two types of saw that could be used to cut out the shape. 1 … 2 … [2] (f) Use sketches and notes to show a modification to either the acrylic headphone stand or the hardwood headphone stand that would allow the cable to be stored neatly. Include details of materials, sizes and constructions used. [4]

25 marks

Mark scheme: 12(a) Two items of research: sizes of headphones weight of headphones, existing designs, location. Accept individual dimensions for lead, width of headphone, depth, etc. 2 × 1 2 12(b) Two reasons: to check sizes, appearance, does it work, cheaper than making a mistake using acrylic, use as a template/development [net] 2 × 1 2 12(c)(i) Use of a line bender, strip heater or heat gun 1 Appropriate former 1 Method of retention 1 Technical accuracy 1 4 12(c)(ii) Acrylic is a smart material because: it can return to its original shape 1 when reheated 1 2 12(d)(i) Acrylic cement would be applied to both parts of the joint 1 The joint is clamped securely while the cement sets 1 Accept clamp together and apply cement along edge relying on capillary action 2 12(d)(ii) Two safety precautions: well-ventilated room, no naked flames, protective gloves worn, face mask worn, avoid contact with skin 2 × 1 2 2(e)(i) Suitable joint: mortise and tenon, biscuit or dowel named. Not butt 1 Award 0–3 for sketch dependent on clarity and technical accuracy 0–3 4 2(e)(ii) Template/pattern 1 2(e)(iii) Two saws: coping saw, Hegner saw, scroll saw or equivalent, band saw, jig saw 2 × 1 2 2(f) Some form of bracket, rods, box, recessed back, added base or other relevant solution Practical modification [0–2] Details of materials, sizes, constructions [0–2] 4

This question in 0445/31 Oct/Nov 2018

Q80 · Two designs of shelf units 0445/31 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

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Q81 · A length of wood marked to the required width 0445/32 Oct/Nov 2018

1 Fig. 1 shows a length of wood marked to the required width. waste edge A side 300 12 Fig. 1 (a) Name a tool, other than a pencil and steel rule, that could be used to mark the line A. … [1] (b) Name a plane that could be used to remove the waste. … [1]

2 marks

Mark scheme: Question Answer Marks 1(a) Marking gauge 1 1(b) Jack, smoothing, block 1

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Q82 · Complete the table below by naming each tool and describing a specific use for each 0445/32 Oct/Nov 2018

3 Complete the table below by naming each tool and describing a specific use for each. Tool Name Use [4]

4 marks

Mark scheme: 3 Dividers = 1, used to mark arcs/circles [on plastic/metal] = 1 4 Centre/dot punch = 1, make an indentation in metal before drilling = 1

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Q83 · Two pieces of wood that will be joined together using a biscuit joint 0445/32 Oct/Nov 2018

4 Fig. 3 shows two pieces of wood that will be joined together using a biscuit joint. B A Fig. 3 Draw on Fig. 3 to show how two biscuits could be used to join A to B. [3]

3 marks

Mark scheme: 4 2 slots drawn in A = 1, 2 slots drawn in B = 1, 2 biscuits drawn = 1 3

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Q84 · A pair of shin pads used by hockey players 0445/32 Oct/Nov 2018

7 Fig. 6 shows a pair of shin pads used by hockey players. The shin pads are made from a composite material. Fig. 6 (a) Name one composite material that could be used to make the shin pads. … [1] (b) Describe two properties of a composite material that makes it suitable for the shin pads. 1 … 2 … [2]

3 marks

Mark scheme: 7(a) Carbon fibre reinforced plastic [CFRP] 1 7(b) Good strength-weight ratio, lightweight, corrosion resistance, stiff, rigid, 2 good tensile strength, low density 2 × 1

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Q85 · Part of a leg and rail of a table and a knock-down (KD) fitting 0445/32 Oct/Nov 2018

9 Fig. 7 shows part of a leg and rail of a table and a knock-down (KD) fitting. rail rail leg leg Fig. 7 Draw on Fig. 7 to show how the knock-down (KD) fitting could be fitted to the leg and rail to make a strong joint. [3]

3 marks

Mark scheme: 9 Screw thread shown inserted into leg [left-to-right] = 1 3 Barrel shown inserted into side of rail = 1 Correct positioning/distances = 1

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Q86 · Views of a toothbrush holder made from 4 mm thick acrylic 0445/32 Oct/Nov 2018

11 Fig. 9 shows views of a toothbrush holder made from 4 mm thick acrylic. 20 support A 100 20 130 180 90 70 end view with end removed Fig. 9 (a) Fig. 10 shows a sheet of acrylic on which the development (net) of the support will be marked out. Corner A is shown in Figs. 9 and 10. A not to scale Fig. 10 (i) Draw on Fig. 10 to show all the bend lines. [4] (ii) From the list below circle one item of equipment used to mark the bend lines on the surface of the acrylic. lead pencil biro scriber felt marker marking knife [1] (b) Use sketches and notes to show how the development (net) could be bent to shape. Include the following details: • the method of softening the acrylic • the method of producing an accurate shape [5] (c) Fig. 11 shows one end marked out, ready to be cut to shape. waste 130 90 Fig. 11 Use sketches and notes to show how the waste could be removed and the rounded corners produced. Name all the tools and equipment used. [4] (d) The edges of the ends and support will be self-finished to a high quality before the parts are joined together. (i) Name the method of filing used to make the edges smooth. … [1] (ii) Explain why two different grades of wet and dry (silicon carbide) paper would be used when self-finishing the edges. … … … [2] (e) The support will be joined to the ends by using acrylic cement. (i) Describe how the acrylic cement would be applied and how the parts would be held together while the acrylic cement sets. … … … [2] (ii) State why it is important to work in a well-ventilated area when using acrylic cement. … [1] (f) Use sketches and notes to show how the toothbrush holder could be modified so that a tube of toothpaste could be stored. Describe how the modification could be made in a school workshop. Name all tools and equipment used. [5]

25 marks

Mark scheme: 11(a)(i) 4 bend lines drawn 4 × 1 4 11(a)(ii) Felt marker 1 11(b) Acrylic shown above strip heater/line bender or hot air gun or in an oven0–2 5 Use of a shaped former or 2 separate blocks 0–2 Technical accuracy of details 0–1 11(c) Waste removed: use of coping saw, Hegner or equivalent, Scroll, band = 1 4 Acrylic held appropriately: vice or clamped to bench = 1 Rounded corners: use of flat/hand and round/rat tail or half-round files = 1 Technical accuracy of details = 1 11(d)(i) Draw filing 1 11(d)(ii) Different grades means a finer grade can be used to remove the scratches 2 produced by the previous coarser grade 2 × 1 11(e)(i) Acrylic cement applied to both parts = 1 2 Clamped using G cramps, sash cramps, vice or weights = 1 11(e)(ii) Fumes given off by acrylic cement can be harmful to user 1 11(f) Practical idea: additional storage joined to appropriate part of holder 0–2 5 Details of appropriate processes 0–2 Technical accuracy of named tools and equipment 0–1

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Q87 · An incomplete design of a desk 0445/32 Oct/Nov 2018

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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Q88 · A wall-mounted adjustable shelving system 0445/32 Oct/Nov 2018

13 Fig. 16 shows a wall-mounted adjustable shelving system. metal support rods Ø8 shelves 700 × 300 × 15 uprights 1200 × 50 × 25 Fig. 16 (a) Name suitable specific materials for the parts of the shelving system: • hardwood uprights … • metal support rods … • manufactured board shelves … [3] (b) The manufactured board used for the shelves is veneered. (i) Give one benefit of covering the manufactured board with veneer. … [1] (ii) Give one drawback of covering the manufactured board with veneer. … [1] (c) Fig. 17 shows part of one upright with the centres for Ø8 holes marked out. 25 50 50 40 centres for Ø8 drilled holes Fig. 17 Use sketches and notes to show a design for a jig to allow three holes to be drilled accurately. Include details of materials used. [5] (d) Fig. 18 shows details of one metal support rod. 60 350 60 Fig. 18 Use sketches and notes to show how the two bends in the support could be produced. [4] (e) The metal support rods will have a clear lacquer finish. Describe how the metal could be prepared before applying clear lacquer. … … … … [3]

17 marks

Mark scheme: 13(a) Hardwood uprights: wide variety of suitable hardwoods = 1 3 Metal rod: mild steel, stainless steel, aluminium, brass = 1 Manufactured board: MDF, chipboard, plywood = 1 13(b)(i) Benefit: gives appearance of solid wood, more attractive 1 Drawback: more easily damaged, veneer could peel off, less hardwearing 13(b)(ii) Drawback: more easily damaged, veneer could peel off, less hardwearing 1 13(c) Template with 3 holes drilled-no location = 1 5 Template + 1 side located = 2 Template + 2 sides located = 3 Template + 2 sides + end located = 4 Specific named material/s appropriate = 1 13(d) Use of vice to support the metal rod = 1 4 Method of force: hammer and scrap wood or mallet = 1 Check correct angle of lower bend with former = 1 90° angle checked against vice jaw/wooden former = 1 13(e) Stages include: degrease metal if necessary. 3 Use steel wool [fine grade] or wet and dry [silicon carbide] paper [2 grades]. Use of polishing mop and appropriate compound to produce quality finish. 13(f)(i) Marking and cutting gauges, marking knife, try square 1 13(f)(ii) Tenon saw, dovetail [tenon] saw 1 13(g) Threaded rod = 1 4 Nut screws onto threaded rod = 1 Nut inset into shelf to become hidden = 1 Technical accuracy of method 0–1 13(h) Adjustable height of shelves, good use of relatively few materials, simple 2 design, straightforward to manufacture, easy to adjust height, easy to maintain/clean 2 × 1

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Q89 · Name the two standard metal sections shown below 0445/33 Oct/Nov 2018

1 Name the two standard metal sections shown below. … … [2]

2 marks

Mark scheme: 1 Round rod, bar 1 Hexagonal bar 1 2

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Q90 · Name the type of tools shown in Fig 0445/33 Oct/Nov 2018

2 (a) Name the type of tools shown in Fig. 1. Fig. 1 … [1] (b) Give one reason why the tools in Fig. 1 can remove wood quickly and efficiently. … [1]

2 marks

Mark scheme: 2(a) Surform/rasp 1 2(b) The teeth have a ‘cheese grater’ shape, sharp edges, very coarse teeth 1

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Q91 · Three different holes drilled before woodscrews can be used to join the two pieces of wood 0445/33 Oct/Nov 2018

3 Fig. 2 shows three different holes drilled before woodscrews can be used to join the two pieces of wood. Each hole has a different purpose. woodscrew A B C Fig. 2 Name each type of hole, A, B and C. A … B … C … [3]

3 marks

Mark scheme: 3 A countersink 1 B clearance 1 C pilot 1 3

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Q92 · Complete the table below by naming a different material that matches each of the… 0445/33 Oct/Nov 2018

4 Complete the table below by naming a different material that matches each of the descriptions. Material Description hard plastic, wide range of colours, used to make car rear light clusters manufactured board made by gluing layers together at 90° to each other close-grained hardwood used to make mallet heads and children’s toys an alloy of copper and zinc, metal with corrosion resistance, electrical conductivity [4]

4 marks

Mark scheme: 4 Hard plastic: acrylic, polystyrene 1 Manufactured board: plywood 1 Close-grained hardwood: beech, hickory, box, maple, lignum vitae 1 Corrosion resistant metal: brass 1 4

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Q93 · An incomplete drawing of a marking gauge 0445/33 Oct/Nov 2018

5 Fig. 3 shows an incomplete drawing of a marking gauge. Fig. 3 Complete the drawing of the marking gauge by adding: (a) the thumbscrew; (b) the pin or spur. [2]

2 marks

Mark scheme: 5(a) Thumbscrew shown 1 5(b) Pin or spur shown 1 Qu uestion Answer Mar rks

This question in 0445/33 Oct/Nov 2018

Q94 · Two sit-on toys used by children 0445/33 Oct/Nov 2018

7 Fig. 5 shows two sit-on toys used by children. Toy A is made from wood and toy B from plastic. A B Fig. 5 Describe one benefit to the user of making a sit-on toy from: wood … plastic … [2]

2 marks

Mark scheme: Qu 7 Wood Plasti uestion d: hard wearing, ic: colour will no stable, solid, no t chip, lightweigh ot easily broken ht, moulded sha apes safe, comfo Answer ortable, water re sistant, easily cl leaned 1 1 Mar 2 rks

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Q95 · A wooden frame construction, a hardboard corner plate and a corrugated fastener 0445/33 Oct/Nov 2018

8 Fig. 6 shows a wooden frame construction, a hardboard corner plate and a corrugated fastener. A 80 B 80 hardboard corner plate 15 25 corrugated fastener Fig. 6 Draw on Fig. 6 to show how the frame construction could be strengthened by means of: (a) the hardboard corner plate at A; [1] (b) the corrugated fastener at B. [1]

2 marks

Mark scheme: Qu 8(a) Hardb 8(b) Metal uestion board corner pla l fastener in corr ate in correct pos rect position sition [not inside e frame] Answer Mar 1 1 rks

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Question 96 0445/33 Oct/Nov 2018

11 Fig. 9 shows a storage unit. A printer will be placed on top of the unit, which will be positioned under a desk. The unit has shelves that will be used to store printer paper. 350 450 top 500 end shelf not all dimensions are given Fig. 9 (a) An incomplete parts list for the storage unit is shown below. Complete the parts list. Number Part Length × width × thickness Material required Top 1 450 × … × 19 Veneered chipboard Shelf 2 … × … × 19 Veneered chipboard End 2 … × 350 × 19 Veneered chipboard [4] (b) Give two advantages of using veneered chipboard rather than solid wood for the storage unit. 1 … 2 … [2] (c) Sketch and name a pre-manufactured component that would enable the storage unit to be moved about easily. [3] (d) Use sketches and notes to show how one shelf could be joined to one end using knock-down (KD) fittings. [4] (e) Fig. 10 shows part of the top of the storage unit. veneered surface Fig. 10 Use sketches and notes to show how a solid wood lipping could be applied to one edge. [3] (f) Use sketches and notes to show a modification to the storage unit so that a quantity of paper clips, pens, pencils and a 300 mm plastic rule could be stored safely. Include details of materials, constructions and fittings used. [5] (g) There is a possibility that the paper stored on the shelves could fall through the back of the unit. Use sketches and notes to show how this could be prevented. Include details of materials, constructions and fittings used. [4]

25 marks

Mark scheme: 11(a) Part Number reqd. Length × width × thickness Material Top 1 450 × 350 × 19 Veneered chipboard Shelf 2 332 – 391 × 300 – 330 × 19 Veneered chipboard End 2 481 – 486 × 350 × 19 Veneered chipboard 4 11(b) Two advantages: cheaper, does not warp/shrink, more readily available, accept environmental advantages, large sheets 2 × 1 2 11(c) Component named: castor, skid 1 Sketch 0–2 dependent on technical accuracy 0–2 3 11(d) KD fitting: corner/modesty block drawn [Accuracy] 0–2 Appropriate number: maximum three under shelf Method of fixing to unit 1 4 11(e) Solid lipping appropriate width and thickness shown 1 Method of fixing: use of adhesive or pin and glue 1 Technical accuracy 1 If iron-on lipping is used award one mark maximum 3 11(f) Practical idea: some form of ‘tidy’ clearly drawn 0–2 Position of modifications clearly shown 1 Details of materials, constructions and fittings 0–2 5 11(g) Method includes addition of a rail, back or ‘tray’: practical idea 0–2 Details of materials, constructions and fittings [screws, dowels, nails and use of an adhesive] 0–2 4

This question in 0445/33 Oct/Nov 2018

Q97 · A headphone stand made from 5 thick acrylic 0445/33 Oct/Nov 2018

12 Fig. 11 shows a headphone stand made from 5 thick acrylic. The headphone stand has two main parts: a base and a support. support headphones base 100 overall height 230 Fig. 11 (a) Give two items of research that would need to be considered when designing the headphone stand. 1 … 2 … [2] (b) Give two reasons why you would make a model of the headphone stand before making it from acrylic. 1 … 2 … [2] (c) Fig. 12 shows the base of the headphone stand made from acrylic. A Fig. 12 (i) Use sketches and notes to show how the bend at A could be formed. [4] (ii) Explain why acrylic can be considered to be a ‘smart’ material. … … … [2] (d) (i) Describe how the support could be joined permanently to the base of the headphone stand using acrylic cement. … … [2] (ii) Give two safety precautions that must be taken when using acrylic cement. 1 … 2 … [2] (e) Fig. 13 shows a different design of headphone stand made from hardwood. support 200 high × 15 thick A base 100 × 100 × 15 Fig. 13 (i) Sketch and name a suitable joint used to join the support to the base at A in Fig. 13. [4] (ii) Fig. 14 shows the shape of the support drawn on paper and glued onto a block of hardwood. Fig. 14 Give the correct term for the paper shape. … [1] (iii) Name two types of saw that could be used to cut out the shape. 1 … 2 … [2] (f) Use sketches and notes to show a modification to either the acrylic headphone stand or the hardwood headphone stand that would allow the cable to be stored neatly. Include details of materials, sizes and constructions used. [4]

25 marks

Mark scheme: 12(a) Two items of research: sizes of headphones weight of headphones, existing designs, location. Accept individual dimensions for lead, width of headphone, depth, etc. 2 × 1 2 12(b) Two reasons: to check sizes, appearance, does it work, cheaper than making a mistake using acrylic, use as a template/development [net] 2 × 1 2 12(c)(i) Use of a line bender, strip heater or heat gun 1 Appropriate former 1 Method of retention 1 Technical accuracy 1 4 12(c)(ii) Acrylic is a smart material because: it can return to its original shape 1 when reheated 1 2 12(d)(i) Acrylic cement would be applied to both parts of the joint 1 The joint is clamped securely while the cement sets 1 Accept clamp together and apply cement along edge relying on capillary action 2 12(d)(ii) Two safety precautions: well-ventilated room, no naked flames, protective gloves worn, face mask worn, avoid contact with skin 2 × 1 2 2(e)(i) Suitable joint: mortise and tenon, biscuit or dowel named. Not butt 1 Award 0–3 for sketch dependent on clarity and technical accuracy 0–3 4 2(e)(ii) Template/pattern 1 2(e)(iii) Two saws: coping saw, Hegner saw, scroll saw or equivalent, band saw, jig saw 2 × 1 2 2(f) Some form of bracket, rods, box, recessed back, added base or other relevant solution Practical modification [0–2] Details of materials, sizes, constructions [0–2] 4

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Q98 · Two designs of shelf units 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

Q99 · Two different methods of filing metal 0445/31 May/June 2019

2 Fig. 1 shows two different methods of filing metal. cross filing draw filing Fig. 1 Describe the purpose of each method of filing. Cross filing … … Draw filing … [2]

2 marks

Mark scheme: 2 Cross filing: quick removal of waste 1 Draw filing: finishing, smoothing 1 2

This question in 0445/31 May/June 2019

Q100 · Complete the drawing below to show an exploded view of a stopped housing joint 0445/31 May/June 2019

3 Complete the drawing below to show an exploded view of a stopped housing joint. [3]

3 marks

Mark scheme: 3 Award 0–3 dependent on technical accuracy. Housing shown correct depth =1, stop on ‘shelf’ =1, stop on vertical side =1. 3 piece only =1, through housing =1

This question in 0445/31 May/June 2019

Q101 · A small dish made from plastic 0445/31 May/June 2019

4 Fig. 2 shows a small dish made from plastic. The dish has been vacuum formed. Fig. 2 (a) The former used to vacuum form the dish could be made from hardwood or MDF. Give two advantages of making the former from MDF rather than hardwood. 1 … 2 … [2] (b) Describe two features of the design of the former to ensure that the dish will be vacuum formed successfully. 1 … 2 … [2]

4 marks

Mark scheme: 4(a) 2 advantages: no grain markings, more stable, easier to shape, cheaper, smooth surfaces 2 × 1 2 Do NOT accept environmentally friendly 4(b) 2 features: draft angle, rounded edges/corners, depth of former 2 × 1 2 Do NOT accept air holes, heat resistant

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Question 102 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

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Q103 · A kitchen roll holder made from acrylic 0445/31 May/June 2019

6 Fig. 4 shows a kitchen roll holder made from acrylic. kitchen roll Fig. 4 Explain how the designer has used the flexible property of acrylic in the design of the kitchen roll holder. … …

2 marks

Mark scheme: 6 Acrylic has a flexible property that allows the material to be bent 1 Returns to original shape 1 2

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Q104 · A basic design for a desk tidy made in a school workshop 0445/31 May/June 2019

7 Fig. 5 shows a basic design for a desk tidy made in a school workshop. The desk tidy is made from 4 mm thick acrylic. Fig. 5 Use sketches and notes to show one functional improvement to the design of the desk tidy. [2]

2 marks

Mark scheme: 7 Functional improvement: some form of ‘second’ base or applied strips to prevent the pens, pencils sliding about, extra compartments for equipment, handles to carry 0–2 2 Marks awarded for practical design idea clearly drawn. Accept holes in base even if shown same size as shown in desk tidy Technical detail not required.

This question in 0445/31 May/June 2019

Q105 · Part of a garden tool rack 0445/31 May/June 2019

8 Fig. 6 shows part of a garden tool rack. Fig. 6 (a) Indicate clearly on Fig. 6 one example of ‘short grain’. [1] (b) Explain why ‘short grain’ is a problem that occurs only in solid wood and not in manufactured boards. … … … [2]

3 marks

Mark scheme: 8(a) Short grain indicated clearly in 4 areas at top of rack 1 8(b) Short grain occurs in solid woods that have grain structure 1 Manufactured boards are constructed to minimise grain weakness 1 2

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Q106 · A round tube that will be joined to a metal strip made from mild steel 0445/31 May/June 2019

9 Fig. 7 shows a round tube that will be joined to a metal strip made from mild steel. tube Ø20 strip 20 × 3 Fig. 7 Add sketches and notes to Fig. 7 to show how they could be joined together. Your method must allow the tube and strip to be taken apart. [3]

3 marks

Mark scheme: 9 Principle/concept sound 1 For example: Use of lugs and plugs, inserted plates Technical details 0–2 3

This question in 0445/31 May/June 2019

Q107 · Two different wall brackets 0445/31 May/June 2019

10 Fig. 8 shows two different wall brackets. 180 230 bracket A fabricated from softwood bracket B moulded plastic Fig. 8 (a) Describe one quality control check that would be carried out during the manufacture of bracket A. … … [1] (b) Describe one quality control check, different to that in part (a), that would be carried out during the manufacture of bracket B. … … [1]

2 marks

Mark scheme: 10(a) Checks include: measurements of wood cut to length, positions for joints, squareness when pinned and glued, removal of glue, parts attached securely, holes in correct position 1 carried out during the manufacture. 10(b) Checks include: dimensions of product after moulding, visual check for blemishes/marks/imperfections, no sharp edges, holes in correct position 1

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Q108 · Views of a child’s counting toy 0445/31 May/June 2019

11 Fig. 9 shows views of a child’s counting toy. When the discs are stacked on the rod, the collar slides down on top of the discs to show the number of discs stacked. Ø5 rod collar 10 9 8 upright 7 discs 6 5 4 base 3 2 1 disc Ø40 × 15 Fig. 9 (a) Fig. 10 shows the base of the counting toy. The base is made from beech. slot 40 × 12 15 centre for hole 150 100 Fig. 10 (i) Give two reasons why beech is commonly used to make children’s toys. 1 … 2 … (ii) Name three marking out tools, other than a pencil, that could be used to mark out the centre for the hole and the slot. 1 … 2 … 3 … [3] (iii) Describe how the slot could be cut out 10 mm deep to take the upright. … … … … … [3] (b) The Ø5 rod is made from non-ferrous metal. (i) Name a suitable non-ferrous metal for the rod. … [1] (ii) Give one reason why a non-ferrous metal could be more suitable than a ferrous metal for the rod. … [1] (c) Use sketches and notes to show how ten identical wooden discs could be made in a school workshop. Show clearly how the holes in each disc could be produced accurately. [5] (d) The discs could also be made from plastic and produced by injection moulding. Give two advantages of using the injection moulding process to produce plastic discs rather than making them from wood. 1 … 2 … [2] (e) Fig. 11 shows a length of beech that will be used to make the four parts of the collar. 25 45 collar 6 Fig. 11 Use sketches and notes to show how the collar could be constructed. Name the tools and equipment used to construct the collar. [4] (f) Describe how CAD/CAM could be used to produce the numbers on the upright. … … … … … … [4]

25 marks

Mark scheme: 11(a)(i) Hardwearing, tough, close grain, does not split easily, good finish, doesn’t chip easily, can be bent to shape, non-toxic, aesthetically pleasing 2 × 1 2 Do NOT accept strong or durable, cheap, easy to work, lightweight 11(a)(ii) 3 marking out tools: steel rule, try square, engineers try square, marking knife, mortise/marking gauges 3 × 1 3 Do NOT accept metalworking tools or any form of felt tip/marker pens 11(a)(iii) Slot cut out: chisel and mallet, mortise machine or drilled holes chiselled out, plunge router, check depth of holes 2 × 1 stages Award 1 mark for technical accuracy 1 3 For example: router or mortise machine =1 + details can = 3 marks 11(b)(i) Brass, aluminium, copper, duralumin, gilding metal 1 11(b)(ii) Can provide an attractive clear finish that does not corrode/rust 1 Accept takes a long time to corrode 11(c) Method 1: Between centres wood turning. Award 0–5 marks for each relevant detail in process including: preparing the wood before setting up, correct set up, use of gouges/scrapers to make round, parting off. Method 2: Make each disc individually by marking out a circle, cutting to shape and finishing on disc sander, hole drilled, method of achieving identical discs 5 × 1 Method 3: Use of hole saw. Accurate sketch of hole saw and mandrel 0–2, fitted into drill 1, wood held securely 1, hole drilled and disc removed 1. 5 Question Answer Marks Guidance 11(d) 2 advantages: quicker process [after mould has been produced], repetitive consistency/accuracy, smoother finish, inherent colours, less waste. 2 × 1 2 Cheaper must be qualified Do NOT accept easier to do 11(e) Lengths marked out 1 Lengths cut 1 Sides joined appropriately: pin and glue, glued butt, mitre, finger, lapped 0–2 4 Do NOT accept dowel 11(f) 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 set up, tool parameters. 0–2 4 Reward answers that demonstrate genuine knowledge of CAD-CAM. Accept laser cutter = 1 mark Details required re set up etc. 4 × 1

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Q109 · An incomplete design for a reading lamp to be made in a school workshop 0445/31 May/June 2019

12 Fig. 12 shows an incomplete design for a reading lamp to be made in a school workshop. The arms, base and supports are made from hardwood. lamp shade arm arm support base Fig. 12 (a) Fig. 13 shows details of the base and supports. 15 60 15 150 150 Fig. 13 Use sketches and notes to show how the base and supports could be joined permanently. (b) Fig. 14 shows views of parts of both arms of the reading lamp. centre for fitting 34 15 Fig. 14 (i) Draw on Fig. 14 to show a metal fitting that could be used to join the arms together and allow them to be adjusted and locked in position. Add two important sizes to the fitting. [4] (ii) The fitting will be chrome plated. Give two benefits of chrome plating metal fittings. 1 … 2 … [2] (c) Fig. 15 shows one of the four sides that will be joined together to make the lamp shade. The sides are made from 3 mm thick veneered plywood. 80 120 120 Fig. 15 (i) Give two advantages of using 3 mm thick veneered plywood rather than solid wood for the sides of the lamp shade. 1 … 2 … [2] (ii) Use sketches and notes to show how the sides could be joined together to form the lamp shade. Consider carefully that the veneered plywood is only 3 mm thick. [4] (d) The lamp shade shown in Fig. 15 could be made from brass. State two properties of brass that make it suitable for the lamp shade. 1 … 2 … [2] (e) Fig. 16 shows a template of the lamp shade glued onto a sheet of 1 mm thick brass. B template A brass sheet Fig. 16 Use sketches and notes to show how the lamp shade could be made from one piece of brass. Include the method of: • cutting out the shape • bending the brass to shape • soldering edge A to edge B • cleaning and finishing. [8]

25 marks

Mark scheme: 12(a) Methods of joining include: dowel, mortise and tenon, housing, biscuit, pin and glue, screw from underneath base. Appropriate construction named 1 Sketch showing constructional details 0–2 3 12(b)(i) Metal fitting: nut and bolt or screw drawn clearly 0–2 2 important sizes: length, diameter of bolt or screwthread or head 2 × 1 4 Do NOT accept rivet Length of screw/bolt must be minimum 35 mm 12(b)(ii) 2 benefits: attractive appearance, prevents corrosion/tarnishing, more hardwearing 2 × 1 2 12(c)(i) 2 advantages: 3 mm thick plywood is more practical than solid wood, more stable, stronger construction less likely to split, easier to work with 2 × 1 2 12(c)(ii) 3 mm thick plywood needs corner reinforcement: use of small blocks/strips glued to the inside. Use of cloth tape, GRP, ‘laced’ Correctly named construction 1 Technical accuracy of construction shown 0–2 One added detail: for example: clamping, holding, gluing 1 4 Question Answer Marks Guidance 12(d) 2 properties of brass: corrosion resistant, easily joined, attractive, malleable, bend to shape, reflects 2 × 1 2 12(e) Cutting out the shape: use of tinsnips, guillotine 0–2 Bending to shape: use of folding bars, wooden former 0–2 Soldering edges: hard silver soldering details 0–2 Cleaning and finishing 0–2 8 e.g. method of holding, securing / cutting e.g. use of mallet, scrap wood, vice e.g. type of solder, flux, blowtorch e.g. use of wet and dry, polishing mop and compound, Brasso. Do NOT accept emery cloth or wire wool

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Q110 · Views of a children’s play table 0445/31 May/June 2019

13 Fig. 17 shows views of a children’s play table. The height of the table can be adjusted by means of sleeves that fit over the ends of the legs. The table is produced as flat-pack for self-assembly. A end rail long rail leg sleeve Fig. 17 (a) (i) Name a suitable manufactured board for the table top. … [1] (ii) Name a suitable softwood for the legs and rails. … [1] (b) Describe two benefits of covering the manufactured board used for the table top with melamine sheet. 1 … 2 … [2] (c) (i) Explain why the designer has made the table height adjustable. … … … [2] (ii) The height of the table can be adjusted by means of sleeves that fit over the ends of the legs. The sleeve shown below will be produced by the extrusion process. 150 65 22 Fig. 18 shows part of an extrusion moulding machine. Add notes to Fig. 18 to describe the extrusion process. Fig. 18 [3] (iii) The height of the table can be adjusted by moving the sleeve up or down and locking it in position. Use sketches and notes to show how the table could be set at three different heights. Include details of any fittings and materials used. [4] (d) The legs and rails are made from the same size section softwood, 60 × 20. Explain one benefit to the manufacturer of using the same size section softwood. … … … [2] (e) The parts of the table shown in Fig. 17 will be assembled using dowels and screws. (i) Use sketches and notes to show how screws could be used to join two rails at A. [3] (ii) Use sketches and notes to show how dowels could be used to join the table top to the rails. [3]

21 marks

Mark scheme: 13(a)(i) Plywood, blockboard, MDF, chipboard, laminboard 1 Do NOT accept hardboard 13(a)(ii) Pine, redwood, deal, parana pine, whitewood, spruce, cedar, scots pine 1 13(b) 2 benefits: attractive finish, hardwearing, stain resistant, heat resistant, easier to clean, hygienic, smooth surface, protects, no splinters, prevents scratches 2 × 1 2 13(c)(i) Adjustable height: children using table are different heights, children will grow 2 Reward any valid reasoning. 13(c)(ii) Granules fed into hopper 1 Rotating feed screw takes the granules through heating chamber to melt 1 Screw forces plastic through die 1 3 Do NOT accept labels without description. For maximum 3 marks the 1st stage [granules in hopper] and the 3rd stage [plastic forced through die] must be noted otherwise maximum 2 marks 13(c)(iii) Adjustable positions 1 Pin, peg or dowel 1 Locking method 1 Notes provide a description of how it works 1 4 Accept existing ‘base’ position as 1st position. Method involves 2 or 3 holes drilled in sleeve and 1 in leg or vice versa. Question Answer Marks Guidance 13(d) Benefit of same section softwood: quicker production time 1 Justification since there is less machine setting up required 1 2 Award 1 mark maximum for ‘cheaper by buying in bulk’. 13(e)(i) Sketch showing 2 screws used 1 Details of screws: length, gauge [diameter], type of head, spacing 2 × 1 3 Ignore use of adhesive Accept any 2 from 3 details 13(e)(ii) Sketch showing minimum of 2 dowels per rail 1 Details of dowels: length, diameter, spacing 2 × 1 3 Accept any 2 from 3 details 13(f) Benefits of self-assembled products to manufacturer: quicker production time means less costs, lower prices available, more profits, less storage space required 0–2 2 13(g) Functional improvement: lipping to top to prevent items falling off, dedicated space/s into table top for storage, rounded corners for safety. 0–2 2 Award marks for a practical design idea clearly communicated.

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Q111 · Complete the table by stating the manufacturing process used to make each product 0445/32 May/June 2019

2 Complete the table by stating the manufacturing process used to make each product. Product Manufacturing process metal model toy vehicle plastic tubes wooden chair legs [3]

3 marks

Mark scheme: 2 Metal models: die casting 1 Plastic tubes: extrusion 1 Wooden chair: lamination, steam bending 1 3 Not casting.

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Q112 · A length of veneered chipboard marked out, ready to be cut into four pieces 0445/32 May/June 2019

3 Fig. 2 shows a length of veneered chipboard marked out, ready to be cut into four pieces. 200 1000 15 mm thick 10 mm waste Fig. 2 (a) Give one reason why the lines would be marked out using a marking knife rather than a pencil. … [1] (b) Give one reason why 10 mm waste has been allowed between the marked lengths. … [1]

2 marks

Mark scheme: 3(a) To cut the fibres of the wood to prevent splitting 1 3(b) To allow for the thickness of saw blade, to leave a small amount to finish square, allow tolerance for sawing, allow margin for error, allows to finish with sanding disc 1

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Q113 · Name the three standard metal sections shown below 0445/32 May/June 2019

4 Name the three standard metal sections shown below. … … … [3]

3 marks

Mark scheme: 4 Angle/angle iron. Round tube. Flat or strip/flat strip. 3 × 1 3

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Q114 · Complete the drawing below to show a finger (comb) joint 0445/32 May/June 2019

5 Complete the drawing below to show a finger (comb) joint. [3]

3 marks

Mark scheme: 5 At least four fingers 1 Equal spacing 1 Accurate drawing of projected lines to show joint 1 3

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Q115 · Composite materials are made by combining materials with different properties to make a… 0445/32 May/June 2019

6 Composite materials are made by combining materials with different properties to make a material with more useful properties. Name two composite materials. 1 … 2 … [2]

2 marks

Mark scheme: 6 CFRP, carbon fibre, GRP, glass fibre, Kevlar, plywood, blockboard, laminboard, MDF, hardboard, chipboard 2 × 1 2

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Q116 · Hardwood strips being glued together to make a chopping board 0445/32 May/June 2019

8 Fig. 3 shows hardwood strips being glued together to make a chopping board. chopping board scrap wood cramp Fig. 3 (a) Name the type of cramps used. … [1] (b) Give two reasons why scrap wood is used between the cramps and the chopping board. 1 … 2 … [2]

3 marks

Mark scheme: 8(a) Sash 1 8(b) To prevent damage to the hardwood strips, to distribute pressure evenly 2 × 1 2

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Q117 · A toast rack made from stainless steel 0445/32 May/June 2019

9 Fig. 4 shows a toast rack made from stainless steel. Fig. 4 Give two reasons why stainless steel is a suitable material for a toast rack. 1 … 2 … [2]

2 marks

Mark scheme: 9 Attractive, hardwearing, does not corrode when in contact with water, easy to clean, does not mark easily, easily bent to shape 2 × 1 2 Accept any valid reasons Durable must be qualified: will last for years, will not deform easily.

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Question 118 0445/32 May/June 2019

10 Fig. 5 shows a wooden chair. legs 30 × 30 Fig. 5 Use sketches and notes to show how the chair could be modified so that it can be linked, side by side, to an identical chair and could be easily separated for stacking. [3]

3 marks

Mark scheme: 10 Practical idea: some sort of ‘hook’ or interlocking components 0–2 Added notes to expand on sketch 0–1 3 Pegs, pins, dowels = 1mark as they can be pulled apart. Technical details not required.

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Q119 · An incomplete design of a child’s novelty clock 0445/32 May/June 2019

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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Q120 · Views of a storage unit designed to hold a tablet, mobile phone and remote control 0445/32 May/June 2019

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.

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Q121 · A child’s ride-on toy made mainly from wood 0445/32 May/June 2019

13 Fig. 13 shows a child’s ride-on toy made mainly from wood. A Ø8 axles Ø100 wooden wheel B Fig. 13 (a) Fig. 14 shows details of part A and the hardwood from which it is made. A 150 100 25 Fig. 14 Use sketches and notes to show how part A could be produced from the hardwood shown. Include details of marking out. Name all the tools and equipment used. [5] (b) Give two features of the ride-on toy that make it safe for children to use. 1 … 2 … [2] (c) Fig. 15 shows one wheel marked out ready to be shaped on a woodturning lathe. wheel Ø100 × 15 waste Fig. 15 (i) Explain why the corners would be removed before the wood is set up on the woodturning lathe. … … … [2] (ii) Name two tools or items of equipment that could be used when making the wheels on a woodturning lathe. 1 … 2 … [2] (iii) Give two advantages of making the wheels from plywood rather than hardwood. 1 … 2 … [2] (d) Fig. 16 shows details of part B of the ride-on toy. Holes will be drilled to take the axles. axle B 50 32 axle Ø8 Fig. 16 (i) Use sketches and notes to show a design for a drilling jig to ensure the holes are drilled accurately. Name the material from which the jig is made. [5] (ii) The axles will be glued into part B. Use sketches and notes to show how one wooden wheel, Ø100 × 15, could be fitted onto an axle and allowed to rotate freely. [3]

21 marks

Mark scheme: 13(a) 4 main stages should include : Mark out shape 1 Cut off waste using a saw 1 Make flat and smooth by means of plane/glasspaper/disc sander, linisher 1 Rounded edge could be planed, glasspapered, filed, use of router + cutter 1 Tools/equipment named 1 5 only 13(b) Safety features include: rounded edges/corners, strong materials, strong constructions, anthropometric considerations of height off ground, reach from seat to handlebars, backrest to prevent falling backwards, no sharp/dangerous protrusions, stability of four wheels 2 × 1 2 Accept any valid safety features in the design of the ride-on toy 13(c)(i) To make it easier to start turning 1 Prevent the wood from splitting 1 2 Corners hitting the tool = 1 mark 13(c)(ii) Two tools include: scraper, gouge, outside calipers, glasspaper 2 × 1 2 Accept named lathe tools including tool rest, faceplate 13(c)(iii) Two advantages: plywood more stable, no grain considerations, less likely to split/break 2 × 1 2 Not cheaper, lighter 13(d)(i) Drilling jig matches shape of end with hole drilled 1 Locates against one side 1 Locates against two sides 1 Locates against three sides 1 Suitable specific material: mild/stainless steel, wide range of non-ferrous metal 1 5 Do not accept wood-based materials 13(d)(ii) Clearance hole larger than axle shown or stated 1 Free rotation: use of washer, bearing, ball race 1 Method of retention: ‘star’ washer, ‘cap’ 1 3 Axle is glued into wooden part B Axle can be made from wood or metal 13(e)(i) Injection moulding, blow moulding 1 13(e)(ii) Soldering, brazing, welding 1 Do not accept adhesives 13(e)(iii) Paint, dip-coated plastic, electroplating. 2 × 1 2 Do not accept lacquer

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Q122 · Two different methods of filing metal 0445/33 May/June 2019

2 Fig. 1 shows two different methods of filing metal. cross filing draw filing Fig. 1 Describe the purpose of each method of filing. Cross filing … … Draw filing … [2]

2 marks

Mark scheme: 2 Cross filing: quick removal of waste 1 Draw filing: finishing, smoothing 1 2

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Q123 · Complete the drawing below to show an exploded view of a stopped housing joint 0445/33 May/June 2019

3 Complete the drawing below to show an exploded view of a stopped housing joint. [3]

3 marks

Mark scheme: 3 Award 0–3 dependent on technical accuracy. Housing shown correct depth =1, stop on ‘shelf’ =1, stop on vertical side =1. 3 piece only =1, through housing =1

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Q124 · A small dish made from plastic 0445/33 May/June 2019

4 Fig. 2 shows a small dish made from plastic. The dish has been vacuum formed. Fig. 2 (a) The former used to vacuum form the dish could be made from hardwood or MDF. Give two advantages of making the former from MDF rather than hardwood. 1 … 2 … [2] (b) Describe two features of the design of the former to ensure that the dish will be vacuum formed successfully. 1 … 2 … [2]

4 marks

Mark scheme: 4(a) 2 advantages: no grain markings, more stable, easier to shape, cheaper, smooth surfaces 2 × 1 2 Do NOT accept environmentally friendly 4(b) 2 features: draft angle, rounded edges/corners, depth of former 2 × 1 2 Do NOT accept air holes, heat resistant

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Question 125 0445/33 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

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Q126 · A kitchen roll holder made from acrylic 0445/33 May/June 2019

6 Fig. 4 shows a kitchen roll holder made from acrylic. kitchen roll Fig. 4 Explain how the designer has used the flexible property of acrylic in the design of the kitchen roll holder. … …

2 marks

Mark scheme: 6 Acrylic has a flexible property that allows the material to be bent 1 Returns to original shape 1 2

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Q127 · A basic design for a desk tidy made in a school workshop 0445/33 May/June 2019

7 Fig. 5 shows a basic design for a desk tidy made in a school workshop. The desk tidy is made from 4 mm thick acrylic. Fig. 5 Use sketches and notes to show one functional improvement to the design of the desk tidy. [2]

2 marks

Mark scheme: 7 Functional improvement: some form of ‘second’ base or applied strips to prevent the pens, pencils sliding about, extra compartments for equipment, handles to carry 0–2 2 Marks awarded for practical design idea clearly drawn. Accept holes in base even if shown same size as shown in desk tidy Technical detail not required.

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Q128 · Part of a garden tool rack 0445/33 May/June 2019

8 Fig. 6 shows part of a garden tool rack. Fig. 6 (a) Indicate clearly on Fig. 6 one example of ‘short grain’. [1] (b) Explain why ‘short grain’ is a problem that occurs only in solid wood and not in manufactured boards. … … … [2]

3 marks

Mark scheme: 8(a) Short grain indicated clearly in 4 areas at top of rack 1 8(b) Short grain occurs in solid woods that have grain structure 1 Manufactured boards are constructed to minimise grain weakness 1 2

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Q129 · A round tube that will be joined to a metal strip made from mild steel 0445/33 May/June 2019

9 Fig. 7 shows a round tube that will be joined to a metal strip made from mild steel. tube Ø20 strip 20 × 3 Fig. 7 Add sketches and notes to Fig. 7 to show how they could be joined together. Your method must allow the tube and strip to be taken apart. [3]

3 marks

Mark scheme: 9 Principle/concept sound 1 For example: Use of lugs and plugs, inserted plates Technical details 0–2 3

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Q130 · Two different wall brackets 0445/33 May/June 2019

10 Fig. 8 shows two different wall brackets. 180 230 bracket A fabricated from softwood bracket B moulded plastic Fig. 8 (a) Describe one quality control check that would be carried out during the manufacture of bracket A. … … [1] (b) Describe one quality control check, different to that in part (a), that would be carried out during the manufacture of bracket B. … … [1]

2 marks

Mark scheme: 10(a) Checks include: measurements of wood cut to length, positions for joints, squareness when pinned and glued, removal of glue, parts attached securely, holes in correct position 1 carried out during the manufacture. 10(b) Checks include: dimensions of product after moulding, visual check for blemishes/marks/imperfections, no sharp edges, holes in correct position 1

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Q131 · Views of a child’s counting toy 0445/33 May/June 2019

11 Fig. 9 shows views of a child’s counting toy. When the discs are stacked on the rod, the collar slides down on top of the discs to show the number of discs stacked. Ø5 rod collar 10 9 8 upright 7 discs 6 5 4 base 3 2 1 disc Ø40 × 15 Fig. 9 (a) Fig. 10 shows the base of the counting toy. The base is made from beech. slot 40 × 12 15 centre for hole 150 100 Fig. 10 (i) Give two reasons why beech is commonly used to make children’s toys. 1 … 2 … (ii) Name three marking out tools, other than a pencil, that could be used to mark out the centre for the hole and the slot. 1 … 2 … 3 … [3] (iii) Describe how the slot could be cut out 10 mm deep to take the upright. … … … … … [3] (b) The Ø5 rod is made from non-ferrous metal. (i) Name a suitable non-ferrous metal for the rod. … [1] (ii) Give one reason why a non-ferrous metal could be more suitable than a ferrous metal for the rod. … [1] (c) Use sketches and notes to show how ten identical wooden discs could be made in a school workshop. Show clearly how the holes in each disc could be produced accurately. [5] (d) The discs could also be made from plastic and produced by injection moulding. Give two advantages of using the injection moulding process to produce plastic discs rather than making them from wood. 1 … 2 … [2] (e) Fig. 11 shows a length of beech that will be used to make the four parts of the collar. 25 45 collar 6 Fig. 11 Use sketches and notes to show how the collar could be constructed. Name the tools and equipment used to construct the collar. [4] (f) Describe how CAD/CAM could be used to produce the numbers on the upright. … … … … … … [4]

25 marks

Mark scheme: 11(a)(i) Hardwearing, tough, close grain, does not split easily, good finish, doesn’t chip easily, can be bent to shape, non-toxic, aesthetically pleasing 2 × 1 2 Do NOT accept strong or durable, cheap, easy to work, lightweight 11(a)(ii) 3 marking out tools: steel rule, try square, engineers try square, marking knife, mortise/marking gauges 3 × 1 3 Do NOT accept metalworking tools or any form of felt tip/marker pens 11(a)(iii) Slot cut out: chisel and mallet, mortise machine or drilled holes chiselled out, plunge router, check depth of holes 2 × 1 stages Award 1 mark for technical accuracy 1 3 For example: router or mortise machine =1 + details can = 3 marks 11(b)(i) Brass, aluminium, copper, duralumin, gilding metal 1 11(b)(ii) Can provide an attractive clear finish that does not corrode/rust 1 Accept takes a long time to corrode 11(c) Method 1: Between centres wood turning. Award 0–5 marks for each relevant detail in process including: preparing the wood before setting up, correct set up, use of gouges/scrapers to make round, parting off. Method 2: Make each disc individually by marking out a circle, cutting to shape and finishing on disc sander, hole drilled, method of achieving identical discs 5 × 1 Method 3: Use of hole saw. Accurate sketch of hole saw and mandrel 0–2, fitted into drill 1, wood held securely 1, hole drilled and disc removed 1. 5 Question Answer Marks Guidance 11(d) 2 advantages: quicker process [after mould has been produced], repetitive consistency/accuracy, smoother finish, inherent colours, less waste. 2 × 1 2 Cheaper must be qualified Do NOT accept easier to do 11(e) Lengths marked out 1 Lengths cut 1 Sides joined appropriately: pin and glue, glued butt, mitre, finger, lapped 0–2 4 Do NOT accept dowel 11(f) 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 set up, tool parameters. 0–2 4 Reward answers that demonstrate genuine knowledge of CAD-CAM. Accept laser cutter = 1 mark Details required re set up etc. 4 × 1

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Q132 · An incomplete design for a reading lamp to be made in a school workshop 0445/33 May/June 2019

12 Fig. 12 shows an incomplete design for a reading lamp to be made in a school workshop. The arms, base and supports are made from hardwood. lamp shade arm arm support base Fig. 12 (a) Fig. 13 shows details of the base and supports. 15 60 15 150 150 Fig. 13 Use sketches and notes to show how the base and supports could be joined permanently. (b) Fig. 14 shows views of parts of both arms of the reading lamp. centre for fitting 34 15 Fig. 14 (i) Draw on Fig. 14 to show a metal fitting that could be used to join the arms together and allow them to be adjusted and locked in position. Add two important sizes to the fitting. [4] (ii) The fitting will be chrome plated. Give two benefits of chrome plating metal fittings. 1 … 2 … [2] (c) Fig. 15 shows one of the four sides that will be joined together to make the lamp shade. The sides are made from 3 mm thick veneered plywood. 80 120 120 Fig. 15 (i) Give two advantages of using 3 mm thick veneered plywood rather than solid wood for the sides of the lamp shade. 1 … 2 … [2] (ii) Use sketches and notes to show how the sides could be joined together to form the lamp shade. Consider carefully that the veneered plywood is only 3 mm thick. [4] (d) The lamp shade shown in Fig. 15 could be made from brass. State two properties of brass that make it suitable for the lamp shade. 1 … 2 … [2] (e) Fig. 16 shows a template of the lamp shade glued onto a sheet of 1 mm thick brass. B template A brass sheet Fig. 16 Use sketches and notes to show how the lamp shade could be made from one piece of brass. Include the method of: • cutting out the shape • bending the brass to shape • soldering edge A to edge B • cleaning and finishing. [8]

25 marks

Mark scheme: 12(a) Methods of joining include: dowel, mortise and tenon, housing, biscuit, pin and glue, screw from underneath base. Appropriate construction named 1 Sketch showing constructional details 0–2 3 12(b)(i) Metal fitting: nut and bolt or screw drawn clearly 0–2 2 important sizes: length, diameter of bolt or screwthread or head 2 × 1 4 Do NOT accept rivet Length of screw/bolt must be minimum 35 mm 12(b)(ii) 2 benefits: attractive appearance, prevents corrosion/tarnishing, more hardwearing 2 × 1 2 12(c)(i) 2 advantages: 3 mm thick plywood is more practical than solid wood, more stable, stronger construction less likely to split, easier to work with 2 × 1 2 12(c)(ii) 3 mm thick plywood needs corner reinforcement: use of small blocks/strips glued to the inside. Use of cloth tape, GRP, ‘laced’ Correctly named construction 1 Technical accuracy of construction shown 0–2 One added detail: for example: clamping, holding, gluing 1 4 Question Answer Marks Guidance 12(d) 2 properties of brass: corrosion resistant, easily joined, attractive, malleable, bend to shape, reflects 2 × 1 2 12(e) Cutting out the shape: use of tinsnips, guillotine 0–2 Bending to shape: use of folding bars, wooden former 0–2 Soldering edges: hard silver soldering details 0–2 Cleaning and finishing 0–2 8 e.g. method of holding, securing / cutting e.g. use of mallet, scrap wood, vice e.g. type of solder, flux, blowtorch e.g. use of wet and dry, polishing mop and compound, Brasso. Do NOT accept emery cloth or wire wool

This question in 0445/33 May/June 2019

Q133 · Views of a children’s play table 0445/33 May/June 2019

13 Fig. 17 shows views of a children’s play table. The height of the table can be adjusted by means of sleeves that fit over the ends of the legs. The table is produced as flat-pack for self-assembly. A end rail long rail leg sleeve Fig. 17 (a) (i) Name a suitable manufactured board for the table top. … [1] (ii) Name a suitable softwood for the legs and rails. … [1] (b) Describe two benefits of covering the manufactured board used for the table top with melamine sheet. 1 … 2 … [2] (c) (i) Explain why the designer has made the table height adjustable. … … … [2] (ii) The height of the table can be adjusted by means of sleeves that fit over the ends of the legs. The sleeve shown below will be produced by the extrusion process. 150 65 22 Fig. 18 shows part of an extrusion moulding machine. Add notes to Fig. 18 to describe the extrusion process. Fig. 18 [3] (iii) The height of the table can be adjusted by moving the sleeve up or down and locking it in position. Use sketches and notes to show how the table could be set at three different heights. Include details of any fittings and materials used. [4] (d) The legs and rails are made from the same size section softwood, 60 × 20. Explain one benefit to the manufacturer of using the same size section softwood. … … … [2] (e) The parts of the table shown in Fig. 17 will be assembled using dowels and screws. (i) Use sketches and notes to show how screws could be used to join two rails at A. [3] (ii) Use sketches and notes to show how dowels could be used to join the table top to the rails. [3]

21 marks

Mark scheme: 13(a)(i) Plywood, blockboard, MDF, chipboard, laminboard 1 Do NOT accept hardboard 13(a)(ii) Pine, redwood, deal, parana pine, whitewood, spruce, cedar, scots pine 1 13(b) 2 benefits: attractive finish, hardwearing, stain resistant, heat resistant, easier to clean, hygienic, smooth surface, protects, no splinters, prevents scratches 2 × 1 2 13(c)(i) Adjustable height: children using table are different heights, children will grow 2 Reward any valid reasoning. 13(c)(ii) Granules fed into hopper 1 Rotating feed screw takes the granules through heating chamber to melt 1 Screw forces plastic through die 1 3 Do NOT accept labels without description. For maximum 3 marks the 1st stage [granules in hopper] and the 3rd stage [plastic forced through die] must be noted otherwise maximum 2 marks 13(c)(iii) Adjustable positions 1 Pin, peg or dowel 1 Locking method 1 Notes provide a description of how it works 1 4 Accept existing ‘base’ position as 1st position. Method involves 2 or 3 holes drilled in sleeve and 1 in leg or vice versa. Question Answer Marks Guidance 13(d) Benefit of same section softwood: quicker production time 1 Justification since there is less machine setting up required 1 2 Award 1 mark maximum for ‘cheaper by buying in bulk’. 13(e)(i) Sketch showing 2 screws used 1 Details of screws: length, gauge [diameter], type of head, spacing 2 × 1 3 Ignore use of adhesive Accept any 2 from 3 details 13(e)(ii) Sketch showing minimum of 2 dowels per rail 1 Details of dowels: length, diameter, spacing 2 × 1 3 Accept any 2 from 3 details 13(f) Benefits of self-assembled products to manufacturer: quicker production time means less costs, lower prices available, more profits, less storage space required 0–2 2 13(g) Functional improvement: lipping to top to prevent items falling off, dedicated space/s into table top for storage, rounded corners for safety. 0–2 2 Award marks for a practical design idea clearly communicated.

This question in 0445/33 May/June 2019

Q134 · A block of metal marked out ready to be drilled 0445/31 Oct/Nov 2019

2 Fig. 1 shows a block of metal marked out ready to be drilled. B A C Fig. 1 Name the marking out tool used to mark line A. … Name the marking out tool used to mark centre B. … Name the marking out tool used to mark arc C. …

3 marks

Mark scheme: 2 A scriber, marker pen, oddleg calipers 1 3 B centre or dot punch 1 C dividers 1

This question in 0445/31 Oct/Nov 2019

Q135 · Two basic designs for kitchen roll holders 0445/31 Oct/Nov 2019

3 Fig. 2 shows two basic designs for kitchen roll holders. wall-mounted freestanding Fig. 2 Give two reasons why consumers may prefer to buy a wall-mounted kitchen roll holder rather than a freestanding kitchen roll holder. 1 … 2 … [2]

2 marks

Mark scheme: 3 Wall-mounted saves space, can be operated with one hand, cannot be moved about 2 2×1

This question in 0445/31 Oct/Nov 2019

Q136 · Timber being seasoned in a kiln 0445/31 Oct/Nov 2019

4 Fig. 3 shows timber being seasoned in a kiln. outlet inlet valve valve steam pipes heating pipes timber stacked on trolley Fig. 3 (a) Explain why timber needs to be seasoned. … … … [2] (b) Name a different method of seasoning timber. … [1]

3 marks

Mark scheme: 4(a) To remove the majority of moisture in a board 1 2 To minimise future problems relating to shrinkage and expansion 1 4(b) Open air or natural seasoning 1

This question in 0445/31 Oct/Nov 2019

Q137 · A Ø10 hole will be drilled in a sheet of 4 mm thick acrylic 0445/31 Oct/Nov 2019

5 A Ø10 hole will be drilled in a sheet of 4 mm thick acrylic. Fig. 4 shows part of a drilling machine used to drill the hole. Add to Fig. 4 to show how the acrylic sheet would be held when drilling the hole. Ø10 drill drilling machine table Fig. 4 [3]

3 marks

Mark scheme: 5 Clamping device shown gripping above and below machine table 1 3 Use of sacrificial board under and on top of acrylic 2×1

This question in 0445/31 Oct/Nov 2019

Q138 · The end grain of a piece of hardwood being planed 0445/31 Oct/Nov 2019

6 Fig. 5 shows the end grain of a piece of hardwood being planed. The wood is planed from each end to the centre, as shown by the arrows, to prevent it from splitting. Fig. 5 Describe a different method of planing the end grain that will prevent the wood from splitting. … … … [2]

2 marks

Mark scheme: 6 Use of scrap wood clamped to the edge/s to provide support so that the plane can travel 2 across the entire end grain without splitting occurring

This question in 0445/31 Oct/Nov 2019

Q139 · Circle from the lists below one material that is: (a) from a sustainable source acrylic… 0445/31 Oct/Nov 2019

7 Circle from the lists below one material that is: (a) from a sustainable source acrylic stainless steel oak nylon [1] (b) biodegradeable. polystyrene cast iron pine copper [1]

2 marks

Mark scheme: 7(a) oak 1 7(b) pine 1

This question in 0445/31 Oct/Nov 2019

Question 140 0445/31 Oct/Nov 2019

8 Fig. 6 shows a computer desk. mild steel tube 20 × 20 × 2 A 500 Fig. 6 Use sketches and notes to show how the corner joint at A could be strengthened. State any constructions and fittings used. [3]

3 marks

Mark scheme: 8 Strengthening requires: use of a single brace [flat strip] joined to the tube, or 3 a triangular shaped gusset joined to the tube 1 Method of joining: soldering, brazing, welding 1 Technical accuracy 1

This question in 0445/31 Oct/Nov 2019

Q141 · Two small wooden tables 0445/31 Oct/Nov 2019

10 Fig. 7 shows two small wooden tables. Both tables are the same overall size. Table A is made by laminating. Table B is made by fabrication. Table A laminated Table B fabricated Fig. 7 Compare the methods of manufacture and state which of the two tables would cost less to batch produce. Give two reasons for your decision. Chosen table … Reason 1 … … Reason 2 … … [2]

2 marks

Mark scheme: 10 Laminated table cheaper: fewer constructions, quicker manufacture 2×1 2 Fabricated table: less material used, expensive moulds not required, simple constructions 2×1

This question in 0445/31 Oct/Nov 2019

Q142 · Views of a planter box and stand 0445/31 Oct/Nov 2019

11 Fig. 8 shows views of a planter box and stand. The planter box is made from 12 mm thick marine plywood and the stand from Ø12 mild steel tube. planter box 150 600 stand 650 250 Fig. 8 (a) Give two benefits of using marine plywood for the planter box. 1 … 2 … [2] (b) The mild steel stand will have a dip-coated finish. Give two benefits of a dip-coated finish for the mild steel stand. 1 … 2 … [2] (c) The planter box and stand is designed as flat-pack for self-assembly by the consumer. Fig. 9 shows the separate parts of the planter box. Fig. 9 Use sketches and notes to show how the parts could be joined together using basic tools. [4] (d) Details of the stand are shown in Fig. 10. The stand is to be self-assembled from eight separate pieces of Ø12 mild steel tube. X rail Y outside Ø12 leg X Y inside Ø8 Fig. 10 Use sketches and notes to show details of connecting pieces that could be used to join: (i) the legs together at X [4] (ii) a rail to a leg at Y. [4] (e) Use sketches and notes to show how the planter box could be fixed to the stand. The method of fixing must allow the planter box to be removed. [4] (f) Fig. 11 shows the basic shape of a box used to package all the parts of the planter box and stand for delivery to consumers. depth length width Fig. 11 Indicate on Fig. 11 a suitable length, width and depth for the box in which all the parts will fit. [3] (g) When designing and making products it is important to consider the choice of materials. Complete the following statement: Usingamanufacturedboardandaferrousmetalfortheplanterboxandstandisnot harmfultotheenvironmentbecause … … … … [2]

25 marks

Mark scheme: 11(a) Stable, hardwearing, water resistant 2×1 2 11(b) Tough, attractive, range of colours, fairly quick process, even application 2 resists corrosion 2×1 11(c) Use of dowels, screws or corner blocks to join sides together 0–2 4 Use of screws to join base to underneath sides 0–2 11(d)(i) Join at X: by means of either an ‘insert’ or an additional tube over existing tube 4 Practical method shown 0–2 Added details 0–2 11(d)(ii) Join at Y: by means of disc insert in [right hand] tube with threaded hole 0–2 4 Screw or bolt through [left hand] tube into threaded hole 0–2 11(e) Use of screws, nuts and bolts for quick removal 1 4 Use of small ‘bracket’ or ‘clips’ shaped over round tube, joined permanently to tube or temporarily 0–2 Technical accuracy 0–1 11(f) 650–700 length × 325–350 width × 70–80 depth 3×1 3 11(g) Answers should relate to the reusable property of manufactured board or that some are 2 made from waste or recycled materials 1 Mild steel can be disassembled, melted down and reused 1

This question in 0445/31 Oct/Nov 2019

Q143 · Views of an incomplete design for a toy helicopter made from 6 mm thick plywood 0445/31 Oct/Nov 2019

12 Fig. 12 shows views of an incomplete design for a toy helicopter made from 6 mm thick plywood. B dowel rotor blade C A C Fig. 12 (a) Give two reasons why 6 mm thick plywood is suitable for the toy helicopter. 1 … 2 … [2] (b) Fig. 13 shows side A marked out ready to be cut to shape. window 120 180 Fig. 13 Complete the table by naming the tools or items of equipment that could be used to make the side A. Stage Process Tools / items of equipment 1 Mark out the shape 2 Remove the window shape 3 Smooth all cut edges [3] (c) A contact adhesive will be used to join most of the parts of the toy helicopter. Give two advantages of using a contact adhesive rather than PVA to join the parts. 1 … 2 … [2] (d) Fig. 14 shows the Ø6 dowel that will be glued into the roof, part B. chamfer saw cut Fig. 14 Describe the purpose of the saw cut and the chamfer in the dowel. Saw cut … Chamfer … [2] (e) Fig. 15 shows one of the feet, part C, made from 5 mm thick acrylic sheet. 100 10 Fig. 15 Use sketches and notes to show how the foot could be made. Include details of: • marking out • cutting out the shape • producing the curved shape. [5] (f) The outline shape of a rotor blade that will be attached to the Ø6 dowel is shown in Fig. 12. Choose a specific wood, metal or plastic for the rotor blade. Use sketches and notes to show a design for a rotor blade that could be fitted to the Ø6 dowel. The rotor blade must be able to turn freely. Include all constructions, named materials and two important sizes. [6] (g) Identify three ways by which the designer has made the toy helicopter suitable for use by young children. 1 … 2 … 3 … [3] (h) Plywood is a manufactured board. Explain why some manufactured boards can be considered environmentally friendly. … … … [2]

25 marks

Mark scheme: 12(a) Stable, stronger than 6 mm solid wood, can be worked without danger of splitting, fairly 2 lightweight 2×1 12(b) Stage 1: pencil, compass, template 1 3 Stage 2: drill, variety of suitable hand and machine saws, router 1 Stage 3: files, glasspaper 1 12(c) Does not need clamping for hours, immediate bonding, quick 2×1 2 12(d) Saw cut: to provide space for the glue otherwise it would be forced out 1 2 Chamfer: to provide ease of entry 1 12(e) Marking out: chinagraph pencil, marker pen, scriber, steel rule 1 5 Cutting out: use of coping saw, tenon saw, Hegner, scroll saws 0–2 Curved shape: use of oven, strip heater, hot air gun 1 Use of former and method of retention 1 12(f) Appropriately named specific material 1 6 Design of rotor blade 1 Method of fitting onto dowel allowing for rotation 0–2 2 important sizes 0–2 12(g) 3 ways include: moving parts, curved/rounded edges, appropriate size, easy to hold, 3 safe materials 3×1 12(h) Environmentally friendly: some boards can be recycled or use recycled materials. Boards 2 are made from sustainable materials

This question in 0445/31 Oct/Nov 2019

Q144 · A ladder plant stand 0445/31 Oct/Nov 2019

13 Fig. 16 shows a ladder plant stand. rung 40 × 25 side rail 50 × 25 plant pot ladder height 1300 ladder width 400 foot Fig. 16 (a) Name and sketch a permanent construction that could be used to join a rung to a side rail. Name of construction … [4] (b) Fig. 17 shows the side rails and rungs ready to be glued together. Fig. 17 (i) Add to Fig. 17 to show how cramps would be used to hold the side rails and rungs while the adhesive sets. [2] (ii) Name the type of cramps used. … [1] (iii) Name a suitable adhesive. … [1] (iv) Describe two checks that would be made after the side rails and rungs have been glued and clamped. 1 … 2 … [2] (c) Fig. 18 shows views of one plant pot and a block of wood that will be made into the former used to vacuum form the plant pots. 150 150 70 plant pot block 150 × 150 × 150 Fig. 18 (i) Name a specific plastic that could be used to vacuum form the plant pots. … [1] (ii) Draw on Fig. 18 to show the finished former ready to be used to make the plant pots. [2] (iii) Use sketches and notes to show how the plant pots would be vacuum formed. [6]

19 marks

Mark scheme: 13(a) Permanent construction: dowel, mortise and tenon, biscuit named 1 4 Quality of sketch dependent on technical accuracy, proportion, orientation 0–3 13(b)(i) At least 2 cramps shown across the ‘ladder’ 2 Award 1 mark for 1 cramp only 13(b)(ii) Sash, speed, ‘F’ cramps/clamps 1 13(b)(iii) Suitable adhesive: PVA, synthetic resin 1 13(b)(iv) 2 checks: squareness using try square or winding strips/diagonals 2 Is the ladder flat on the cramps, removal of surplus glue 2×1 13(c)(i) Polystyrene, acrylic, ABS 1 13(c)(ii) Former must show the draft angle 1 2 rounded corners ‘mirroring’ the plant pot 1 13(c)(iii) Award 0–4 for specific stages: 0–4 6 Place mould in machine [on platen] Clamp plastic in place Bring heater across to soften plastic Check flexibility of plastic Bring up mould into soft plastic Turn pump on to remove air Lower mould [on platen] and leave to cool Award 0–2 for technical accuracy of sketches 0–2 13(d) Practical idea: some form of ‘hook’ or bracket or clip over rung 0–2 4 Appropriate material/s 1 Appropriate construction/s 1 13(e) Modification: some form of ‘cap’ or cover, material with added friction 0–2 2

This question in 0445/31 Oct/Nov 2019

Q145 · A block of metal marked out ready to be drilled 0445/32 Oct/Nov 2019

2 Fig. 1 shows a block of metal marked out ready to be drilled. B A C Fig. 1 Name the marking out tool used to mark line A. … Name the marking out tool used to mark centre B. … Name the marking out tool used to mark arc C. …

3 marks

Mark scheme: 2 A scriber, marker pen, oddleg calipers 1 3 B centre or dot punch 1 C dividers 1

This question in 0445/32 Oct/Nov 2019

Q146 · Two basic designs for kitchen roll holders 0445/32 Oct/Nov 2019

3 Fig. 2 shows two basic designs for kitchen roll holders. wall-mounted freestanding Fig. 2 Give two reasons why consumers may prefer to buy a wall-mounted kitchen roll holder rather than a freestanding kitchen roll holder. 1 … 2 … [2]

2 marks

Mark scheme: 3 Wall-mounted saves space, can be operated with one hand, cannot be moved about 2 2×1

This question in 0445/32 Oct/Nov 2019

Q147 · Timber being seasoned in a kiln 0445/32 Oct/Nov 2019

4 Fig. 3 shows timber being seasoned in a kiln. outlet inlet valve valve steam pipes heating pipes timber stacked on trolley Fig. 3 (a) Explain why timber needs to be seasoned. … … … [2] (b) Name a different method of seasoning timber. … [1]

3 marks

Mark scheme: 4(a) To remove the majority of moisture in a board 1 2 To minimise future problems relating to shrinkage and expansion 1 4(b) Open air or natural seasoning 1

This question in 0445/32 Oct/Nov 2019

Q148 · A Ø10 hole will be drilled in a sheet of 4 mm thick acrylic 0445/32 Oct/Nov 2019

5 A Ø10 hole will be drilled in a sheet of 4 mm thick acrylic. Fig. 4 shows part of a drilling machine used to drill the hole. Add to Fig. 4 to show how the acrylic sheet would be held when drilling the hole. Ø10 drill drilling machine table Fig. 4 [3]

3 marks

Mark scheme: 5 Clamping device shown gripping above and below machine table 1 3 Use of sacrificial board under and on top of acrylic 2×1

This question in 0445/32 Oct/Nov 2019

Q149 · The end grain of a piece of hardwood being planed 0445/32 Oct/Nov 2019

6 Fig. 5 shows the end grain of a piece of hardwood being planed. The wood is planed from each end to the centre, as shown by the arrows, to prevent it from splitting. Fig. 5 Describe a different method of planing the end grain that will prevent the wood from splitting. … … … [2]

2 marks

Mark scheme: 6 Use of scrap wood clamped to the edge/s to provide support so that the plane can travel 2 across the entire end grain without splitting occurring

This question in 0445/32 Oct/Nov 2019

Q150 · Circle from the lists below one material that is: (a) from a sustainable source acrylic… 0445/32 Oct/Nov 2019

7 Circle from the lists below one material that is: (a) from a sustainable source acrylic stainless steel oak nylon [1] (b) biodegradeable. polystyrene cast iron pine copper [1]

2 marks

Mark scheme: 7(a) oak 1 7(b) pine 1

This question in 0445/32 Oct/Nov 2019

Question 151 0445/32 Oct/Nov 2019

8 Fig. 6 shows a computer desk. mild steel tube 20 × 20 × 2 A 500 Fig. 6 Use sketches and notes to show how the corner joint at A could be strengthened. State any constructions and fittings used. [3]

3 marks

Mark scheme: 8 Strengthening requires: use of a single brace [flat strip] joined to the tube, or 3 a triangular shaped gusset joined to the tube 1 Method of joining: soldering, brazing, welding 1 Technical accuracy 1

This question in 0445/32 Oct/Nov 2019

Q152 · Two small wooden tables 0445/32 Oct/Nov 2019

10 Fig. 7 shows two small wooden tables. Both tables are the same overall size. Table A is made by laminating. Table B is made by fabrication. Table A laminated Table B fabricated Fig. 7 Compare the methods of manufacture and state which of the two tables would cost less to batch produce. Give two reasons for your decision. Chosen table … Reason 1 … … Reason 2 … … [2]

2 marks

Mark scheme: 10 Laminated table cheaper: fewer constructions, quicker manufacture 2×1 2 Fabricated table: less material used, expensive moulds not required, simple constructions 2×1

This question in 0445/32 Oct/Nov 2019

Q153 · Views of a planter box and stand 0445/32 Oct/Nov 2019

11 Fig. 8 shows views of a planter box and stand. The planter box is made from 12 mm thick marine plywood and the stand from Ø12 mild steel tube. planter box 150 600 stand 650 250 Fig. 8 (a) Give two benefits of using marine plywood for the planter box. 1 … 2 … [2] (b) The mild steel stand will have a dip-coated finish. Give two benefits of a dip-coated finish for the mild steel stand. 1 … 2 … [2] (c) The planter box and stand is designed as flat-pack for self-assembly by the consumer. Fig. 9 shows the separate parts of the planter box. Fig. 9 Use sketches and notes to show how the parts could be joined together using basic tools. [4] (d) Details of the stand are shown in Fig. 10. The stand is to be self-assembled from eight separate pieces of Ø12 mild steel tube. X rail Y outside Ø12 leg X Y inside Ø8 Fig. 10 Use sketches and notes to show details of connecting pieces that could be used to join: (i) the legs together at X [4] (ii) a rail to a leg at Y. [4] (e) Use sketches and notes to show how the planter box could be fixed to the stand. The method of fixing must allow the planter box to be removed. [4] (f) Fig. 11 shows the basic shape of a box used to package all the parts of the planter box and stand for delivery to consumers. depth length width Fig. 11 Indicate on Fig. 11 a suitable length, width and depth for the box in which all the parts will fit. [3] (g) When designing and making products it is important to consider the choice of materials. Complete the following statement: Usingamanufacturedboardandaferrousmetalfortheplanterboxandstandisnot harmfultotheenvironmentbecause … … … … [2]

25 marks

Mark scheme: 11(a) Stable, hardwearing, water resistant 2×1 2 11(b) Tough, attractive, range of colours, fairly quick process, even application 2 resists corrosion 2×1 11(c) Use of dowels, screws or corner blocks to join sides together 0–2 4 Use of screws to join base to underneath sides 0–2 11(d)(i) Join at X: by means of either an ‘insert’ or an additional tube over existing tube 4 Practical method shown 0–2 Added details 0–2 11(d)(ii) Join at Y: by means of disc insert in [right hand] tube with threaded hole 0–2 4 Screw or bolt through [left hand] tube into threaded hole 0–2 11(e) Use of screws, nuts and bolts for quick removal 1 4 Use of small ‘bracket’ or ‘clips’ shaped over round tube, joined permanently to tube or temporarily 0–2 Technical accuracy 0–1 11(f) 650–700 length × 325–350 width × 70–80 depth 3×1 3 11(g) Answers should relate to the reusable property of manufactured board or that some are 2 made from waste or recycled materials 1 Mild steel can be disassembled, melted down and reused 1

This question in 0445/32 Oct/Nov 2019

Q154 · Views of an incomplete design for a toy helicopter made from 6 mm thick plywood 0445/32 Oct/Nov 2019

12 Fig. 12 shows views of an incomplete design for a toy helicopter made from 6 mm thick plywood. B dowel rotor blade C A C Fig. 12 (a) Give two reasons why 6 mm thick plywood is suitable for the toy helicopter. 1 … 2 … [2] (b) Fig. 13 shows side A marked out ready to be cut to shape. window 120 180 Fig. 13 Complete the table by naming the tools or items of equipment that could be used to make the side A. Stage Process Tools / items of equipment 1 Mark out the shape 2 Remove the window shape 3 Smooth all cut edges [3] (c) A contact adhesive will be used to join most of the parts of the toy helicopter. Give two advantages of using a contact adhesive rather than PVA to join the parts. 1 … 2 … [2] (d) Fig. 14 shows the Ø6 dowel that will be glued into the roof, part B. chamfer saw cut Fig. 14 Describe the purpose of the saw cut and the chamfer in the dowel. Saw cut … Chamfer … [2] (e) Fig. 15 shows one of the feet, part C, made from 5 mm thick acrylic sheet. 100 10 Fig. 15 Use sketches and notes to show how the foot could be made. Include details of: • marking out • cutting out the shape • producing the curved shape. [5] (f) The outline shape of a rotor blade that will be attached to the Ø6 dowel is shown in Fig. 12. Choose a specific wood, metal or plastic for the rotor blade. Use sketches and notes to show a design for a rotor blade that could be fitted to the Ø6 dowel. The rotor blade must be able to turn freely. Include all constructions, named materials and two important sizes. [6] (g) Identify three ways by which the designer has made the toy helicopter suitable for use by young children. 1 … 2 … 3 … [3] (h) Plywood is a manufactured board. Explain why some manufactured boards can be considered environmentally friendly. … … … [2]

25 marks

Mark scheme: 12(a) Stable, stronger than 6 mm solid wood, can be worked without danger of splitting, fairly 2 lightweight 2×1 12(b) Stage 1: pencil, compass, template 1 3 Stage 2: drill, variety of suitable hand and machine saws, router 1 Stage 3: files, glasspaper 1 12(c) Does not need clamping for hours, immediate bonding, quick 2×1 2 12(d) Saw cut: to provide space for the glue otherwise it would be forced out 1 2 Chamfer: to provide ease of entry 1 12(e) Marking out: chinagraph pencil, marker pen, scriber, steel rule 1 5 Cutting out: use of coping saw, tenon saw, Hegner, scroll saws 0–2 Curved shape: use of oven, strip heater, hot air gun 1 Use of former and method of retention 1 12(f) Appropriately named specific material 1 6 Design of rotor blade 1 Method of fitting onto dowel allowing for rotation 0–2 2 important sizes 0–2 12(g) 3 ways include: moving parts, curved/rounded edges, appropriate size, easy to hold, 3 safe materials 3×1 12(h) Environmentally friendly: some boards can be recycled or use recycled materials. Boards 2 are made from sustainable materials

This question in 0445/32 Oct/Nov 2019

Q155 · A ladder plant stand 0445/32 Oct/Nov 2019

13 Fig. 16 shows a ladder plant stand. rung 40 × 25 side rail 50 × 25 plant pot ladder height 1300 ladder width 400 foot Fig. 16 (a) Name and sketch a permanent construction that could be used to join a rung to a side rail. Name of construction … [4] (b) Fig. 17 shows the side rails and rungs ready to be glued together. Fig. 17 (i) Add to Fig. 17 to show how cramps would be used to hold the side rails and rungs while the adhesive sets. [2] (ii) Name the type of cramps used. … [1] (iii) Name a suitable adhesive. … [1] (iv) Describe two checks that would be made after the side rails and rungs have been glued and clamped. 1 … 2 … [2] (c) Fig. 18 shows views of one plant pot and a block of wood that will be made into the former used to vacuum form the plant pots. 150 150 70 plant pot block 150 × 150 × 150 Fig. 18 (i) Name a specific plastic that could be used to vacuum form the plant pots. … [1] (ii) Draw on Fig. 18 to show the finished former ready to be used to make the plant pots. [2] (iii) Use sketches and notes to show how the plant pots would be vacuum formed. [6]

19 marks

Mark scheme: 13(a) Permanent construction: dowel, mortise and tenon, biscuit named 1 4 Quality of sketch dependent on technical accuracy, proportion, orientation 0–3 13(b)(i) At least 2 cramps shown across the ‘ladder’ 2 Award 1 mark for 1 cramp only 13(b)(ii) Sash, speed, ‘F’ cramps/clamps 1 13(b)(iii) Suitable adhesive: PVA, synthetic resin 1 13(b)(iv) 2 checks: squareness using try square or winding strips/diagonals 2 Is the ladder flat on the cramps, removal of surplus glue 2×1 13(c)(i) Polystyrene, acrylic, ABS 1 13(c)(ii) Former must show the draft angle 1 2 rounded corners ‘mirroring’ the plant pot 1 13(c)(iii) Award 0–4 for specific stages: 0–4 6 Place mould in machine [on platen] Clamp plastic in place Bring heater across to soften plastic Check flexibility of plastic Bring up mould into soft plastic Turn pump on to remove air Lower mould [on platen] and leave to cool Award 0–2 for technical accuracy of sketches 0–2 13(d) Practical idea: some form of ‘hook’ or bracket or clip over rung 0–2 4 Appropriate material/s 1 Appropriate construction/s 1 13(e) Modification: some form of ‘cap’ or cover, material with added friction 0–2 2

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Question 156 0445/33 Oct/Nov 2019

1 Fig. 1 shows a cycle helmet. The outer and inner shells are made from different plastics. outer shell inner shell Fig. 1 Give two properties required of the plastics used to make the cycle helmet. 1 … 2 … [2]

2 marks

Mark scheme: Question Answer Marks 1 Lightweight, tough, impact resistant, rigid, weather resistant 2×1 2

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Q157 · Two pieces of wood being glued together 0445/33 Oct/Nov 2019

3 Fig. 3 shows two pieces of wood being glued together. Fig. 3 Draw on Fig. 3 to show how the glued joint could be strengthened by dovetail nailing. [2]

2 marks

Mark scheme: 3 2 pairs of nails shown angled 2

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Question 158 0445/33 Oct/Nov 2019

4 Fig. 4 shows a saucepan. handle saucepan body Fig. 4 (a) Name a thermosetting plastic that could be used for the handle. … Give a reason for your choice. … [2] (b) Name a ferrous alloy that could be used for the saucepan body. … Give a reason for your choice. … [2]

4 marks

Mark scheme: 4(a) Phenol formaldehyde 1 2 Hard, hardwearing, heat resistant 1 4(b) Stainless steel 1 2 Heat resistant, does not corrode, attractive 1

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Q159 · Three pre-drilled holes to take a screw 0445/33 Oct/Nov 2019

5 Fig. 5 shows three pre-drilled holes to take a screw. 1 1 … 2 … 2 3 … 3 Fig. 5 Select from the list below the correct name for each hole. countersunk hole stopped hole angled hole pilot hole clearance hole [3]

3 marks

Mark scheme: 5 1. pilot hole 3 2. clearance hole 3. countersunk hole 3×1

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Q160 · A board made from hardwood 0445/33 Oct/Nov 2019

6 Fig. 6 shows a board made from hardwood. The board needs to be seasoned. Fig. 6 Draw on Fig. 6 to show what could happen to the shape of the board if it was incorrectly seasoned. [1]

1 marks

Mark scheme: 6 Board shown cupping [narrower top of board/wider below] 1

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Question 161 0445/33 Oct/Nov 2019

7 Fig. 7 shows a wheelbarrow. The mild steel body of the wheelbarrow is galvanised. body Fig. 7 (a) State what is meant by the term ‘galvanised’. … [1] (b) State why it is necessary for the body of the wheelbarrow to be galvanised. … [1]

2 marks

Mark scheme: 7(a) Galvanised means coating the metal with zinc 1 7(b) Zinc coating with prevent the mild steel body from corrosion 1

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Q162 · An incomplete metal bracket used to support a net on a table-tennis table 0445/33 Oct/Nov 2019

10 Fig. 11 shows an incomplete metal bracket used to support a net on a table-tennis table. net bracket threaded hole threaded rod Fig. 11 (a) Name the tool that has been used to cut the thread in the hole on the bracket. … [1] (b) Name the tool that has been used to cut the thread on the rod. … [1] (c) In use, the threaded rod is difficult to tighten by hand. Use sketches and notes to show how the threaded rod could be made easier to tighten. [2]

4 marks

Mark scheme: 10(a) Tap 1 10(b) Die 1 10(c) Practical idea: small ‘tommy bar’, ‘wing’ joined to rod 0–2 2

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Q163 · A desk tidy made from 4 mm thick plywood 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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Q164 · A basic design for a toothbrush holder made from 4 mm thick acrylic 0445/33 Oct/Nov 2019

12 Fig. 17 shows a basic design for a toothbrush holder made from 4 mm thick acrylic. Ø15 100 Ø8 100 100 Fig. 17 (a) Give two specification points for the toothbrush holder in addition to the one given below. The toothbrush holder must: 1 hold up to four toothbrushes 2 … 3 … [2] (b) Fig. 18 shows the development (net) of the toothbrush holder marked out showing the bend lines and centres for Ø15 and Ø8 holes to be drilled. centres for Ø15 holes bend line bend line centres for Ø8 holes Fig. 18 (i) Give one reason why a marker pen would be used to mark the bend lines rather than a scriber. … [1] (ii) Use sketches and notes to show how the acrylic sheet could be held when the Ø15 holes are drilled. [3] (c) Acrylic is a thermoplastic. Explain a benefit of using a thermoplastic for the toothbrush holder. … … … [2] (d) The edges of the acrylic toothbrush holder will be self-finished. (i) Name the method of filing that would be used to finish the edges. … [1] (ii) Explain why it is necessary to use different grades of wet and dry (silicon carbide) paper to finish the edges. … … … [2] (e) A batch of 40 toothbrush holders is to be made in a school workshop. Use sketches and notes to show: (i) a design for a drilling jig that could be used to speed up production [3] (ii) how the acrylic shape could be bent accurately to the required shape. [3] (f) Use sketches and notes to show a modification to the design of the toothbrush holder shown in Fig. 17 so that the tube of toothpaste shown below could be stored. width 40 Ø25 Ø15 overall length 130 [4] (g) Fig. 19 shows a commercially produced toothbrush holder made from stainless steel. Fig. 19 (i) Give two benefits of using stainless steel for products that will be used in a bathroom. 1 … 2 … [2] (ii) Explain why, other than the cost of the material, the stainless steel toothbrush holder could be expensive to manufacture. … …

25 marks

Mark scheme: 12(a) The toothbrush holder must: be easy to clean, be stable in use, keep the brushes 2 separate, be attractive, keep the brushes upright, be water resistant attractive appearance 2×1 12(b)(i) Marks can be erased whereas a scriber leaves permanent mark, possible damage to 1 surface 12(b)(ii) Some form of clamping device 1 3 G cramp named 1 Use of scrap wood underneath acrylic sheet 1 12(c) Thermoplastics can be heated and formed 1 2 Can be reheated and formed 1 12(d)(i) Draw filing 1 12(d)(ii) Wet and dry paper scratches the surface of the acrylic 1 2 Using a finer grade replaces more coarse scratches 1 12(e)(i) Drilling jig: ‘template’ with holes drilled 1 3 Template located against 1 edge 1 Template located against 2 or more edges 1 12(e)(ii) Bending: use of a former or mould 1 3 Method of heating acrylic; oven, line bender, strip heater 1 Method of retention: use of clamping devices 1 12(f) Basic shape must be enlarged 1 4 Some form of hole or cut-out to support tube of toothpaste 1 Toothpaste supported 1 Notes to explain details of modification 1 12(g)(i) Stainless steel is attractive, it is extremely hardwearing, it does not corrode, it can be 2 easily cleaned 2×1 12(g)(ii) Expensive to manufacture: 2 several parts that need to be machined and assembled 1 increased time to manufacture which increases the cost of the product 1

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Q165 · A wall-mounted cycle rack made from 19 mm thick manufactured board 0445/33 Oct/Nov 2019

13 Fig. 20 shows a wall-mounted cycle rack made from 19 mm thick manufactured board. back 330 side 250 350 de Fig. 20 (a) Give two advantages of making the cycle rack from a manufactured board rather than a solid wood. 1 … 2 … [2] (b) Fig. 21 shows one side marked out ready to be cut to shape. 250 waste to be removed 350 Fig. 21 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] (c) The sides will be joined to the back using four Ø9 dowels. Fig. 22 shows part of the back of the cycle rack. 250 19 Fig. 22 (i) Draw on Fig. 22 to show the positions and spacing of the four dowels. [2] (ii) Design a drilling jig that could be used on the sides and back to speed up production.

8 marks

Mark scheme: 13(a) Manufactured board: more stable, wider boards available, less likely to split 2 2×1 13(b) Method: drill hole inside curved shape, cut out shape using band saw, jig saw, coping 4 saw, smooth shape with files, glasspaper 3×1 Tools and equipment named accurately 1 13(c)(i) 4 centres or dowels shown 1 2 Correctly spaced 1 13(c)(ii) Drilling jig: ‘template’ with holes drilled 1 4 Template located against 1 side 1 Template located against 2 sides 1 Template located against 2 sides and 1 edge 1 13(d) Mild steel sheet: hardwearing, tough, can be bent to shape, relatively cheap 1 13(e) To visualise final product, to check for errors, to allow for quick modifications, to check 2 sizes, prevents wastage of materials, check sizes, can be used with CAM 2×1 13(f) Bench shears. Tinsnips 2×1 2 13(g)(i) Weld, solder, braze 1 13(g)(ii) Epoxy resin adhesive, riveting 1 13(h)(i) B 1 2 Mild steel sheet is too thin for a countersunk headed screw 1 13(h)(ii) Make sure it is clamped securely, scrap wood underneath for support, correct 2 speed of drill 2×1 13(i) Manufactured board rack would be more expensive 1 2 Material is more expensive, more materials are used, there are more processes; e.g. cutting shape and joining, resulting in longer manufacturing time and higher costs 1

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Q166 · Give two pieces of information required when buying woodscrews 0445/31 May/June 2020

1 Give two pieces of information required when buying woodscrews. 1 … 2 … [2]

2 marks

Mark scheme: Question Answer Marks 1 Accept any 2 from length, type of head, material, gauge, 2 × 1 2 number reqd.

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Q167 · A list of materials is given below 0445/31 May/June 2020

2 A list of materials is given below. brass CFRP copper polycarbonate stainless steel Select from the list one material that is: (a) an alloy … [1] (b) a composite … [1]

2 marks

Mark scheme: 2(a) Alloy: brass or stainless steel 1 1 2(b) Composite: carbon fibre 1 1

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Q168 · Complete the drawing below to show an exploded view of a corner halving joint 0445/31 May/June 2020

3 Complete the drawing below to show an exploded view of a corner halving joint. [3]

3 marks

Mark scheme: 3 Joint recognised 1 3 Accuracy of two halvings 2 × 1

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Q169 · Complete Table 4.1 by naming a suitable material for each product 0445/31 May/June 2020

4 Complete Table 4.1 by naming a suitable material for each product. Table 4.1 Product Suitable material plastic chair metal water pipe fittings wooden model glider [3]

3 marks

Mark scheme: 4 Plastic chair: polypropylene, ABS 1 3 Metal pipe fittings: copper, brass, stainless steel, aluminium 1 Model glider kit: balsa 1

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Q170 · The end of a mild steel strip marked out, ready to be shaped 0445/31 May/June 2020

7 Fig. 7.1 shows the end of a mild steel strip marked out, ready to be shaped. waste 25 70 3 mm thick Fig. 7.1 Name the hand tool used to: (a) mark out the lines … [1] (b) saw off the waste metal … [1] (c) make the sawn edge flat and smooth … [1]

3 marks

Mark scheme: 7(a) Scriber, steel rule, try square 1 1 7(b) Hacksaw 1 1 7(c) File [specific name not required] 1 1

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Q171 · A box made from softwood 0445/31 May/June 2020

9 Fig. 9.1 shows a box made from softwood. The box will have a base made from 4 mm thick manufactured board. 15 mm thick 400 220 Fig. 9.1 Use sketches and notes to show how the base could be fitted inside the box so that the edges of the base are not seen. [3]

3 marks

Mark scheme: 9 Appropriate method 1 3 Accuracy of drawing: proportion/orientation 0–2

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Q172 · A pen and pencil holder 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

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Q173 · An incomplete design for a storage box made from wood 0445/31 May/June 2020

12 Fig. 12.1 shows an incomplete design for a storage box made from wood. 6 mm thick partitions lifts out 50 15 mm thick sides A 80 360 180 Fig. 12.1 (a) Complete Table 12.1 by adding the missing dimensions of the parts. Table 12.1 Number Part Length × Width × Thickness Material required Long side 2 360 × 80 × 15 beech Short side 2 180 × × 15 beech Base 1 × 180 × 6 plywood Long partition 1 × 50 × 6 plywood Short partition 5 × 50 × 6 plywood [4] (b) Name and sketch a permanent joint that could be used at corner A. Name of joint … [4] (c) Fig. 12.2 shows a cross-halving joint used so that the partitions can fit together and be removed. Fig. 12.2 (i) Name two different saws that could be used to cut out the cross-halving joint. 1 … 2 … [2] (ii) Give two advantages, other than cost, of making the partitions from plywood rather than beech. 1 … 2 … [2] (d) Use sketches and notes to show a different method of keeping items separate inside a storage box. [3] (e) To complete the design of the storage box in Fig. 12.1 modifications need to be made. (i) Use sketches and notes to show a design for a lid that could be fitted to the storage box. Include all details of materials, constructions and fittings used. [5] (ii) Use sketches and notes to show a modification that would make it easier to carry the storage box. Include all details of materials, constructions and fittings used. [3] (f) Fig. 12.3 shows a similar design for a storage box made from injection moulded plastic. 80 360 180 Fig. 12.3 Give two advantages of making the storage box from plastic rather than wood. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Short side width: 80 mm 1 4 Base length: 330–360 mm 1 Long partition length: 330 mm * 1 Short partition: 150 mm * 1 12(b) Dovetail, finger [comb], dowel, lapped, half-lapped, mitre 4 named 1 Suitable joint recognised 1 Correct orientation [as per Fig. 12.1] 1 Good proportion/accuracy 1 12(c)(i) Tenon, dovetail, coping, Hegner, scroll, band saws 2 × 1 2 12(c)(ii) Stable, will not warp or twist, less likely to split, strong in all directions 2 × 1 2 12(d) Different method: use of vacuum formed plastic tray inserted 1 3 Sketch showing separate partitions 1 Added notes to explain process 1 12(e)(i) Lid can fit inside, on top of or over the sides of the box 5 12(e)(ii) Modification: some sort of ‘handle’: practical method 1 3 Appropriate materials 1 Suitable constructions 1 12(f) Moulded shape : less constructions, rounded shape, inherent colours-no 2 need for an applied finish 2 × 1

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Q174 · Wind chimes that will be batch produced in a school workshop 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

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Q175 · A drawer made from hardwood 0445/32 May/June 2020

2 Fig. 2.1 shows a drawer made from hardwood. Sketch a suitable joint, other than a butt joint, that could be used at corner A. A Fig. 2.1 [3]

3 marks

Mark scheme: 2 Dovetail, finger [comb], dowel, lapped, half-lapped 3 Suitable joint recognised 1 Correct orientation [as per Fig. 2.1] 1 Good proportion/accuracy 1

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Q176 · Complete Table 3.1 by naming a suitable material for each product 0445/32 May/June 2020

3 Complete Table 3.1 by naming a suitable material for each product. Table 3.1 Product Suitable material wooden building blocks metal toothbrush holder plastic cup and plate [3]

3 marks

Mark scheme: 3 Beech 1 3 Stainless steel, mild steel, aluminium, brass 1 Melamine 1

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Q177 · Details of a shelf bracket and a length of softwood from which the bracket is made 0445/32 May/June 2020

4 Fig. 4.1 shows details of a shelf bracket and a length of softwood from which the bracket is made. 250 300 25 × 25 Fig. 4.1 State three processes that need to be carried out to produce the shelf bracket in Fig. 4.1. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 4 Marking out 1 3 Cutting to length 1 Method of joining 1

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Q178 · A garden table made from plastic and the top of one of the removable table legs 0445/32 May/June 2020

5 Fig. 5.1 shows a garden table made from plastic and the top of one of the removable table legs. The legs are fastened to the underside of the table top. Fig. 5.1 Use sketches and notes to show how one leg could be fastened to the underside of the table top and be removable. [2]

2 marks

Mark scheme: 5 Method of locating end against underside of table 1 2 Method of fixing must be removeable 1

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Q179 · Views of a bracket made from 3 mm thick aluminium 0445/32 May/June 2020

7 Fig. 7.1 shows views of a bracket made from 3 mm thick aluminium. 30 × 30 Fig. 7.1 Describe how the square holes 30 × 30 could be produced by hand. … … … [2]

2 marks

Mark scheme: 7 2 main processes: drill hole 1 2 file to shape 1

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Q180 · A draining rack used for drying crockery and cutlery 0445/32 May/June 2020

8 Fig. 8.1 shows a draining rack used for drying crockery and cutlery. The draining rack is made from steel and has a plastic coated finish. Fig. 8.1 (a) Give one benefit of a plastic coated finish on the draining rack. … [1] (b) Give one drawback of a plastic coated finish on the draining rack. … [1]

2 marks

Mark scheme: 8(a) Tough, durable, attractive, resists corrosion, evenly applied 1 1 8(b) When cut/chipped can be difficult to repair 1

This question in 0445/32 May/June 2020

Q181 · Views of a desk tidy made from 3 mm thick MDF 0445/32 May/June 2020

10 Fig. 10.1 shows views of a desk tidy made from 3 mm thick MDF. The front, back and base fit into slots in the ends. 160 slots in end 130 Fig. 10.1 Use sketches and notes to show how the parts could be ‘locked’ in position without the use of an adhesive. [3]

3 marks

Mark scheme: 10 Use of pegs, dowels 1 3 Ease of fitting 1 Attractive/practical for product 1

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Q182 · Views of an incomplete design for a key rack made from hardwood 0445/32 May/June 2020

11 Fig. 11.1 shows views of an incomplete design for a key rack made from hardwood. The front of the key rack can swing open and closed as shown. 10 170 70 back dowel rod Ø9 front swings open and closed 5 thick Fig. 11.1 (a) The front of the key rack is made by laminating wood veneers. Use sketches and notes to show how the front could be produced. [4] (b) The keys will hang on Ø9 dowel pegs that are joined to the back of the key rack. Use sketches and notes to show a modification to the dowel pegs so that the keys are prevented from sliding off. [2] (c) Use sketches and notes to show how the front could be joined to the back and allowed to open and close as shown in Fig. 11.1. Include details of the materials and constructions used. [4] (d) (i) The front of the key rack will have a clear finish applied to it. State two clear finishes, other than varnish, that would be suitable for the front of the key rack. 1 … 2 … [2] (ii) Give two stages of preparation that would need to be carried out before a clear finish could be applied to the front of the key rack. 1 … 2 … [2] (e) The key rack shown in Fig. 11.1 could be made completely from acrylic. (i) Use sketches and notes to show how the front of the key rack could be formed when made from 5 mm thick acrylic sheet. [3] (ii) The dowel rods will be replaced with acrylic rod and the back replaced with acrylic sheet. Describe how the acrylic rod could be joined permanently to the back of the key rack. … … … [2] (iii) The edges of the acrylic front and back will be self-finished to a high quality. Complete Table 11.1 by describing three stages when self-finishing the edges of the acrylic. Table 11.1 Stage Process 1 Draw file edges using a hand file 2 3 4 [3] (f) When designing products, designers should select materials that are sustainable. The key rack could be made from wood or plastic. Explain why wood is considered to be more sustainable than plastic. … … … … [3]

25 marks

Mark scheme: 11(a) Male former 1 4 Female former 1 Veneers glued together 1 Clamping method 1 11(b) Modification should retain the keys: use of grooves or ‘stopped’ end 0–2 2 11(c) Additional plate/bracket added to front and back 2 × 1 4 Method of pivoting, e.g. use of pin or peg 1 Named materials 1 11(d)(i) Teak oil, Danish oil, white/French polish, lacquer, wax 2 × 1 2 11(d)(ii) 2 stages: glasspaper, damp cloth to wipe off dust, different grades of 2 glasspaper 2 × 1 11(e)(i) Use of oven to soften acrylic 1 3 Use of a former 1 Method of retention 1 11(e)(ii) Acrylic [Tensol] cement named 1 2 Method of application 1 11(e)(iii) Award any 3: use of scraper, wet and dry [silicon carbide ] paper, 2different 3 grades, polishing mop/ buffing wheel polishing compound 3 × 1 11(f) Explanation: 3 Timber can be ‘managed’ and trees replanted, low carbon footprint, wood decomposes Plastic is a finite resource

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Q183 · An incomplete design for a rack to store items of equipment used for cycle maintenance 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

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Q184 · A small table to be made in a school workshop 0445/32 May/June 2020

13 Fig. 13.1 shows a small table to be made in a school workshop. 700 500 table top: manufactured board 400 legs: solid wood Fig. 13.1 (a) (i) Name a suitable manufactured board for the table top. … [1] (ii) Give two reasons for your choice of manufactured board. 1 … 2 … [2] (b) Give two items of research that the designer would need to consider when deciding on the dimensions for the table. 1 … 2 … [2] (c) The legs are made from solid wood. Fig. 13.2 shows one leg marked out ready to be shaped. waste Fig. 13.2 (i) Name a suitable plane that could be used to remove the waste. … [1] (ii) Show how the leg could be held securely while the waste wood is removed. [2] (d) Fig. 13.3 shows a palm sander. Fig. 13.3 (i) Give two benefits of using a palm sander to prepare the table top to take a finish. 1 … 2 … [2] (ii) Describe two safety precautions, other than items of personal protection equipment, that must be considered when using portable power tools. 1 … … 2 … … [2] (iii) The table top will be finished with clear lacquer. Give two benefits of applying clear lacquer to the table top. 1 … 2 … [2] (e) Fig. 13.4 shows one leg in position to be hinged to the underside of the table top. leg 60 wide × 20 thick underside of table top Fig. 13.4 (i) Add sketches and notes to Fig. 13.4 to show a suitable hinge that could be used to join the leg to the table top. [3] (ii) Name the type of hinge used. … [1] (iii) State the material from which the hinge is made. … [1] (f) Use sketches and notes to show how the legs could be prevented from folding inwards when in use. Include details of materials and fittings used. [6]

25 marks

Mark scheme: 13(a)(i) Suitable manufactured board: plywood, chipboard, blockboard, MDF. 1 13(a)(ii) Reasons for manufactured board: stable, does not shrink, available in wide 2 boards. 2 × 1 13(b) 700 long dependent upon the items for which the table is intended 1 2 400 high dependent upon anthropometrics, existing furniture 1 13(c)(i) Smoothing, jack 1 13(c)(ii) Leg shown in vice 1 2 Angled slightly 1 OR Use of bench stop 1 Leg shown clearly against bench stop 1 13(d)(i) Quicker than by hand, even finish possible, removal of stubborn marks 2 easier 2 × 1 13(d)(ii) Portable tool safety: no trailing leads, clear area below tool, set up of tool 2 correctly before use, electrical safety in use [e.g. unplugging when changing blades etc.] 2 × 1 13(d)(iii) 2 benefits: tough, heat, stain and water resistant, attractive 2 × 1 2 13(e)(i) Accurate drawing of hinge 0–2 3 Correct position 1 13(e)(ii) Suitable hinge: butt, back flap, flush named 1 1 13(e)(iii) Suitable material: steel or brass 1 1 13(f) ‘Locking’ method: some form of ‘stay’, rods and holes. 0–3 6 Appropriate materials 1 Details of fittings used 0–2

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Q185 · Give two pieces of information required when buying woodscrews 0445/33 May/June 2020

1 Give two pieces of information required when buying woodscrews. 1 … 2 … [2]

2 marks

Mark scheme: Question Answer Marks 1 Accept any 2 from length, type of head, material, gauge, 2 × 1 2 number reqd.

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Q186 · A list of materials is given below 0445/33 May/June 2020

2 A list of materials is given below. brass CFRP copper polycarbonate stainless steel Select from the list one material that is: (a) an alloy … [1] (b) a composite … [1]

2 marks

Mark scheme: 2(a) Alloy: brass or stainless steel 1 1 2(b) Composite: carbon fibre 1 1

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Q187 · Complete the drawing below to show an exploded view of a corner halving joint 0445/33 May/June 2020

3 Complete the drawing below to show an exploded view of a corner halving joint. [3]

3 marks

Mark scheme: 3 Joint recognised 1 3 Accuracy of two halvings 2 × 1

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Q188 · Complete Table 4.1 by naming a suitable material for each product 0445/33 May/June 2020

4 Complete Table 4.1 by naming a suitable material for each product. Table 4.1 Product Suitable material plastic chair metal water pipe fittings wooden model glider [3]

3 marks

Mark scheme: 4 Plastic chair: polypropylene, ABS 1 3 Metal pipe fittings: copper, brass, stainless steel, aluminium 1 Model glider kit: balsa 1

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Q189 · The end of a mild steel strip marked out, ready to be shaped 0445/33 May/June 2020

7 Fig. 7.1 shows the end of a mild steel strip marked out, ready to be shaped. waste 25 70 3 mm thick Fig. 7.1 Name the hand tool used to: (a) mark out the lines … [1] (b) saw off the waste metal … [1] (c) make the sawn edge flat and smooth … [1]

3 marks

Mark scheme: 7(a) Scriber, steel rule, try square 1 1 7(b) Hacksaw 1 1 7(c) File [specific name not required] 1 1

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Q190 · A box made from softwood 0445/33 May/June 2020

9 Fig. 9.1 shows a box made from softwood. The box will have a base made from 4 mm thick manufactured board. 15 mm thick 400 220 Fig. 9.1 Use sketches and notes to show how the base could be fitted inside the box so that the edges of the base are not seen. [3]

3 marks

Mark scheme: 9 Appropriate method 1 3 Accuracy of drawing: proportion/orientation 0–2

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Q191 · A pen and pencil holder 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

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Q192 · An incomplete design for a storage box made from wood 0445/33 May/June 2020

12 Fig. 12.1 shows an incomplete design for a storage box made from wood. 6 mm thick partitions lifts out 50 15 mm thick sides A 80 360 180 Fig. 12.1 (a) Complete Table 12.1 by adding the missing dimensions of the parts. Table 12.1 Number Part Length × Width × Thickness Material required Long side 2 360 × 80 × 15 beech Short side 2 180 × × 15 beech Base 1 × 180 × 6 plywood Long partition 1 × 50 × 6 plywood Short partition 5 × 50 × 6 plywood [4] (b) Name and sketch a permanent joint that could be used at corner A. Name of joint … [4] (c) Fig. 12.2 shows a cross-halving joint used so that the partitions can fit together and be removed. Fig. 12.2 (i) Name two different saws that could be used to cut out the cross-halving joint. 1 … 2 … [2] (ii) Give two advantages, other than cost, of making the partitions from plywood rather than beech. 1 … 2 … [2] (d) Use sketches and notes to show a different method of keeping items separate inside a storage box. [3] (e) To complete the design of the storage box in Fig. 12.1 modifications need to be made. (i) Use sketches and notes to show a design for a lid that could be fitted to the storage box. Include all details of materials, constructions and fittings used. [5] (ii) Use sketches and notes to show a modification that would make it easier to carry the storage box. Include all details of materials, constructions and fittings used. [3] (f) Fig. 12.3 shows a similar design for a storage box made from injection moulded plastic. 80 360 180 Fig. 12.3 Give two advantages of making the storage box from plastic rather than wood. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Short side width: 80 mm 1 4 Base length: 330–360 mm 1 Long partition length: 330 mm * 1 Short partition: 150 mm * 1 12(b) Dovetail, finger [comb], dowel, lapped, half-lapped, mitre 4 named 1 Suitable joint recognised 1 Correct orientation [as per Fig. 12.1] 1 Good proportion/accuracy 1 12(c)(i) Tenon, dovetail, coping, Hegner, scroll, band saws 2 × 1 2 12(c)(ii) Stable, will not warp or twist, less likely to split, strong in all directions 2 × 1 2 12(d) Different method: use of vacuum formed plastic tray inserted 1 3 Sketch showing separate partitions 1 Added notes to explain process 1 12(e)(i) Lid can fit inside, on top of or over the sides of the box 5 12(e)(ii) Modification: some sort of ‘handle’: practical method 1 3 Appropriate materials 1 Suitable constructions 1 12(f) Moulded shape : less constructions, rounded shape, inherent colours-no 2 need for an applied finish 2 × 1

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Q193 · Wind chimes that will be batch produced in a school workshop 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

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Q194 · Part of a jig used when bending metal 0445/32 Oct/Nov 2020

2 Fig. 2.1 shows part of a jig used when bending metal. The base and pegs are made from mild steel. The pegs will be brazed into the base. pegs Ø8 base Fig. 2.1 Complete Table 2.1 by giving the missing stages required to braze the pegs into the base. Table 2.1 Stage Description of stage 1 Degrease and clean ends of pegs 2 3 4 5 Allow to cool [3]

3 marks

Mark scheme: 2 3 stages include: apply flux, insert pegs into holes, position on hearth [firebricks], heat to appropriate temperature, apply brazing rod, make sure brazing rod ‘runs’ into joint, degrease holes 3 × 1

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Q195 · Views of a mortise and tenon joint 0445/32 Oct/Nov 2020

3 Fig. 3.1 shows views of a mortise and tenon joint. Add sketches and notes to Fig. 3.1 to show how the joint could be strengthened. Fig. 3.1 [2]

2 marks

Mark scheme: 3 Methods: use of a wedge, dowel, nails, screws, bolts 1 nail/screw/bolt = 1mark 2 nails/screws/bolts = 2 marks 1 or 2 dowels = 2 marks

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Q196 · A wall-mounted bench used outdoors 0445/32 Oct/Nov 2020

4 Fig. 4.1 shows a wall-mounted bench used outdoors. 800 Fig. 4.1 Explain how anthropometric data would be used to decide the height at which the bench should be fixed to a wall. … … … [2]

2 marks

Mark scheme: 4 Basic understanding of the term ‘anthropometrics’ 1 Height dependent on distance from part of the leg behind the knee to the ground [popliteal height]. 1 2 Reference to human measurements

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Q197 · Explain what is meant by the term ‘alloy’ 0445/32 Oct/Nov 2020

5 (a) Explain what is meant by the term ‘alloy’. … … … [2] (b) Circle , from the list below, two alloys. stainless steel aluminium tin brass copper [2]

4 marks

Mark scheme: 5(a) Alloy is a mixture 1 Two or more metals 1 2 Accept purpose is to create a metal with specific properties 1 mark Must refer to metals not materials 5(b) Stainless steel, brass 2 × 1 2

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Q198 · The back of a hardwood gate 0445/32 Oct/Nov 2020

6 Fig. 6.1 shows the back of a hardwood gate. post positions for hinges A Fig. 6.1 (a) State the purpose of part A. … [1] (b) Circle , from the list below, the most suitable hinge that could be used to support the gate against the post. flush backflap tee butt [1]

2 marks

Mark scheme: 6(a) Purpose: to prevent the load [weight of the gate] sagging inwards towards the post, increase rigidity, acts as a brace, support, keep shape 1 Accept answers that show basic understanding of ‘sagging’ effect. Do not accept vague answers such as ‘stronger’. 6(b) Tee hinge 1

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Q199 · A notelet holder made from plastic 0445/32 Oct/Nov 2020

7 Fig. 7.1 shows a notelet holder made from plastic. Fig. 7.1 Explain why the use of plastic to make products has an impact on the environment. … … … [2]

2 marks

Mark scheme: 7 Plastic made from oil, a finite source, many plastics cannot be recycled, do not decompose, produce landfill, products thrown away, manufacturing creates toxic gases, 2 Accept any valid environmental impact point. Accept one point well explained or separate points.

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Q200 · Views of an incomplete design for a photograph frame 0445/32 Oct/Nov 2020

8 Fig. 8.1 shows views of an incomplete design for a photograph frame. 1 mm thick mild steel 3 mm thick hardboard front back Fig. 8.1 Use sketches and notes to show how the photograph frame could be made freestanding. [3]

3 marks

Mark scheme: 8 Practical idea: some sort of ‘stand’ or ‘support’ shown 1 ‘Stand’ joined to hardboard back or mild steel frame 0–2 3 Appropriate materials 1 Appropriate constructions 1

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Q201 · A mild steel rod that will be joined to a mild steel base by means of a screw thread 0445/32 Oct/Nov 2020

9 Fig. 9.1 shows a mild steel rod that will be joined to a mild steel base by means of a screw thread. rod base Fig. 9.1 Name the tool that would be used to cut the thread: (a) on the rod … (b) in the hole in the base … [2]

2 marks

Mark scheme: 9 (a) Die 1 2 Not tapper (b) Tap 1

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Q202 · A balance that will be used by young children 0445/32 Oct/Nov 2020

11 Fig. 11.1 shows a balance that will be used by young children. The balance will be made in a school workshop. arm arrow support weights pan base Fig. 11.1 (a) Complete Table 11.1 by naming a specific material for each of the parts of the balance. Table 11.1 Parts Type of material Specific material Arm, support, base Hardwood Arrow Manufactured board Pans Thermoplastic Weights Non-ferrous metal [4] (b) Fig. 11.2 shows the support that will be joined to the base. support 15 base 120 15 Fig. 11.2 Use sketches and notes to show how the support could be joined permanently to the base. [3] (c) Fig. 11.3 shows details of one end of the arm. The ends of the arm are rounded and there are slots for the string holding the pans to hook over. 10 wide × 10 deep 40 waste Fig. 11.3 Use sketches and notes to show how: (i) the slots could be cut out [2] (ii) the waste wood could be removed and the ends rounded. [2] (d) (i) Fig. 11.4 shows a length of Ø25 non-ferrous metal rod from which the weights will be cut. Fig. 11.4 Use sketches and notes to show how one weight, 40 mm long, could be marked out and cut to length using hand tools. Name all the tools and equipment used. [4] (ii) Give two advantages of using non-ferrous metal for the weights rather than ferrous metal. 1 … 2 … [2] (iii) The weights could also be cut to length on a centre lathe. Fig. 11.5 shows two centre lathe operations, A and B, that could be used to produce the weights. work rotates work rotates A B Fig. 11.5 Name the two centre lathe operations A and B. A … B … [2] (iv) Use sketches and notes to show how the basic shape of the weights could be modified so that they could be picked up more easily by young children. [2] (e) Fig. 11.6 shows the basic shape of a wooden former that will be used when vacuum forming the pans. Ø80 × 15 thick Fig. 11.6 (i) Use sketches and notes to show two modifications that need to be made to the basic shape so that the thermoplastic can be vacuum formed successfully. [2] (ii) Explain why it is important to heat the plastic to the correct temperature when vacuum forming. … … … [2]

25 marks

Mark scheme: 11(a) Hardwood: accept any appropriate/correctly named hardwood 1 Manufactured board: plywood, MDF, hardboard 1 Thermoplastic: acrylic, polystyrene, ABS, PVC, LDPE, HDPE, polypropylene, PET 1 Non-ferrous metal: aluminium, brass, copper 1 Not lead 11(b) Appropriate recognised joint: 0–2 Accuracy of sketch, correct orientation, proportion 1 3 Butt, dowel, half-lapped, finger, dovetail Butt: 2 marks= nail/screw +glue otherwise 1 mark for nail/screw only or 1 mark for glue only 11(c)(i) Method of cut out: use of tenon, coping, Hegner, scroll saw, band saw Named 1 Finished using chisel or file 1 2 Not hacksaw 11(c)(ii) Use of tenon, coping, Hegner, scroll, jig saws or chisel to remove waste 1 Use of disc sander, files, glasspaper to finish shape 1 2 11(d)(i) Measure length using a steel rule, ruler, tape measure 1 Mark out using a scriber 1 Hold metal rod in vice 1 Saw off length using a hacksaw 1 4 Must be hand tools. Award max. 2 marks for answers with no sketches 11(d)(ii) Less likely to corrode, self-finishing, do not need an applied finish, attractive 2 × 1 2 Accept any valid advantages Not cheaper, lighter, last longer Question Answer Marks Guidance 11(d)(iii) A facing off 1 B parting off 1 2 Accept: facing, parting 11(d)(iv) Modifications include the use of grooves, ‘ridges’, tapered shape, knurled surface 0–2 2 1st mark for practical modification 2nd mark for accuracy of sketch 11(e)(i) Two modifications include : draft angle, rounded edges, air holes in top of former 2 × 1 2 11(e)(ii) Plastic not hot enough: plastic will not form to the required shape 1 Plastic too hot: it can melt or produce webbing 1 2

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Q203 · A box of giant dominoes used by young children 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

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Q204 · A plant holder and the brackets that will support it on a wall 0445/32 Oct/Nov 2020

13 Fig. 13.1 shows a plant holder and the brackets that will support it on a wall. The sides and ends of the plant holder are made from 15 mm thick hardwood and its base from 10 mm thick manufactured board. The brackets are made from mild steel. 200 brackets 170 A plant holder 800 Fig. 13.1 (a) Give two properties of hardwood that makes it suitable for the plant holder. 1 … 2 … [2] (b) The plant holder will be joined at each corner by means of a dowelled joint. Use sketches and notes to show how a side and an end could be joined at corner A by means of a dowelled joint. Include the following details: • the size and number of dowel pegs to be used • accurate marking out of the dowel positions • a suitable adhesive. [5] (c) Fig. 13.2 shows the base of the plant holder with Ø15 holes drilled to allow for drainage. Ø15 holes base: 10 mm thick manufactured board Fig. 13.2 (i) Name a specific type of drill bit that could be used to drill the Ø15 holes. … [1] (ii) Give two reasons why the base would need to be clamped to a scrap wood board when drilling the Ø15 holes. 1 … 2 … [2] (d) Fig. 13.3 shows one bracket and a strip of 3 mm thick mild steel from which the bracket will be made. Holes will be drilled at centres A and the strip will be bent at B. centres A bends B 200 200 50 Fig. 13.3 (i) Name two marking out tools that could be used to mark out centres A. 1 … 2 … [2] (ii) Use sketches and notes to show how the mild steel strip could be bent to shape at B. Name all the tools and equipment used when making the bends. [3] (iii) Give two reasons why the mild steel brackets would need to be painted. 1 … 2 … [2] (e) The hardwood used to make the plant holder is a sustainable material. Explain what is meant by the term ‘sustainable’. … … … [2]

19 marks

Mark scheme: 13(a) Two properties: tough, durable, hardwearing, attractive, moisture resistant 2 × 1 2 Accept any valid property. 13(b) Recognised dowel joint drawn 1 Diameter of dowel Ø6 – Ø9 1 Number of dowels reqd. min. 2 max. 4 1 Accurate marking out of dowel centres for drilling Named adhesive: e.g. PVA 1 5 Accept use of jig for accurate marking out 13(c)(i) Centre bit, twist bit, forstner bit, saw tooth bit, flat bit, speed bit 1 Not twist drill 13(c)(ii) To prevent splitting underneath the base. To secure the wood for safe drilling. To prevent damage to surface underneath base. Prevent damage to drill bit. Stop wood moving around. Indicates drill through workpiece. Produces a clean hole. 2 × 1 2 13(d)(i) Steel rule, try square, scriber, odd legs, centre or dot punch, scribing block and surface plate 2 × 1 2 Not pencil, marker pen, felt tip 13(d)(ii) Metal strip held securely in vice or around former 1 Method of force: mallet or hammer 1 Correctly named tools and equipment 1 3 Accept heat treatment/annealing as a stage. 13(d)(iii) Attractive appearance, protect metal from corrosion 2 × 1 2 Accept any valid reason. 13(e) Trees can be planted to replace those used, wood can be reused to make manufactured boards, material that does not run out 2 Accept any valid point to support sustainability. Question Answer Marks Guidance 13(f) Some form of recognisable ‘legs’ 1 Supported at 500 height 1 Plant holder ‘fits’ into/onto ‘leg’ support 1 Suitable materials 1 Appropriate constructions and fittings 1 Accuracy of design drawings 1 6

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Q205 · Two standard timber sections, A and B 0445/33 Oct/Nov 2020

1 Fig. 1.1 shows two standard timber sections, A and B. 50 × 25 50 × 50 A B Fig. 1.1 Give the correct name for each of the standard timber sections. A … B … [2]

2 marks

Mark scheme: 1 A strip [1] B square [1] 2 A accept ‘batten’.

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Q206 · Part of a length of Ø20 aluminium tube that will be cut into 50 mm long pieces 0445/33 Oct/Nov 2020

2 Fig. 2.1 shows part of a length of Ø20 aluminium tube that will be cut into 50 mm long pieces. Fig. 2.1 Complete Table 2.1 by naming one tool or item of equipment for each stage of the process. Table 2.1 Stage Tool or item of equipment Measuring Marking out Cutting to length [3]

3 marks

Mark scheme: 2 Measuring: steel rule, ruler, rule, measuring tape [1] Marking out: scriber [1] Cutting to length: hacksaw, junior hacksaw [1] 3 Marker pen/felt tip=0

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Q207 · A former that will be used when vacuum forming plastic 0445/33 Oct/Nov 2020

3 Fig. 3.1 shows a former that will be used when vacuum forming plastic. Fig. 3.1 State two features of the former that will ensure that the plastic will be vacuum formed successfully. 1 … 2 … [2]

2 marks

Mark scheme: 3 Two features: draft angle, rounded edges/corners, air holes, smooth surfaces [2 × 1] 2

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Q208 · A nameplate used in a garden centre 0445/33 Oct/Nov 2020

4 Fig. 4.1 shows a nameplate used in a garden centre. The nameplate is made from mild steel. card label to be attached here 200 Golden Rose 150 card label Fig. 4.1 Use sketches and notes to show a modification to the mild steel nameplate to allow the card label to be attached and removed easily. [3]

3 marks

Mark scheme: 4 Some sort of rebate to provide a ‘sleeve’ for the label. Hold label in place [1] Easy to change label [1] Added details to explain design [1]

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Q209 · Complete Table 6.1 by naming a suitable specific material for each product 0445/33 Oct/Nov 2020

6 Complete Table 6.1 by naming a suitable specific material for each product. Table 6.1 Product Suitable specific material body of metalwork vice fast food container made from plastic softwood cabinet [3]

3 marks

Mark scheme: 6 Metalwork vice: cast iron [1] Fast food container: polystyrene, Styrofoam [1] Softwood cabinet: pine, redwood, scots pine, fir, red deal [1] 3 Larch = 0

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Q210 · Complete Table 8.1 by naming a suitable finish, other than paint, for each of the… 0445/33 Oct/Nov 2020

8 Complete Table 8.1 by naming a suitable finish, other than paint, for each of the products made from metal. Table 8.1 Product Suitable finish handle of steel pliers aluminium comb steel bucket [3]

3 marks

Mark scheme: 8 Handle of pliers: plastic dip coating, fluidisation [1] Aluminium comb: anodised, lacquer [1] Steel bucket: galvanised, zinc [1] 3

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Q211 · Details of a knock-down (KD) fitting 0445/33 Oct/Nov 2020

9 Fig. 9.1 shows details of a knock-down (KD) fitting. 40 barrel Ø10 Ø6 allen screw Fig. 9.1 Fig. 9.2 shows the corner of a small wooden box. 15 Fig. 9.2 Add sketches to Fig. 9.2 to show how a corner joint could be made using the knock-down (KD) fitting shown in Fig. 9.1. [2]

2 marks

Mark scheme: 9 Correct position of barrel [1] Correct position of screw [1] 2

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Q212 · Views of a small table made from 15 mm thick plywood 0445/33 Oct/Nov 2020

11 Fig. 11.1 shows views of a small table made from 15 mm thick plywood. The table top has been removed to show details of the frame and legs. Legs B and C are joined through frame A by means of dowels. table top Ø400 dowels leg B leg C frame A frame A leg B leg C table height 500 width 400 Fig. 11.1 (a) Use sketches and notes to show why plywood is a more suitable material than solid wood for the design of this table. [3] (b) Fig. 11.2 shows the shape of frame A marked out on a sheet of plywood. Use sketches and notes to show how the shape could be cut out. Name all the tools and equipment used. waste 485 400 Fig. 11.2 [5] (c) Legs B and C will be joined through frame A by means of dowels. Fig. 11.3 shows details of leg C. 15 Fig. 11.3 (i) State an appropriate diameter of dowel that could be used to join leg B to leg C through frame A. … [1] (ii) Use sketches and notes to show how the holes for the dowels could be drilled accurately in the legs and frame. [4] (d) Fig. 11.4 shows the table top marked out on a sheet of plywood. The table top will be made on a woodturning lathe. Fig. 11.4 (i) Give two reasons why the corners need to be removed before the plywood is set up on the woodturning lathe. 1 … 2 … [2] (ii) Describe one check that must be made when setting up the plywood on the woodturning lathe before the machine is switched on. … … [1] (iii) Name two tools or items of equipment that could be used when making the table top on a woodturning lathe. 1 … 2 … [2] (e) Use sketches and notes to show a method of fixing the table top to the frame and legs. Additional materials may be used. [4] (f) The table will have a painted finish. (i) Give one reason why the parts of the table would be painted before they are assembled. … [1] (ii) A primer coat will be applied first. Explain the purpose of a primer coat. … … … [2]

25 marks

Mark scheme: 11(a) Odd number of plies shown [1] Alternate grain direction shown [1] Notes to explain why this provides a stable board [1] 3 Accept answers that relate to short grain on solid woods. 11(b) Hold plywood securely [1] Cut outer shape: jig, Hegner, scroll, band saws, router [1] Cut inner shape: drill hole for jig saw, coping saw, router [1] Use of jig saw to cut inner shape [1] Correctly named tools and equipment [1] 5 Files = 0 Laser = 0 11(c)(i) Ø 6–9 mm 1 11(c)(ii) Use of dowel jig with studs or panel pins [heads cut off] to mark accurate centres for drilled holes [0–2] Correct sequence [1] Additional explanatory notes [1] 4 Award 0–3 marks dependent on accuracy of detailed notes. Holes drilled in end of B. Dowel jig/panel pins used to mark centres on frame A. Holes drilled in A. Repeat process for frame joined to leg C. 11(d)(i) Corners removed: makes it easier to turn round shape, avoids splitting, safer [2 × 1] 2 11(d)(ii) Checks include: free rotation of workpiece, correct height and clearance of tee rest, correct speed 1 Clothing caught =0 11(d)(iii) Faceplate, tee rest, gouge, scraper, chisel [2 × 1] 2 Files=0 Glasspaper =0 11(e) Additional strips of wood joined to top of frame to increase area to which table top can be fastened OR Additional strips of wood joined to underside of table top into which the top of the frame will ‘sit’. [0–2] Methods of fastening; use of screws, brackets [0–2] 4 Use of screws, brackets without additional strips = 0–2 marks 11(f)(i) Quicker to apply paint before assembly, easier to paint all areas [especially corners] 1 Question Answer Marks Guidance 11(f)(ii) Primer coat: ensures better adhesion of paint, inceases durability of paint, provides additional protection, paint goes on smoother, less absorption [2 × 1] 2 Accept 2 separate points

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Q213 · Views of an incomplete design of a stand for a tablet 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

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Q214 · A table lamp that could be made in a school workshop 0445/33 Oct/Nov 2020

13 Fig. 13.1 shows a table lamp that could be made in a school workshop. base 2 mm thick brass Ø15 brass tube hardwood legs Fig. 13.1 (a) The base and tube of the lamp are made from brass. Brass is a non-ferrous alloy. Explain what is meant by the term ‘non-ferrous alloy’. … … … [2] (b) Fig. 13.2 shows the base of the lamp that will be cut from a sheet of 2 mm thick brass. base Fig. 13.2 (i) Give two benefits of using a template to mark out the shape of the base on brass sheet. 1 … 2 … [2] (ii) Give the correct name of tools A and B shown below that could be used when cutting out the shape of the base. A B A … B … [2] (c) (i) The Ø15 brass tube could be joined to the base by means of hard (silver) soldering. State the purpose of the following materials and items of equipment used during the soldering process. emery cloth … fire bricks … flux … silver solder … blow torch … [5] (ii) The brass tube could be joined to the base by means of a screw thread. Use sketches and notes to describe how the items of equipment, A and B shown below, could be used to produce a screw threaded joint. A B [6] (d) Fig. 13.3 shows one hardwood leg marked out ready to be shaped. 60 waste to be removed 300 25 Fig. 13.3 (i) Name one machine saw that could be used to remove the waste. … [1] (ii) Name one specific plane that could be used to make the sawn edge flat and smooth. … [1] (e) The hardwood legs will have an applied finish to protect the wood and give it an attractive appearance. Give one other benefit of applying: (i) a painted finish … [1] (ii) a clear varnish. … [1] (f) Describe how the brass fittings could be polished to a high quality. … … … [2] (g) The base will be joined to the legs using epoxy resin adhesive and brass pins. Describe how the epoxy resin adhesive would be prepared before it is applied. … … … [2]

25 marks

Mark scheme: 13(a) Non-ferrous metal does not contain iron [1] Alloy is a mixture of two or more metals [1] 2 13(b)(i) Templates allow quick marking out of irregular shapes, repetitive accuracy, avoids errors [2 × 1] 2 13(b)(ii) A tin snips [1] B junior hacksaw, hacksaw [1] 2 13(c)(i) Emery cloth: used to clean the joint [1] Fire bricks: tube is positioned on firebricks so that heat from torch is reflected [1] Flux is used to keep the joint clean and allow the spelter to flow [1] Silver solder is heated and melted to make the joint [1] Blow torch is used to heat the metal to the required temperature [1] 5 Question Answer Marks Guidance 13(c)(ii) A Die is secured in a die stock or holder End of tube is chamfered Die is placed firmly on end of tube and turned to start cutting thread Die is turned back to break off swarf cuttings [3 × 1] B Tap is secured in a tap wrench Tap is placed firmly in hole Tap is turned with pressure to start cutting thread Tap is turned back to break off swarf cuttings [3 × 1] 6 Reward any valid, technically correct stages. 13(d)(i) Jig saw, band saw, scroll saw, Hegner saw 1 13(d)(ii) Smoothing, jack. 1 13(e)(i) Wide choice of types of paint and colours available. Could be used to ‘match’ surroundings [1] 1 13(e)(ii) Clear varnish allows the natural colour and grain features to be seen [1] 1 13(f) Two stages include: dip into an acid bath to ‘pickle’, clean metal with pumice powder, use of fine grades of silicon carbide [wet and dry] paper, buff to a fine finish on a polishing wheel and compound, use of metal polish [2 × 1] 2 13(g) Epoxy resin is presented as two separate components: resin and hardener [1] Equal amounts of resin and hardener are mixed thoroughly before application [1] 2

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Q215 · A workshop operation where there is a danger of damaging the material 0445/32 May/June 2021

1 Fig. 1.1 shows a workshop operation where there is a danger of damaging the material. two pieces of 20 mm thick softwood Fig. 1.1 State the possible damage to the material and describe how it could be prevented. Possible damage … Method of prevention … [2]

2 marks

Mark scheme: 1 Damage: bruising to softwood, scratching, crushing, marking, spoiling, marked 1 Prevention: use of scrap wood, sponge, cardboard between cramp and softwood 1 2 Not ‘crack’,’ break’ or ‘snap’

This question in 0445/32 May/June 2021

Q216 · A photograph holder and two hardwood stands 0445/32 May/June 2021

2 Fig. 2.1 shows a photograph holder and two hardwood stands. photograph holder slot 35 hardwood stand 110 Fig. 2.1 Complete Table 2.1 by stating the purpose of each tool used to produce the hardwood stands. Table 2.1 Tool Purpose of tool Sliding bevel Tenon saw Bevel-edge chisel [3]

3 marks

Mark scheme: 2 Sliding bevel: to mark out chamfer or sides of slot. Mark out angle 1 Tenon saw: to saw down the sides of the slot or chamfer, cut straight lines 1 Bevel-edge chisel: to cut out/ remove the waste after sawing 1 Not ‘mark out’ on its own Not ‘cut out’ on its own Consider sequence when awarding marks

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Q217 · Complete the statement below by adding the correct term from the list 0445/32 May/June 2021

3 Complete the statement below by adding the correct term from the list. soft flexible hard corrosion resistant Steel that contains a high amount of carbon is very … [1]

1 marks

Mark scheme: 3 Hard 1

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Question 218 0445/32 May/June 2021

4 Draw on Fig. 4.1 to show an exploded view of a tee-halving joint. Fig. 4.1 [3]

3 marks

Mark scheme: 4 Recognised ‘halving’ shown on each piece 2x1 Accuracy and proportion 1 3 Award 1 mark for halving shown not exploded Award 2 marks for halving shown not exploded but showing accurate hidden detail

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Q219 · Two lengths of 5 mm thick mild steel strip with pre-drilled holes 0445/32 May/June 2021

6 Fig. 6.1 shows two lengths of 5 mm thick mild steel strip with pre-drilled holes. Fig. 6.1 Name different types of fastening that could be used in the pre-drilled holes to join the mild steel strips together: temporarily … permanently … [2]

2 marks

Mark scheme: 6 Temporarily: nut and bolt, nut and screw, self tapping screw 1 Permanently: rivets, pop rivets 1 2 For 1 mark nut and bolt or nut and screw. Do not accept heat processes or gluing. Not ‘bolt’ or ‘screw’ on its own

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Q220 · Two lengths of softwood, A and B 0445/32 May/June 2021

9 Fig. 9.1 shows two lengths of softwood, A and B. Draw on A to show a rebate. Draw on B to show a groove. A B Fig. 9.1 [4]

4 marks

Mark scheme: 9 A Rebate 0–2 B Groove 0–2 4 Award 0–2 dependent on accuracy of drawings Do not reward drawings with added pieces of wood to make rebate or groove Accept rebate drawn as part of a half lapped joint =2 Grooves drawn in end or across the grain =1 Award 1 mark for routered groove Rebate and groove must be drawn on Fig.9.1 otherwise 0 marks

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Q221 · A table made from oak with a detachable magazine rack made from acrylic 0445/32 May/June 2021

11 Fig. 11.1 shows a table made from oak with a detachable magazine rack made from acrylic. 500 750 top rail 40 × 20 500 leg 40 × 20 magazine rack Ø12 rod view with table top and magazine rack removed Fig. 11.1 (a) Give two reasons why oak is a suitable hardwood from which to make the table. 1 … 2 … [2] (b) The table top is constructed from three separate boards. Fig. 11.2 shows the end of the table top. 20 500 end grain Fig. 11.2 (i) Give one reason why the table top is constructed from three boards rather than one board 500 mm wide. … [1] (ii) Explain why the boards have been arranged as shown by the end grain. … … … [2] (c) Fig. 11.3 shows a brass plate screwed into the top rail. The oak table top will be fixed to the top rail by means of a screw inserted from underneath the brass plate. The hole to take the screw is slotted. top rail screwed through plate into underside of table top Fig. 11.3 Explain why the hole for the screw that goes into the table top is slotted. … … … [2] (d) The legs and top rails are joined together by means of glued dowel joints. Fig. 11.4 shows one of the dowels that will be used. chamfer grooves Fig. 11.4 State the purpose of: (i) the grooves … (ii) the chamfer. … [2] (e) Fig. 11.5 shows details of a jig that could be used to mark out the positions for the dowels on the ends of the top rails and legs. The jig is made from 1 mm thick mild steel sheet. The jig fits neatly over the end of the top rails and legs. leg top rail 40 20 20 internal jig dimensions Fig. 11.5 Fig. 11.6 shows the development (net) of the dowel jig marked out, ready to be cut to shape. 20 waste 20 centres for Ø2 holes 20 20 40 1 mm thick mild steel sheet Fig. 11.6 (i) Name two marking out tools that could be used to mark out the development (net). 1 … 2 … [2] (ii) Give one reason why a centre punch would be used before drilling holes in the mild steel sheet. … [1] (iii) Use sketches and notes to show how the development (net) could be cut out. Name all the tools and equipment used. [3] (iv) Use sketches and notes to show how the cut out development (net) could be bent to shape. Name all the tools and equipment used. [4] (f) The magazine rack is made from 4 mm thick acrylic sheet. Fig. 11.7 shows a CAD screenshot of the magazine rack that will be cut out using a laser cutter. Fig. 11.7 Complete Table 11.1 by adding three stages when cutting out the magazine rack using a laser cutter. Table 11.1 Stages Action to be taken 1 Set up sheet on laser cutter bed 2 3 4 5 Remove acrylic from laser cutter bed [3] (g) Fig. 11.8 shows an end view of the magazine rack. The two edges are curved to fit over Ø12 rod. Ø12 Fig. 11.8 Use sketches and notes to show how the Ø12 curves could be produced along the two edges. [3]

25 marks

Mark scheme: 11(a) Two reasons: hardwearing, attractive, finishes well, tough, durable, long lasting, resistant to scratches 2 × 1 2 Not ‘easy to work with’ Not ‘can be used outdoors’ or ‘weather resistant’ 11(b)(i) Wider boards are not available, hardwood boards have limited width 500 mm wide boards are more expensive 1 Candidates giving ‘warping’ or ‘cupping’ in 11(b)(i) can be awarded 1 mark but do not accept a repeated answer in (b)(ii) 11(b)(ii) Boards arranged with alternating positions for end grain to provide stability 1 Without the arrangement the whole table top would ‘cup’, prevents splitting, prevents deforming over time 1 2 Candidates giving ‘warping’ or ‘cupping’ in 11(b)(i) can be awarded 1 mark but do not accept a repeated answer in (b)(ii) 11(c) Movement of solid wood occurs across the grain 1 Slots allow the screw to move as the wood expands or contracts 1 2 Award 1 mark for ‘ease of alignment of top to rails’ 11(d) (i) Grooves provide space for glue inside the drilled hole, allows excess glue/air to escape, provides better grip 1 (ii) Chamfer allows for easier entry into drilled hole 1 2 11(e)(i) Two marking out tools: scriber, try square, steel rule, metre rule, ruler, odd leg calipers, engineers/marking blue 2 × 1 2 Not ‘centre punch’ 11(e)(ii) To guide the tip of the drill, to prevent tip of drill ‘wandering’, to provide an accurately positioned hole 1 Question Answer Marks Guidance 11(e)(iii) Use of tin snips or hacksaw shown 1 Tin snips or hacksaw named 1 Held in vice or clamped 1 3 Accept ‘guillotine’, ‘notcher’ 11(e)(iv) Use of a former the same shape as the section of legs/rails 1 Use of vice or clamps 1 Use of a mallet or hammer 1 Technical accuracy 1 4 11(f) Three stages include: edit CAD drawing score, engrave and cut lines, position CAD drawing on A2 size paper, turn on laser, position acrylic on bed of machine, enter ‘set up’ parameters , computer file ‘Print’, ‘Run’ 3 × 1 3 Accept any valid stages 11(g) Use of a Ø12 rod or former 1 Heat the acrylic or the Ø12 rod or former 1 Bend around former 1 3

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Q222 · A storage unit with adjustable shelves that will be used in a bathroom 0445/32 May/June 2021

12 Fig. 12.1 shows a storage unit with adjustable shelves that will be used in a bathroom. The storage unit is made from acrylic and could be produced in a school workshop by means of hand tools and CAD / CAM. top Ø240 upright height of storage unit 300 mm shelf slot shelf base Fig. 12.1 (a) Give two benefits of using acrylic to make products that will be used in a bathroom. 1 … 2 … [2] (b) State two important items of information that could be obtained by making either a card model or computer-generated model of the storage unit. 1 … 2 … [2] (c) The shelf slots will be cut out of the uprights. Describe how CAD / CAM could be used to produce the shelf slots quickly and accurately. … … … … … … [4] (d) Fig. 12.2 shows how the two uprights slot together to produce the main part of the storage unit. 240 300 5 mm thick slot 150 mm deep Fig. 12.2 Give two benefits, other than speed, of using a scroll saw to cut out the slots. 1 … 2 … [2] (e) Fig. 12.3 shows details of one shelf and a separate edging that will be joined to the front edge of the shelf. waste edging 160 × 15 × 4 110 shelf 4 mm thick 20 Fig. 12.3 (i) Name two hand tools that could be used to produce the shelf. 1 … 2 … [2] (ii) The edging will be made from a length of acrylic. The acrylic will be heated and bent to match the curved front edge of the shelf. Explain why the acrylic would be heated in an oven rather than by a strip heater or line bender. … … … [2] (iii) The edging will be joined to the front edge using acrylic cement. Use sketches and notes to show how the edging could be held securely against the front edge of the shelf while the acrylic cement sets. [4] (iv) State one safety precaution that must be taken when using acrylic cement. … [1] (f) The items stored in the unit could be made easier to access if the unit could be made to rotate. Use sketches and notes to show how an additional base could be used to make the storage unit rotate. Give details of the materials and constructions used. [6]

25 marks

Mark scheme: 12(a) Two benefits: attractive appearance, colours available to ‘match’, resistant to moisture, easy to clean, water resistant 2 × 1 2 Accept any valid benefit Not ‘lightweight’ 12(b) Two items of information: appropriate size/dimensions, will products fit/sufficient space, appearance/aesthetics, CAD modelling allows for on-screen modelling edits including colour, ease of removal of shelves 2 × 1 2 Accept any valid item of information as a result of modelling Accept only one ref. to dimensions 12(c) CAD drawing data transferred to appropriate machine [e.g. laser cutter or equivalent CNC machine], machine parameters set, acrylic positioned on bed of machine, ‘Run’. 0–4 4 Award 0-4 dependent on technical accuracy of relevant individual points. Question Answer Marks Guidance 12(d) Two benefits of using a scroll saw: easy to control, easy to use/control/handle, thin blade, acrylic in flat position during cut and less likely to snap 2 × 1 2 Accept any valid advantage Not ‘accurate’ 12(e)(i) Two hand tools: hacksaw, coping saw, variety of files, piercing saw, tenon saw, junior hacksaw, needle files 2 × 1 2 Do not reward marking out stages 12(e)(ii) A line bender or strip heater only heats a small, specific area 1 An oven heats and softens the whole strip of acrylic 1 2 12(e)(iii) Sketch showing some form of female mould 0–2 Method of clamping across moulds in 2 directions 2 × 1 4 For maximum 2 marks each mould must ‘fit’ contour of front edge of shelf and allow for stable clamping Award 1 mark for use of G cramp or vice when curved part is glued onto the shelf [not edge] 12(e)(iv) Barrier cream, gloves for hands, mask, good ventilation. 1 12(f) Some form of additional ‘base’ 0–2 Method of rotation 0–2 Materials and constructions 0–2 6 Reward practical ideas for a base and the method of rotation

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Q223 · An incomplete design for a novelty adjustable lamp made from hardwood 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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Question 224 0445/33 May/June 2021

1 Draw on Fig. 1.1 to show the construction of blockboard. Fig. 1.1 [4]

4 marks

Mark scheme: 1 Top ply 1 Bottom ply 1 ‘Strips’ run through front to back 1 Accuracy and proportion 1 4

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Q225 · Complete the statement below by adding the correct term from the list 0445/33 May/June 2021

2 Complete the statement below by adding the correct term from the list. manufactured composite pure hardened Carbon fibre reinforced plastic (CFRP) is an example of a … material. [1]

1 marks

Mark scheme: 2 Composite 1

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Q226 · A solid wood board that has warped 0445/33 May/June 2021

3 Fig. 3.1 shows a solid wood board that has warped. Fig. 3.1 Give two reasons why the solid wood board has warped. 1 … 2 … [2]

2 marks

Mark scheme: 3 Two reasons: uneven seasoning, drying out too quickly, brought into warm conditions while wet, not ‘stacked’ properly during seasoning or storage after seasoning, subjected to uneven weight applied to board 2 × 1 2 Must relate to wood in dry/warm conditions Not ‘wet’ or ‘outdoors’

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Q227 · A surface plate and scribing block 0445/33 May/June 2021

5 Fig. 5.1 shows a surface plate and scribing block. scribing block surface plate Fig. 5.1 Give two reasons why the surface plate and scribing block provide great accuracy when marking out metal. 1 … 2 … [2]

2 marks

Mark scheme: 5 Two reasons: surface plate and base of gauge machined to high specification, Provide a true surface from which to mark out, repetitive accuracy possible, parallel lines can be drawn, heights tested, fine adjustments can be made 2 × 1 Scribing block fixed position

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Q228 · Complete the statement below by adding the correct term from the list 0445/33 May/June 2021

6 (a) Complete the statement below by adding the correct term from the list. polystyrene polypropylene polythene polyester Glass-reinforced plastic (GRP) is produced by laminating layers of glass-fibre mat with … resin. [1] (b) Some car bodies are made from glass-reinforced plastic (GRP). Give two advantages of using GRP rather than steel for car bodies. 1 … 2 … [2]

3 marks

Mark scheme: 6(a) Polyester 1 6(b) Two advantages: lightweight, corrosion resistant, easily formed, excellent strength-weight ratio, easily repaired, inherent colour, weather resistant 2 × 1 2 Not ‘cheaper’, ‘impact resistant’, ‘tough’, ‘strong’, ‘easier to work’, easier to make ‘durable’

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Q229 · An incomplete drawing of a hasp and staple fitting 0445/33 May/June 2021

7 Fig. 7.1 shows an incomplete drawing of a hasp and staple fitting. Fig. 7.1 Add sketches and notes to Fig. 7.1 to complete the drawing of the hasp and staple fitting. [2]

2 marks

Mark scheme: 7 Staple shown inserted through slot 1 Staple includes bottom plate/base 1 2

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Q230 · A chair leg made from a length of hardwood 100 mm wide × 20 mm thick 0445/33 May/June 2021

8 Fig. 8.1 shows a chair leg made from a length of hardwood 100 mm wide × 20 mm thick. The chair leg has been formed by steam bending. Fig. 8.1 Give three main stages when steam bending the length of hardwood to make the chair leg. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 8 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 before removing from chest 3 × 1 Must include clamping for maximum marks Do not accept ‘steam machine’

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Q231 · A workshop operation where there is a danger of damaging the material 0445/33 May/June 2021

9 Fig. 9.1 shows a workshop operation where there is a danger of damaging the material. line to be sawn 4 mm thick acrylic Fig. 9.1 State the possible damage to the material and describe how it could be prevented. Possible damage … Method of prevention … [2]

2 marks

Mark scheme: 9 Damage: plastic can vibrate and snap/break during sawing, scratched in vice jaws 1 Prevention: place plastic as low as possible in vice, saw slowly, support with scrap wood, soft vice jaws or protected material 1 2 Damage: not ‘crack’, ‘shatter’ or ‘split’

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Q232 · A wooden mould used to vacuum form a small tray 0445/33 May/June 2021

10 Fig. 10.1 shows a wooden mould used to vacuum form a small tray. Fig. 10.1 (a) Give two advantages of making the mould from MDF rather than oak. 1 … 2 … [2] (b) Describe two features of the mould required to produce a quality vacuum formed tray. 1 … 2 … [2]

4 marks

Mark scheme: 10(a) Two advantages of MDF: easier to cut and shape, no prominent/open grain, more stable, finishes well, less likely to shrink or expand, less likely to split, cheaper, smooth surface 2 × 1 10(b) Two features: draft angle, no sharp edges, rounded corners, no undercuts, smooth surface, no indents or scratches 2 × 1 2 Do not award references to air holes in base

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Q233 · Details of an incomplete design for an adjustable mirror made mainly from acrylic 0445/33 May/June 2021

11 Fig. 11.1 shows details of an incomplete design for an adjustable mirror made mainly from acrylic. Parts of the adjustable mirror will be batch produced in a school workshop using a laser cutter. mirror glass frame 10 mm thick acrylic Ø4 hole stand 5 mm thick acrylic 140 200 60 Fig. 11.1 (a) Give two benefits of using acrylic to make the adjustable mirror. 1 … 2 … [2] (b) The stand will be produced by means of a laser cutter. Fig. 11.2 shows a screenshot of a CAD drawing of the development (net) of the stand. Fig. 11.2 (i) Complete five stages of producing the acrylic stand using a laser cutter. The first one has been done for you. 1 Draw the development (net) of the stand design using CAD. 2 … 3 … 4 … 5 … [4] (ii) Give two benefits, other than speed, of using a laser cutter to batch produce parts of the adjustable mirror. 1 … 2 … [2] (c) After the development (net) of the stand has been cut out it will be bent to shape. Use sketches and notes to show how the acrylic stand could be bent to shape. [3] (d) Fig. 11.3 shows views of part of the stand and mirror. The mirror will pivot inside the stand and must be able to be locked in position when adjusted. 10 30 Ø4 hole mirror glass 5 mm gap Fig. 11.3 Use sketches and notes to show a fitting that could be used to adjust the mirror and lock it in position. The fitting must be adjustable by hand and be attractive. Include details of materials and constructions used. [6] (e) The stand could also be made from mild steel sheet. Fig. 11.4 shows the development (net) of the stand made from 1.6 mm thick mild steel sheet. 20 60 waste 140 200 Fig. 11.4 Use sketches and notes to show how the stand could be cut out by hand and bent to shape. Give the names of the tools and equipment used. [6] (f) The stand made from mild steel sheet will have a spray painted finish. (i) Name one abrasive paper that could be used to prepare the surfaces to take a spray painted finish. … [1] (ii) Give one advantage of a spray painted finish rather than a painted finish applied by brush. … [1]

25 marks

Mark scheme: 11(a) Two benefits: colourful, easily shaped, attractive finish, hardwearing, self-finishing, variety of colours, easily cleaned, attractive appearance 2 × 1 2 Accept any valid advantages Not ‘lightweight’, ‘easy to work’ 11(b)(i) Four stages: edit CAD drawing score, engrave and cut lines, position CAD drawing on A2 size paper, turn on laser, position acrylic on bed of machine, enter ‘set up’ parameters , computer file ‘Print’, ‘Run’ 4 × 1 4 Accept any valid stages 11(b)(ii) Two benefits: repetitive accuracy, accurate, clean cut, requires less finishing, machine can be set up quickly, repeated quickly, eliminate human error, lower cost of production, minimal waste 2 × 1 2 Question Answer Marks Guidance 11(c) Use of a line bender, strip heater, heat gun 1 Use of former or jig 1 Method of retention while cooling 1 3 11(d) Some sort of rod/pivot/screw/bolt through stand and into mirror frame 1 Retained in mirror frame / pivot attached to stand and loose in mirror frame 1 Use of screw thread to provide tightening or alternative locking method 1 Appropriate use of ‘spacers’/washers 1 Materials and constructions 0–2 6 Accept ‘stuck in frame’ without additional details for method of retention 11(e) Waste cut off: tinsnips, hacksaw, Hegner saw and appropriate blade, cold chisel named 1 Steel held in vice, clamp, folding bars 1 Cut edges filed flat and smooth: filed 1 Use of hand, flat, half round files named 1 Bent to shape: vice, clamp, folding bars, former, hammer, mallet, bending machine 2 × 1 6 11(f)(i) Emery cloth, wet and dry [silicon carbide] paper, steel wool 1 11(f)(ii) Advantage: quicker, even finish possible, no brush strokes 1

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Q234 · A folding stool made from hardwood with a fabric seat 0445/33 May/June 2021

12 Fig. 12.1 shows a folding stool made from hardwood with a fabric seat. The stool will be used outdoors. position for coach bolt A rail Fig. 12.1 (a) Give two additional specification points for the folding stool. The folding stool must: 1 be comfortable to use 2 … 3 … [2] (b) Fig. 12.2 shows the shape of the rail marked out, ready to be cut out. waste 400 50 20 Fig. 12.2 Use sketches and notes to show how the curved shape could be produced. Show how the rail could be held securely while the shape is produced. Give the correct names of the tools and equipment used. [4] (c) Sketch and name a suitable construction that could be used to join the rail to the leg at A in Fig. 12.1. Name of construction … [4] (d) Fig. 12.3 shows a type of cramp that could be used when gluing a rail to the legs. Fig. 12.3 (i) Name the type of cramp shown in Fig. 12.3. … [1] (ii) Name an adhesive that would be suitable for use outdoors. … [1] (iii) Use sketches and notes to show how the cramp in Fig. 12.3 could be used to clamp the rail to the legs while the adhesive sets. [2] (iv) State two checks that must be made when clamping the rail and legs together. 1 … 2 … [2] (e) Fig. 12.4 shows a coach bolt and nut. Fig. 12.4 Describe one benefit of using this type of fitting to join the legs together at the position shown in Fig. 12.1. … … [2] (f) Fig. 12.5 shows a folding stool made from Ø20 aluminium tube with a fabric seat. A Fig. 12.5 Give two properties of aluminium tube that make it suitable for the folding stool. 1 … 2 … [2] (g) State the purpose of the plastic ‘foot’ shown at A in Fig. 12.5. … [1] (h) Fig. 12.6 shows the folding stool made from aluminium tube with the fabric seat removed. Fig. 12.6 Use sketches and notes to show a design for a moulded plastic seat that could be attached securely to the Ø20 tube and allow the stool to be folded and carried. Name a specific plastic for the seat. [4]

25 marks

Mark scheme: 12(a) Two specification points: lightweight, safe in use, no sharp edges, folds flat easily, holds weight, water resistant, easy to clean, compact, easy to carry, portable, durable 2 × 1 2 Accept any valid points Not ‘easy to use’ Question Answer Marks Guidance 12(b) Curved shaped removed: use of spokeshave, rasp, Surform tool, coping or Scroll saws and files, compass plane, band saw, jig saw 2 × 1 Rail held securely: use of vice, bench stop, G cramps 1 Quality of sketches of tools/equipment 1 4 Do not accept ‘use of glasspaper’ 12(c) Suitable construction: mortise and tenon, dowel named 1 Award 0-3 dependent on technical accuracy 0–3 4 12(d)(i) Sash 1 Only acceptable answer 12(d)(ii) Wide range of adhesives available must be water resistant Includes epoxy resin, contact adhesive, PVA, synthetic resin 1 Check internet for ‘unheard of’ answers 12(d)(iii) Cramp shown directly under rail and square against legs 1 Use of scrap wood to prevent bruising, apply even pressure 1 2 Must show 2 legs 12(d)(iv) Two checks: squareness using a try square, make sure rail and leg are flat [not in winding], removal of surplus glue, rail and legs close fitting, check joint is secure, cramps tightened, not overtight 2 × 1 2 12(e) Benefit: the bolt has a square section under the head 1 the bolt does not move/rotate when the nut is tightened 1 2 Award 1 mark for: ‘allow stool to fold/be taken apart’ 12(f) Two properties: corrosion resistant, lightweight, no finish required, rounded tube comfortable, easily bent/formed 2 × 1 2 Accept any valid properties Not ‘attractive’, ‘durable’, ‘tough’ 12(g) Foot gives stability, prevents end of tube ‘digging’ into ground, slipping, sliding, provides grip, prevents dirt in end of tube 1 Question Answer Marks Guidance 12(h) Supports weight of user 1 Seat is attached onto/around tube and stool can be folded 0–2 Named plastic: polypropylene, PVC, ABS,HIPS, HDPE 1 4 Must be one piece moulded seat Do not award mark for hinged seats

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Q235 · A nesting box made from 15 mm thick softwood 0445/33 May/June 2021

13 Fig. 13.1 shows a nesting box made from 15 mm thick softwood. A batch of twenty nesting boxes is to be made in a school workshop. back roof roof opens and closes side front Fig. 13.1 (a) (i) Name a suitable softwood for the nesting box. … [1] (ii) Give one reason for your choice of softwood. … [1] (b) Fig. 13.2 shows the parts of one nesting box marked out on a length of softwood. 5 mm waste between parts 140 sideside sideside frontfront roofroof backback floorfloor 260 225 225 200 370 110 Fig. 13.2 (i) Explain why 5 mm waste has been marked out between each of the parts. … … … [2] (ii) Name a machine saw that could be used to cut the parts to length. … [1] (iii) Fig. 13.3 shows the front part of the nesting box after it has been cut from the length of softwood. waste Fig. 13.3 Describe how the waste could be removed to produce flat and square ends. … … … [2] (c) The front, back and sides of the nesting box will be glued and nailed together. (i) Name a specific type of nail suitable to join the parts of the nesting box. … [1] (ii) Name an adhesive that would be suitable outdoors. … [1] (d) Fig. 13.4 shows the floor of the nesting box. Fig. 13.4 Give one reason why the corners of the floor have been removed. … [1] (e) A Ø40 hole will be drilled in the front part of the nesting box. (i) Name a suitable drill bit that could be used to drill the Ø40 hole in the front part of the nesting box. … [1] (ii) Use sketches and notes to show how the front part of the nesting box could be clamped in position while the Ø40 hole is drilled. [2] (f) Use sketches and notes to show how the roof of the nesting box could be made to open and close as shown in Fig. 13.1. [4]

17 marks

Mark scheme: 13(a)(i) Red deal, pine, red wood, Scots pine, Douglas Fir, Columbian pine, Western red cedar, spruce 1 Not ‘parana pine’ If chosen wood is incorrect candidates’ answers to part (a)(ii) can be marked as correct 13(a)(ii) Reason: good outdoors, water resistant, decay resistant, available, relatively cheap, cost effective, durable, sustainable 1 Not ‘cheap’, ‘strong’, ‘lightweight’, ‘aesthetically pleasing’ 13(b)(i) The saw used to cut the parts will remove 1–2 mm of wood 1 The 5 mm waste allows for the saw cut without reducing the length required 1 2 Acceptable points: ‘thickness of saw blade’, ‘space for errors’, ‘waste to be removed later’ 13(b)(ii) Machine saw: Scroll, Hegner, jig saw, band saw, circular/table saw, mitre saw 1 13(b)(iii) Waste removed by planing. Wood held in vice and smoothing or jack plane used, from end to centre [then repeat from other end] OR Wood placed on table of sanding disc and pushed against disc or use of linisher 2 Do not reward the use of files and glasspaper Candidates can achieve max. 2 marks for the planing option by a combination of: 1 mark for ‘planing’ stated 1 mark for name of plane 1 mark for method 13(c)(i) round [wire] nail oval [wire] nail panel pin 1 13(c)(ii) Wide range of adhesives available must be water resistant Includes epoxy resin, PVA, contact adhesive, synthetic resin 1 Check internet for ‘unheard of’ answers Question Answer Marks Guidance 13(d) Corners have been removed to prevent build up of rubbish, easier to keep clean, allow for drainage, allow more air/ventilation 1 13(e)(i) Drill bits: forstner, saw tooth, hole saw, flat bit, step drill 1 13(e)(ii) Softwood shown flat on bench or drill table with thick scrap wood underneath 1 G cramp to secure softwood 1 2 13(f) Suitable hinge drawn 1 Named 1 Hinge in correct position screwed to roof and back 1 2 hinges required or single type of pliable material across width of box 1 4 Suitable hinges: butt, back flap, piano, flush Accept ‘rubber strip’ or other pliable material attached to top and box Award 0–2 for ‘lift-off’ lids dependent on technical accuracy 13(g) Cutting jig: could be used to assist sawing sides to length Assembly jig: could help position the sides when nailing the parts together 2 × 3 6 Appropriate type of jig 1 Show it in use 1 Describe its purpose 1 × 2 13(h) Two factors: weather conditions, aesthetic appearance, vandalism, durability, Insect resistant, easy to clean, stability in use 2 × 1 2 Accept any valid factors described

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Q236 · A method of joining two lengths of hardwood 0445/31 Oct/Nov 2021

1 Fig. 1.1 shows a method of joining two lengths of hardwood. An adhesive is used. slot Fig. 1.1 (a) State the method of joining shown in Fig. 1.1. … [1] (b) State an alternative method of joining the two lengths of hardwood. … [1]

2 marks

Mark scheme: 1(a) Biscuit 1 1(b) Dowel, tongue and groove, domino, butt 1

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Q237 · There are three main stages to be carried out to produce a high quality finish to the… 0445/31 Oct/Nov 2021

2 There are three main stages to be carried out to produce a high quality finish to the edges of acrylic sheet. Fig. 2.1 shows the first stage. Fig. 2.1 (a) Name the method of filing shown in Fig. 2.1. … [1] (b) After filing the edges, silicon carbide paper will be used. Give the common name for silicon carbide paper. … [1] (c) The third stage is to polish the edges on a buffing wheel. Give two safety precautions that must be taken when using a buffing wheel. 1 … 2 … [2]

4 marks

Mark scheme: 2(a) Draw filing 1 Do accept ‘drawing’ 2(b) Wet and dry paper 1 2(c) Loose clothing tucked in, hair tied back, safety glasses, work piece presented to lower half of buffing wheel 2 × 1 2 Do accept items of PPE Do not accept ear defenders, gloves

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Q238 · Circle from the list of materials below one material that can be anodised 0445/31 Oct/Nov 2021

4 Circle from the list of materials below one material that can be anodised. copper steel lead aluminium [1]

1 marks

Mark scheme: 4 Aluminium 1

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Q239 · Two items of equipment, A and B, used when marking out metal 0445/31 Oct/Nov 2021

5 Fig. 5.1 shows two items of equipment, A and B, used when marking out metal. B A Fig. 5.1 Name the items of equipment A and B in Fig. 5.1. A … B … [2]

2 marks

Mark scheme: 5 A surface plate 1 B surface gauge, scribing block 1 2

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Question 240 0445/31 Oct/Nov 2021

6 Fig. 6.1 shows a chair. The curved parts of the chair have been produced by steam bending. Fig. 6.1 Give two benefits of using steam bending to make the curved parts of the chair. 1 … 2 … [2]

2 marks

Mark scheme: 6 Two benefits: quicker than fabricating, greater profit for manufacturer, easier to produce comfortable curved shapes, aesthetically more interesting, less machining, stronger as it is made in one piece, design does not need joints, interesting shape, even curve produced 2 × 1

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Q241 · A design for a wall-mounted leaflet holder 0445/31 Oct/Nov 2021

7 Fig. 7.1 shows a design for a wall-mounted leaflet holder. Fig. 7.1 Add sketches and notes to Fig. 7.1 to show a modification to the design that would make it easier to access the leaflets. [2]

2 marks

Mark scheme: 7 Modification to allow easier access: some sort of ‘recess’ for fingers to access leaflets, hinges on bottom of holder, recess on side of holder, lower top of holder by up to 1/3 0–2 2 Constructional detail not required. Look for simple modification and technical accuracy Award 1 mark for vertical ‘separators’

This question in 0445/31 Oct/Nov 2021

Q242 · A car body shell made from carbon fibre reinforced plastic (CFRP) 0445/31 Oct/Nov 2021

8 Fig. 8.1 shows a car body shell made from carbon fibre reinforced plastic (CFRP). Fig. 8.1 Give two advantages of making the car body shell from carbon fibre reinforced plastic (CFRP) rather than mild steel. 1 … 2 … [2]

2 marks

Mark scheme: 8 Two advantages: lighter weight, greater fuel economy, corrosion resistant, easily moulded parts, good strength- weight ratio, easier to shape, stronger 2 × 1

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Question 243 0445/31 Oct/Nov 2021

9 Fig. 9.1 shows two serving trays. Tray A is made from moulded thermosetting plastic. Tray B is made from hardwood. A B thermosetting plastic hardwood Fig. 9.1 (a) Name a suitable specific material for each tray. Tray A … Tray B … [2] (b) Give two reasons, other than cost, why consumers may prefer to purchase tray A rather than tray B. 1 … 2 … [2]

4 marks

Mark scheme: 9(a) A melamine and urea [formaldehyde], GRP 1 B wide variety of hardwoods available 1 2 9(b) Two reasons for preference: rounded moulded plastic shape, more hardwearing, no joints to come apart, easier to clean, colours to ‘match’ environment, more durable, smoother surface, more aesthetic shape, lasts longer, water resistant 2 ×1 2 Do not accept lightweight, stackable, cheaper

This question in 0445/31 Oct/Nov 2021

Q244 · A child’s rocking horse made from hardwood 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

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Q245 · An incomplete design for a desk tidy 0445/31 Oct/Nov 2021

12 Fig. 12.1 shows an incomplete design for a desk tidy. The trays are made from vacuum formed plastic and can rotate as shown. tray Ø80 × 10 deep tray rotates Ø10 column solid base Fig. 12.1 (a) Name a suitable plastic for the trays. … [1] (b) Use sketches and notes to show how one tray could be vacuum formed. [6] (c) Fig. 12.2 shows the solid base for the desk tidy. centre for hole to take column Ø Fig. 12.2 (i) Name a suitable material for the solid base. … [1] (ii) Give one reason for your choice of material. … [1] (iii) Add two dimensions to Fig. 12.2 to show a suitable thickness and diameter for the solid base. [2] (iv) Use sketches and notes to show how the solid base shown in Fig. 12.2 could be produced in a school workshop. [5] (v) Name a suitable material for the Ø10 column and use sketches and notes to show how the column could be joined securely to the solid base. [3] (d) Use sketches and notes to show how the trays could be supported on the column and allowed to rotate freely as shown in Fig. 12.1. [4] (e) The trays could be replaced with lids from used containers that would otherwise be thrown away. Fig. 12.3 shows a variety of lids. Fig. 12.3 Give two benefits of reusing items that would otherwise be thrown away. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Acrylic, polystyrene, high density polythene, PET, PETE, ABS, polypropylene 1 Do not accept uPVC 12(b) Stages include: place mould on platen, clamp plastic in place, heat plastic sheet, check ‘softness’ of plastic, turn on vacuum and raise platen, check if shape has formed, turn off vacuum, leave to cool 6 × 1 6 12(c)(i) Wide variety of suitable wood, metal or plastic available 1 1 12(c)(ii) Reason for choice of material in previous part (c)(i) Variety of material properties available 1 1 12(c)(iii) Dimensions provided for thickness and diameter must relate to the chosen material. 2 × 1 2 Maximum Ø 150 minimum Ø 120 Maximum thickness 20 minimum 15 Question Answer Marks Guidance 12(c)(iv) Main stages of production: Marking out 1 Cutting [at least 1 tool named] 1 Shaping [at least 1 tool named] 1 Finishing [glasspapering] 1 Finishing [named finish] 1 5 Consider technical accuracy and quality of communication Ignore hole to be drilled in base 12(c)(v) Suitable material: wood, metal or plastic rod or plastic and metal tube 1 Method of joining: drilled hole 1 Use of epoxy resin or adhesive corresponding to chosen material 1 3 12(d) Some form of collar/pin/peg to be fitted onto column 1 Named material for collar/pin/peg 1 Method of joining pin/peg fitted to column 1 Additional details 1 4 12(e) Two benefits: saves raw materials, reduces impact of landfill, reduces possible pollution caused by recycling or incineration, reduces need for collection, reduces plastic waste, less money spent on new materials 2x1 2 Accept any valid benefits of re-using items Do not accept less environmental damage, protects the environment

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Q246 · Details of a ‘floating’ shelf 0445/31 Oct/Nov 2021

13 Fig. 13.1 shows details of a ‘floating’ shelf. • The shelf bracket is screwed to the wall. • The shelf slides onto the bracket, hiding it from view. • The shelf appears to be ‘floating’ because there is no visible means of support. 200 500 tube 150 × Ø15 400 shelf 25 mm thick bracket 20 × 3 mild steel holes to fix to wall Fig. 13.1 (a) (i) Give one advantage of using a manufactured board for the shelf rather than solid wood. … [1] (ii) Give one advantage of using MDF rather than plywood for the shelf. … [1] (b) Fig. 13.2 shows part of the mild steel bracket with the centres marked out for two holes to be drilled. mild steel 20 × 3 centre Fig. 13.2 (i) Name one tool that could be used to mark the lines on the surface of the mild steel bracket. … [1] (ii) Give one reason why it is important to use a centre punch before drilling holes in the mild steel bracket. … [1] (c) Fig. 13.3 shows part of the back of the shelf. A recess has been cut out to take the mild steel bracket. A power router could be used to cut out most of the recess. recess 20 wide × 5 deep Fig. 13.3 State two checks that must be made before using the power router to cut out the recess. 1 … 2 … [2] (d) Fig. 13.4 shows one tube that will be joined to the bracket by means of brazing. Fig. 13.4 (i) Add to Fig. 13.4 to show how the position of the tube could be checked to make sure it is vertical. Name the tools or equipment used. [3] (ii) Complete Table 13.1 by describing how each of the materials or items of equipment could be used when brazing the tube to the bracket. Table 13.1 Material / item of Use equipment emery cloth flux blow torch brazing rod [4] (e) Fig. 13.5 shows the position of the two tubes inside the shelf when the bracket is screwed to a wall. In use, there is nothing to prevent the shelf from sliding off the tubes. hidden detail showing tubes in position bracket set into shelf Fig. 13.5 Use sketches and notes to show how the shelf could be secured to the tubes to prevent the shelf from sliding off. The method of securing the shelf must: • not be visible when the shelf is on a wall • be able to be removed. Include details of fittings and fixings used.

13 marks

Mark scheme: 13(a)(i) Manufactured boards more stable, less likely to expand or shrink, twist or warp, cheaper 1 Do not accept easier to work, cut, shape, lightweight 13(a)(ii) MDF gives a better finish, smoother surface, less likely to splinter, easier to work 1 Do not accept cheaper 13(b)(i) Scriber, odd-leg calipers, odd-legs, Jenny calipers 1 Do not accept calipers, marker pens Question Answer Marks Guidance 13(b)(ii) To prevent the tip of the drill wandering, to produce an accurate hole, no risk of damage to surface of metal, to guide the drill 1 13(c) Two checks: no trailing leads, check set up of tool, fence position and secure, check condition of electrical fittings, no ‘observers’, workpiece held securely 2 × 1 2 Do not accept items of PPE, no loose clothing etc. 13(d)(i) Use of a try square/engineers square, spirit level, ‘level’ named 1 Clear sketch showing tool in position against tube 0–2 3 Award 1 mark maximum for set square shown in position 13(d)(ii) Emery cloth used to clean up joint before brazing 1 Flux applied to parts of the joint to keep joint ‘clean’ and allow ‘spelter’ to flow 1 Blowtorch is used to heat the metal joint 1 Brazing rod applied to joint at appropriate temperature and heated to flow 1 4 13(e) Use of some type of screw fitted through underside of shelf 1 Head ‘sunk’ [hidden] 1 Inserted into tube 1 Added details 1 4 13(f) Two reasons: MDF has an unattractive natural colour, marks more easily covered, colour of paint can ‘match’ environment 2 × 1 2 Do not accept easier to paint 13(g) Three main processes involved in constructing the bracket: Marking out sketch shows marking out 1 at least one tool named 1 1 + 1 Cutting 2 tools/items of equipment used 2 × 1 Joining nailed/screwed and glued =1 dowels/M&T = 2 0–2 6

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Q247 · Circle from the list of materials below one metal that can be hardened 0445/32 Oct/Nov 2021

2 Circle from the list of materials below one metal that can be hardened. lead zinc high carbon steel cast iron [1]

1 marks

Mark scheme: 2 High carbon steel 1

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Q248 · Two pieces of hardwood that are to be joined by means of a KD (Knock-Down) fitting 0445/32 Oct/Nov 2021

3 Fig. 3.1 shows two pieces of hardwood that are to be joined by means of a KD (Knock-Down) fitting. Fig. 3.1 Add sketches and notes to Fig. 3.1 to show how a suitable KD (Knock-Down) fitting could be used to join the hardwood together. [3]

3 marks

Mark scheme: 3 Recognised KD fitting shown: screws shown in 2 directions 2 × 1 Technical accuracy 1 Do accept different KD fittings; e.g. cam lock, wooden block

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Q249 · An item of equipment used to hold components when drilling holes 0445/32 Oct/Nov 2021

5 Fig. 5.1 shows an item of equipment used to hold components when drilling holes. handle Fig. 5.1 (a) Give the correct name for the item of equipment shown in Fig. 5.1. … [1] (b) State the name of a centre lathe process that could have been carried out to the handle to improve grip. … [1]

2 marks

Mark scheme: 5(a) Machine vice 1 Not vice on its own. 5(b) Knurling 1

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Question 250 0445/32 Oct/Nov 2021

6 Fig. 6.1 shows a hardwood bracket. The bracket has been fabricated using hardwood. 160 Fig. 6.1 (a) State what is meant by the term ‘fabricated’. … [1] (b) The bracket could be made from aluminium. State a manufacturing process that could be used to produce the bracket from one piece of aluminium. … [1]

2 marks

Mark scheme: 6(a) Fabricated: the way in which materials are joined together 1 6(b) Casting, die casting, sand casting 1

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Q251 · A leaflet holder made from 3 mm thick acrylic 0445/32 Oct/Nov 2021

8 Fig. 8.1 shows a leaflet holder made from 3 mm thick acrylic. 200 150 Fig. 8.1 Complete Table 8.1 by describing what each of the tools or items of equipment could be used for when making the leaflet holder. Table 8.1 Tool/item of equipment What they are used for Chinagraph pencil Scroll saw Hand file Buffing machine [4]

4 marks

Mark scheme: 8 Chinagraph pencil to mark out the shape of the holder 1 Scroll saw to cut out the shape 1 Hand file to work to the lines after sawing, smooth/flatten cut edges 1 Buffing machine to polish the acrylic, apply a finish, finishing, shine 1 Do not accept smooth the surfaces

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Q252 · The underside of a table top 0445/32 Oct/Nov 2021

10 Fig. 10.1 shows the underside of a table top. The table top is made by gluing together three hardwood boards. positions for screws slot batten to hold 500 hardwood boards end grain Fig. 10.1 (a) Give one reason why the table top is made by gluing together three hardwood boards rather than one board. … [1] (b) Explain why the boards have been glued together with the end grains arranged as shown in Fig. 10.1. … … … [2] (c) Fig. 10.1 shows a batten that is used to hold the three hardwood boards. The batten will be screwed to the underside of the table top. Give one reason why the screw holes are slotted. … [1]

4 marks

Mark scheme: 10(a) Hardwood boards of required width not available, to provide a stable table top 1 Do accept rigidity Question Answer Marks Guidance 10(b) Hardwoods dry out and shrink If all three boards were joined with same end grain arrangement the table top is more likely to ‘cup’ or warp To stabilise the table top, to prevent warping 2 If stability is given in question 10(a) the answer must give additional information; e.g. to prevent warping, splitting, allow for movement Look for answers that indicate an understanding of the drying out, shrinkage and allowance issues in explanation 10(c) To allow the screws to move when the table top shrinks or expands 1

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Q253 · An incomplete design for a step stool made from oak 0445/32 Oct/Nov 2021

11 Fig. 11.1 shows an incomplete design for a step stool made from oak. platform 20 mm thick through housing joint area A step 20 mm thick leg 60 × 20 Fig. 11.1 (a) Give two properties of oak that make it suitable for the step stool. 1 … 2 … [2] (b) The legs will be cut from one length of 60 × 20 oak. Use sketches and notes to show how a sliding bevel could be used when marking out one leg. [2] (c) Fig. 11.2 shows part of one leg. Fig. 11.2 (i) Draw on Fig. 11.2 to show a through housing joint that could be used to join the step to the leg. [3] (ii) Fig. 11.3 shows a portable power tool that could be used to cut the through housing joints. Fig. 11.3 Name the portable power tool. … [1] (iii) State one safety precaution, other than wearing PPE (Personal Protection Equipment), that must be taken when using portable power tools. … [1] (d) The platform shown in Fig. 11.1 will be joined to the tops of the legs using dowels. Fig. 11.4 shows the tops of two legs. 20 70 Fig. 11.4 Draw on Fig. 11.4 to show: • the diameter of dowel pegs used • the number of dowel pegs required • the spacing between the dowel pegs. [3] (e) Area A shown in Fig. 11.1 is weak and needs to be strengthened. Use sketches and notes to show how additional materials and constructions could be used to make area A stronger and more rigid. [3] (f) The step stool will be given an oiled finish rather than a painted finish. (i) Give two advantages of an oiled finish rather than a painted finish for the step stool. 1 … 2 … [2] (ii) The step will be glasspapered, ready to take the oiled finish, before it is glued to the legs. Give two benefits of glasspapering the step before it is glued to the legs. 1 … 2 … [2] (g) A hand-hold will be joined to the step stool to provide support for the user. Add sketches and notes to Fig. 11.5 to show a design for a hand-hold that would provide support at a height of 1 metre above the platform. Include the following details: • the method of joining the hand-hold securely to the step stool • two important sizes • how the hand-hold is made comfortable to grip. platform 20 mm thick leg 60 × 20 step 20 mm thick Fig. 11.5 [6]

25 marks

Mark scheme: 11(a) Two properties: hardwearing, long lasting, tough, finishes well, attractive, durable, weather resistant, shock resistant 2 × 1 2 Accept any valid property Do not accept hard, strong 11(b) Sliding bevel could be used to mark out the ‘angled’ joint across the leg Sketch showing sliding bevel 1 Sketch showing sliding bevel in use 1 2 11(c)(i) Through housing drawn across the grain/width of the leg 1 Proportion/size/angle relates to Fig. 11.1 0–2 3 Must be cut out of leg, not step 11(c)(ii) Router 1 11(c)(iii) No trailing leads, check set up of tool in cutting tools, check condition of electrical fittings, no ‘observers’, work piece held securely, switch off power source when not in use, check condition of wiring, keep both hands on machine 1 Accept any valid safety precaution 11(d) Ø of dowels used appropriate: 6–10 1 Number of dowels used 2–3 max. 1 Spacing between dowels stated or shown in sketch 1 3 Question Answer Marks Guidance 11(e) Strengthened. Some form of ‘gusset’, triangular piece or added rail on or below area A 1 Correct position 1 Constructions 1 3 11(f)(i) Two advantages: quicker and easier to apply, paint more likely to chip, oil easier to maintain, oil shows natural features of attractive oak 2 × 1 2 Do not accept easier to clean 11(f)(ii) Two benefits: easier to access, able to glasspaper along the grain 2 × 1 2 11(g) Position of hand-hold 1 Method of joining hand-hold to stool 0–2 Comfortable to grip 1 2 important sizes Do not include 1metre height 2 × 1 6

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Q254 · Parts of an incomplete model car 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

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Q255 · An incomplete design for a jewellery stand made from mahogany and brass 0445/32 Oct/Nov 2021

13 Fig. 13.1 shows an incomplete design for a jewellery stand made from mahogany and brass. Ø30 mahogany bar brass cap Ø15 brass tube base: 15 mm thick mahogany 60 200 100 Fig. 13.1 (a) The Ø30 mahogany bars will be produced on a woodturning lathe by means of between- centres turning. Fig. 13.2 shows the length of mahogany marked out and prepared, ready to be set up on a woodturning lathe. waste 220 marked out corners removed Fig. 13.2 (i) Give one reason why the corners of the mahogany have been removed. … [1] (ii) When setting up the mahogany on a woodturning lathe state one check that would be carried out before switching on the machine. … … [1] (iii) Name one tool that could be used to check that the mahogany has been turned to the correct diameter. … [1] (iv) Name one lathe tool that could be used to remove the waste to make the length of mahogany round. … [1] (b) Fig. 13.3 shows an engineers vice that will be used to hold each of the Ø15 brass tubes while they are sawn to the required length. Fig. 13.3 Describe one precaution that could be taken to prevent the brass tubes from being damaged when held in the engineers vice. … … [2] (c) Fig. 13.4 shows a brass cap that is fixed over the end of the mahogany bars. Fig. 13.4 (i) State the purpose of the brass caps. … [1] (ii) The brass caps are pre-manufactured components that have been purchased. Give two advantages of using pre-manufactured components rather than making the components in a school workshop. 1 … 2 … [2] (d) The sides of the base, made from mahogany, will be joined by means of mitre joints. Fig. 13.5 shows a mitre joint marked out on the end of one side. waste 100 15 Fig. 13.5 (i) Name two tools that could be used to mark out the mitre joint. 1 … 2 … [2] (ii) Use sketches and notes to show how the waste could be removed to produce the mitre joint. Name the tools and equipment used. [4]

15 marks

Mark scheme: 13(a)(i) To make it easier to turn, to prevent the edges from splitting, personal safety 1 Question Answer Marks Guidance 13(a)(ii) Work piece is secured between centres, free rotation of work piece to ensure it is clear of the tee rest, lathe tools are sharp and free from damage, fork centre fitted correctly 1 13(a)(iii) Outside or external calipers, digital calipers, vernier calipers, micrometer 1 Must state ‘outside’ or ‘external’ calipers 13(a)(iv) Gouge, scraper, chisel 1 13(b) Avoid over tightening in vice 1 Vice: use of soft metal or plastic jaw covers or scrap wood against brass cap 1 2 13(c)(i) Purpose is mostly aesthetic, could give end grain protection from splitting, to protect the side of the mahogany 1 Do not accept to cover [too vague] 13(c)(ii) Two advantages: better quality components, quicker than making them, more accurate 2 × 1 2 13(d)(i) Pencil, steel rule, try square, sliding bevel, marking knife, cutting gauge, mitre square, engineers square 2 × 1 2 13(d)(ii) Method 1 plane off waste using a smoothing or jack plane 1 wood held in vice 1 Process: the wood is planed from end to centre then reverse process 0–2 Method 2 use of mitre saw 1 finish with plane or sanding disc 1 Process: the wood is sawn and pushed against the sanding disc at 45° angle 1 4 Process shown clearly 0–2 Look for technical accuracy, e.g. named tools and equipment Question Answer Marks Guidance 13(e) Completed drawer shown 1 Appropriate constructions used and clearly shown 0–3 Suitable materials 1 Sizes must fit the carcase 1 6 Appropriate constructions: 3 marks available Sides: butt, pin and glue, mitre = 1 Half lap. Lap, finger, dovetail = 0–2 Base: groove, rebate, flush = 1 13(f) Hand-hold shape made from brass strip 1 Cutting and shaping processes 0–3 4

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Q256 · A method of joining two lengths of hardwood 0445/33 Oct/Nov 2021

1 Fig. 1.1 shows a method of joining two lengths of hardwood. An adhesive is used. slot Fig. 1.1 (a) State the method of joining shown in Fig. 1.1. … [1] (b) State an alternative method of joining the two lengths of hardwood. … [1]

2 marks

Mark scheme: 1(a) Biscuit 1 1(b) Dowel, tongue and groove, domino, butt 1

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Q257 · There are three main stages to be carried out to produce a high quality finish to the… 0445/33 Oct/Nov 2021

2 There are three main stages to be carried out to produce a high quality finish to the edges of acrylic sheet. Fig. 2.1 shows the first stage. Fig. 2.1 (a) Name the method of filing shown in Fig. 2.1. … [1] (b) After filing the edges, silicon carbide paper will be used. Give the common name for silicon carbide paper. … [1] (c) The third stage is to polish the edges on a buffing wheel. Give two safety precautions that must be taken when using a buffing wheel. 1 … 2 … [2]

4 marks

Mark scheme: 2(a) Draw filing 1 Do accept ‘drawing’ 2(b) Wet and dry paper 1 2(c) Loose clothing tucked in, hair tied back, safety glasses, work piece presented to lower half of buffing wheel 2 × 1 2 Do accept items of PPE Do not accept ear defenders, gloves

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Q258 · Circle from the list of materials below one material that can be anodised 0445/33 Oct/Nov 2021

4 Circle from the list of materials below one material that can be anodised. copper steel lead aluminium [1]

1 marks

Mark scheme: 4 Aluminium 1

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Q259 · Two items of equipment, A and B, used when marking out metal 0445/33 Oct/Nov 2021

5 Fig. 5.1 shows two items of equipment, A and B, used when marking out metal. B A Fig. 5.1 Name the items of equipment A and B in Fig. 5.1. A … B … [2]

2 marks

Mark scheme: 5 A surface plate 1 B surface gauge, scribing block 1 2

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Question 260 0445/33 Oct/Nov 2021

6 Fig. 6.1 shows a chair. The curved parts of the chair have been produced by steam bending. Fig. 6.1 Give two benefits of using steam bending to make the curved parts of the chair. 1 … 2 … [2]

2 marks

Mark scheme: 6 Two benefits: quicker than fabricating, greater profit for manufacturer, easier to produce comfortable curved shapes, aesthetically more interesting, less machining, stronger as it is made in one piece, design does not need joints, interesting shape, even curve produced 2 × 1

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Q261 · A design for a wall-mounted leaflet holder 0445/33 Oct/Nov 2021

7 Fig. 7.1 shows a design for a wall-mounted leaflet holder. Fig. 7.1 Add sketches and notes to Fig. 7.1 to show a modification to the design that would make it easier to access the leaflets. [2]

2 marks

Mark scheme: 7 Modification to allow easier access: some sort of ‘recess’ for fingers to access leaflets, hinges on bottom of holder, recess on side of holder, lower top of holder by up to 1/3 0–2 2 Constructional detail not required. Look for simple modification and technical accuracy Award 1 mark for vertical ‘separators’

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Q262 · A car body shell made from carbon fibre reinforced plastic (CFRP) 0445/33 Oct/Nov 2021

8 Fig. 8.1 shows a car body shell made from carbon fibre reinforced plastic (CFRP). Fig. 8.1 Give two advantages of making the car body shell from carbon fibre reinforced plastic (CFRP) rather than mild steel. 1 … 2 … [2]

2 marks

Mark scheme: 8 Two advantages: lighter weight, greater fuel economy, corrosion resistant, easily moulded parts, good strength- weight ratio, easier to shape, stronger 2 × 1

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Question 263 0445/33 Oct/Nov 2021

9 Fig. 9.1 shows two serving trays. Tray A is made from moulded thermosetting plastic. Tray B is made from hardwood. A B thermosetting plastic hardwood Fig. 9.1 (a) Name a suitable specific material for each tray. Tray A … Tray B … [2] (b) Give two reasons, other than cost, why consumers may prefer to purchase tray A rather than tray B. 1 … 2 … [2]

4 marks

Mark scheme: 9(a) A melamine and urea [formaldehyde], GRP 1 B wide variety of hardwoods available 1 2 9(b) Two reasons for preference: rounded moulded plastic shape, more hardwearing, no joints to come apart, easier to clean, colours to ‘match’ environment, more durable, smoother surface, more aesthetic shape, lasts longer, water resistant 2 ×1 2 Do not accept lightweight, stackable, cheaper

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Q264 · A child’s rocking horse made from hardwood 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

Q265 · An incomplete design for a desk tidy 0445/33 Oct/Nov 2021

12 Fig. 12.1 shows an incomplete design for a desk tidy. The trays are made from vacuum formed plastic and can rotate as shown. tray Ø80 × 10 deep tray rotates Ø10 column solid base Fig. 12.1 (a) Name a suitable plastic for the trays. … [1] (b) Use sketches and notes to show how one tray could be vacuum formed. [6] (c) Fig. 12.2 shows the solid base for the desk tidy. centre for hole to take column Ø Fig. 12.2 (i) Name a suitable material for the solid base. … [1] (ii) Give one reason for your choice of material. … [1] (iii) Add two dimensions to Fig. 12.2 to show a suitable thickness and diameter for the solid base. [2] (iv) Use sketches and notes to show how the solid base shown in Fig. 12.2 could be produced in a school workshop. [5] (v) Name a suitable material for the Ø10 column and use sketches and notes to show how the column could be joined securely to the solid base. [3] (d) Use sketches and notes to show how the trays could be supported on the column and allowed to rotate freely as shown in Fig. 12.1. [4] (e) The trays could be replaced with lids from used containers that would otherwise be thrown away. Fig. 12.3 shows a variety of lids. Fig. 12.3 Give two benefits of reusing items that would otherwise be thrown away. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Acrylic, polystyrene, high density polythene, PET, PETE, ABS, polypropylene 1 Do not accept uPVC 12(b) Stages include: place mould on platen, clamp plastic in place, heat plastic sheet, check ‘softness’ of plastic, turn on vacuum and raise platen, check if shape has formed, turn off vacuum, leave to cool 6 × 1 6 12(c)(i) Wide variety of suitable wood, metal or plastic available 1 1 12(c)(ii) Reason for choice of material in previous part (c)(i) Variety of material properties available 1 1 12(c)(iii) Dimensions provided for thickness and diameter must relate to the chosen material. 2 × 1 2 Maximum Ø 150 minimum Ø 120 Maximum thickness 20 minimum 15 Question Answer Marks Guidance 12(c)(iv) Main stages of production: Marking out 1 Cutting [at least 1 tool named] 1 Shaping [at least 1 tool named] 1 Finishing [glasspapering] 1 Finishing [named finish] 1 5 Consider technical accuracy and quality of communication Ignore hole to be drilled in base 12(c)(v) Suitable material: wood, metal or plastic rod or plastic and metal tube 1 Method of joining: drilled hole 1 Use of epoxy resin or adhesive corresponding to chosen material 1 3 12(d) Some form of collar/pin/peg to be fitted onto column 1 Named material for collar/pin/peg 1 Method of joining pin/peg fitted to column 1 Additional details 1 4 12(e) Two benefits: saves raw materials, reduces impact of landfill, reduces possible pollution caused by recycling or incineration, reduces need for collection, reduces plastic waste, less money spent on new materials 2x1 2 Accept any valid benefits of re-using items Do not accept less environmental damage, protects the environment

This question in 0445/33 Oct/Nov 2021

Q266 · Details of a ‘floating’ shelf 0445/33 Oct/Nov 2021

13 Fig. 13.1 shows details of a ‘floating’ shelf. • The shelf bracket is screwed to the wall. • The shelf slides onto the bracket, hiding it from view. • The shelf appears to be ‘floating’ because there is no visible means of support. 200 500 tube 150 × Ø15 400 shelf 25 mm thick bracket 20 × 3 mild steel holes to fix to wall Fig. 13.1 (a) (i) Give one advantage of using a manufactured board for the shelf rather than solid wood. … [1] (ii) Give one advantage of using MDF rather than plywood for the shelf. … [1] (b) Fig. 13.2 shows part of the mild steel bracket with the centres marked out for two holes to be drilled. mild steel 20 × 3 centre Fig. 13.2 (i) Name one tool that could be used to mark the lines on the surface of the mild steel bracket. … [1] (ii) Give one reason why it is important to use a centre punch before drilling holes in the mild steel bracket. … [1] (c) Fig. 13.3 shows part of the back of the shelf. A recess has been cut out to take the mild steel bracket. A power router could be used to cut out most of the recess. recess 20 wide × 5 deep Fig. 13.3 State two checks that must be made before using the power router to cut out the recess. 1 … 2 … [2] (d) Fig. 13.4 shows one tube that will be joined to the bracket by means of brazing. Fig. 13.4 (i) Add to Fig. 13.4 to show how the position of the tube could be checked to make sure it is vertical. Name the tools or equipment used. [3] (ii) Complete Table 13.1 by describing how each of the materials or items of equipment could be used when brazing the tube to the bracket. Table 13.1 Material / item of Use equipment emery cloth flux blow torch brazing rod [4] (e) Fig. 13.5 shows the position of the two tubes inside the shelf when the bracket is screwed to a wall. In use, there is nothing to prevent the shelf from sliding off the tubes. hidden detail showing tubes in position bracket set into shelf Fig. 13.5 Use sketches and notes to show how the shelf could be secured to the tubes to prevent the shelf from sliding off. The method of securing the shelf must: • not be visible when the shelf is on a wall • be able to be removed. Include details of fittings and fixings used.

13 marks

Mark scheme: 13(a)(i) Manufactured boards more stable, less likely to expand or shrink, twist or warp, cheaper 1 Do not accept easier to work, cut, shape, lightweight 13(a)(ii) MDF gives a better finish, smoother surface, less likely to splinter, easier to work 1 Do not accept cheaper 13(b)(i) Scriber, odd-leg calipers, odd-legs, Jenny calipers 1 Do not accept calipers, marker pens Question Answer Marks Guidance 13(b)(ii) To prevent the tip of the drill wandering, to produce an accurate hole, no risk of damage to surface of metal, to guide the drill 1 13(c) Two checks: no trailing leads, check set up of tool, fence position and secure, check condition of electrical fittings, no ‘observers’, workpiece held securely 2 × 1 2 Do not accept items of PPE, no loose clothing etc. 13(d)(i) Use of a try square/engineers square, spirit level, ‘level’ named 1 Clear sketch showing tool in position against tube 0–2 3 Award 1 mark maximum for set square shown in position 13(d)(ii) Emery cloth used to clean up joint before brazing 1 Flux applied to parts of the joint to keep joint ‘clean’ and allow ‘spelter’ to flow 1 Blowtorch is used to heat the metal joint 1 Brazing rod applied to joint at appropriate temperature and heated to flow 1 4 13(e) Use of some type of screw fitted through underside of shelf 1 Head ‘sunk’ [hidden] 1 Inserted into tube 1 Added details 1 4 13(f) Two reasons: MDF has an unattractive natural colour, marks more easily covered, colour of paint can ‘match’ environment 2 × 1 2 Do not accept easier to paint 13(g) Three main processes involved in constructing the bracket: Marking out sketch shows marking out 1 at least one tool named 1 1 + 1 Cutting 2 tools/items of equipment used 2 × 1 Joining nailed/screwed and glued =1 dowels/M&T = 2 0–2 6

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Question 267 0445/31 May/June 2022

1 Fig. 1.1 shows a screw. Fig. 1.1 Give three additional items of information required when ordering 200 of the screws shown in Fig. 1.1. 1 Number of screws required- 200 2 … 3 … 4 … [3]

3 marks

Mark scheme: 1 3 items: length, type of head, type of ‘slot’, gauge, material, size, width of screw, type of screw 3  1 3 Accept recognised length of screw stated

This question in 0445/31 May/June 2022

Q268 · Two pieces of softwood glued together 0445/31 May/June 2022

2 Fig. 2.1 shows two pieces of softwood glued together. Fig. 2.1 (a) Name the type of joint shown in Fig. 2.1. … [1] (b) Add sketches to Fig. 2.1 to show how the joint could be strengthened by dovetail nailing. [2]

3 marks

Mark scheme: 2(a) Rebate joint, lap joint, half lap 1 Accept ‘lap’ variants 2(b) Minimum 2 pins shown angled. 2 pairs of angled pins 2

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Q269 · Three different types of ‘square’, A, B and C, that could be used when marking out and… 0445/31 May/June 2022

3 Fig. 3.1 shows three different types of ‘square’, A, B and C, that could be used when marking out and testing. A B C Fig. 3.1 Give the correct name for each type of square shown in Fig. 3.1. A … square B … square C … square [3]

3 marks

Mark scheme: 3 A [engineers] try square B mitre square C combination square 3

This question in 0445/31 May/June 2022

Q270 · A sundial that could be made in a school workshop 0445/31 May/June 2022

4 Fig. 4.1 shows a sundial that could be made in a school workshop. triangular plate (gnomon) 3 mm thick brass face of sundial 2 mm thick brass hour scale Fig. 4.1 The triangular plate will be attached to the face of the sundial by means of silver soldering. Complete Table 4.1 by stating three further stages in the silver soldering process. Table 4.1 Stage Process 1 Clean joint with emery cloth 2 3 4 [3]

3 marks

Mark scheme: 4 3 stages: apply flux, wire joint, lay hard solder along joint, heat joint [with blowtorch], apply solder at appropriate temperature, remove heat when solder runs, leave to cool 3  1 Incorrect sequence: award 1 mark max. for any one correct stage

This question in 0445/31 May/June 2022

Q271 · A slot marked out on sheet material 0445/31 May/June 2022

5 Fig. 5.1 shows a slot marked out on sheet material. A hole has been drilled to allow a saw blade to be inserted to cut out the slot. 10 mm wide slot drilled hole Fig. 5.1 Name a specific type of saw suitable for cutting out the slot when the material is: (a) 4 mm thick plywood … [1] (b) 1 mm thick brass … [1]

2 marks

Mark scheme: 5(a) Scroll saw, coping saw, jig saw, fret saw 1 5(b) Piercing saw, abra file saw 1 Accept bow saw

This question in 0445/31 May/June 2022

Q272 · Plastic tableware for outdoor use 0445/31 May/June 2022

6 Fig. 6.1 shows plastic tableware for outdoor use. The tableware is made from melamine formaldehyde. Fig. 6.1 Give two reasons why melamine formaldehyde is a suitable material for the tableware. 1 … 2 … [2]

2 marks

Mark scheme: 6 2 reasons: tough, will not break easily, shapes well, bright colours available, easily cleaned, durable, attractive, lightweight, safe to eat from, does not scratch, will not shatter, heatproof 2  1 Not weather resistant/weatherproof

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Q273 · A list of materials is given below 0445/31 May/June 2022

7 A list of materials is given below. acrylic redwood polystyrene carbon steel Circle from the list one material that is from a sustainable source. [1]

1 marks

Mark scheme: 7 Redwood 1

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Q274 · Two tools, A and B, that are used to mark lines parallel to the edges of materials 0445/31 May/June 2022

8 Fig. 8.1 shows two tools, A and B, that are used to mark lines parallel to the edges of materials. edge of wood edge of metal strip marked line marked line A B Fig. 8.1 Name tools A and B shown in Fig. 8.1. Tool A … Tool B … [2]

2 marks

Mark scheme: 8 A marking gauge B odd leg calipers 2 Accept odd legs, Jenny calipers

This question in 0445/31 May/June 2022

Q275 · A storage unit for three remote controls 0445/31 May/June 2022

9 Fig. 9.1 shows a storage unit for three remote controls. The storage unit has two sides, a base and four partitions made from 5 mm thick MDF. The storage unit is supplied as flat pack for customers to self-assemble. partition side 150 200 base Fig. 9.1 Use sketches and notes to show one construction method that could be used to join the parts of the storage unit together without the use of any tools, adhesive or additional fittings. [3]

3 marks

Mark scheme: 9 ‘Slot’ construction principle 1 Technical accuracy of sketches showing various parts joined using slots 0–2 3

This question in 0445/31 May/June 2022

Q276 · Views of a table that will be assembled by customers 0445/31 May/June 2022

11 Fig. 11.1 shows views of a table that will be assembled by customers. The parts of the table are joined by means of knock-down (KD) fittings. plywood table top 15 mm thickmiddle rail side rail 400 leg 500 400 all legs and rails 50 × 20 mahogany Fig. 11.1 (a) Give two reasons why mahogany is a suitable hardwood for the legs and rails of the table. 1 … 2 … [2] (b) Use sketches and notes to show how the scan fitting shown below could be used to join a side rail to a leg. barrel Ø10 70 Ø6 allen screw [3] (c) Corner block knock-down (KD) fittings will be used to join the middle rails to the side rails. (i) Draw an accurate sketch of a corner block knock-down (KD) fitting. [2] (ii) Use sketches and notes to show how one corner block knock-down (KD) fitting could be used to join the middle rail to the side rail. [2] (d) Fig. 11.2 shows the edges of the plywood table top. Fig. 11.2 (i) Use sketches and notes to show how the appearance of the edges of the plywood could be made to look attractive. [2] (ii) A sheet of 6 mm thick glass is to be set into the plywood table top. Fig. 11.3 shows the waste material to be removed to allow the glass to be set in. 150 220 waste 15 mm thick Fig. 11.3 Use sketches and notes to show how the waste material could be removed. [3] (iii) Use sketches and notes to show how the 6 mm thick glass sheet could be supported inside the 15 mm thick plywood table top. [3] (iv) Fig. 11.4 shows a sectional view through the table top and side rail. table top 15 mm thick 50 side rail 20 Fig. 11.4 Add sketches and notes to Fig. 11.4 to show how one screw could be used to fasten the side rail to the underside of the table top. The screw head must not be visible. State the length of the screw used. [3] (e) When trees are felled, (cut down), they are cut into boards, (converted) and seasoned. (i) State the meaning of the term ‘seasoned’. … [1] (ii) Fig. 11.5 shows views of part of a table top made from solid wood. Fig. 11.5 Sketch, onto Fig. 11.5, to show what could happen to the shape of the solid wood table top if it was seasoned incorrectly. [2] (f) Give two benefits to manufacturers of producing flat pack products that are assembled by customers. 1 … 2 … [2]

25 marks

Mark scheme: 11(a) 2 reasons: hardwearing, attractive, relatively easy to work, long lasting, durable 2 Accept any valid reasons 11(b) Barrel shown in side or top edge of rail 1 Screw shown in end of leg 1 Technical accuracy of joint shown 1 3 11(c)(i) Accuracy of one-piece or two-piece corner block 0–2 2 Award 1 mark for simple block Award 2 marks for block showing screw holes 11(c)(ii) Corner block shown against middle rail 1 Corner block shown against side rail 1 2 11(d)(i) Use of veneer or strip of solid wood shown clearly 1 Explanatory notes: for example, method of attachment 1 2 Not paint, stain 11(d)(ii) Drill hole, insert saw blade, cut out waste, clean up sawn edges 3  1 3 Accept router. For maximum marks details required on setting up etc. 11(d)(iii) Use of rebate, applied strips 1 Technical accuracy and added details 0–2 3 Accept reference to ‘ledge’ 11(d)(iv) Screw in side rail 1 Screw in table top 1 Appropriate length of screw stated 1 3 Award 0 if screw is through top Accept ‘pocket screwing’ and counterboring’ 11(e)(i) Drying out of excess moisture in newly cut wood 1 Accept answers that include reference to ‘drying out’ 11(e)(ii) Award 0–2 mark for clear, accurate ‘cupping’. 2 Award 1 mark for reference to ‘cupping’ Question Answer Marks Guidance 11(f) 2 benefits to manufacturers: no assembly required, less labour costs, reduced prices passed on to customers, less storage space required, reduced transport costs, easier to manufacture, less packaging 2  1 2 Accept any valid benefits Cheaper + justification 

This question in 0445/31 May/June 2022

Q277 · Details of a desktop toy 0445/31 May/June 2022

12 Fig. 12.1 shows details of a desktop toy. The suspended weight can be made to swing forwards and backwards around a central pivot. Ø90 central pivot Ø3 mild steel rod acrylic support 5 mm thick mild steel weight hardwood base Ø100 × 20 mm thick Fig. 12.1 (a) Fig. 12.2 shows the hardwood base marked out ready to be cut to shape. waste base 100 × 100 × 20 thick Fig. 12.2 Use sketches and notes to show how the base could be produced. Name the tools and equipment used. [3] (b) Fig. 12.3 shows one of the supports marked out, ready to be cut out of 5 mm thick acrylic sheet. waste 120 80 Fig. 12.3 Use sketches and notes to show how two identical supports could be produced. Include the following details to show how: • the shape could be cut from the acrylic sheet • the cut edges could be made flat • the edges could be polished to a high quality. [6] (c) Fig. 12.4 shows how the supports will be joined to the base. support slot 60 × 5 × 10 deep base Fig. 12.4 Use sketches and notes to show how the slots could be cut out of the hardwood base. Name all the tools and equipment used. [3] (d) The circular shape will be produced by cold bending the Ø3 mild steel rod using a jig and/or former. Use sketches and notes to show a design for a jig and/or former that could be used to produce the circular shape. Ø90 circular shape Ø3 mild steel rod [5] (e) The mild steel weight could be produced on a centre lathe. Fig. 12.5 shows three lathe operations, A, B and C, that could be used to produce the mild steel weight. work rotates work rotates lathe tool lathe tool lathe tool A B C Fig. 12.5 Complete the names of each of the three centre lathe operations A, B and C. A … off B … turning C … off [3] (f) Fig. 12.6 shows how the Ø3 mild steel rod will be joined to the mild steel weight by means of a screw thread. rod weight Fig. 12.6 Name the tool used to cut the screw thread: (i) inside the weight … [1] (ii) on the rod. … [1] (g) (i) State two different finishes that could be applied to the mild steel parts of the desktop toy. 1 … 2 … [2] (ii) The hardwood base requires a finish to preserve the wood and enhance its appearance. Give one reason why a clear finish would be applied to the hardwood base. … [1]

25 marks

Mark scheme: 12(a) 2 stages: cut off corners, sanding disc/belt sander or files to round shape 2  1 Technical accuracy of tools and equipment stated 1 12(b) Shape cut: use of coping, scroll saws, band saw 0–2 Edges made flat: use of files 1 Edges polished: use of draw file, scraper, wet and dry paper, buffing wheel 0–2 Method to provide identical shapes: tape together 1 6 Accept use of one shape to be used as a template for a second piece 12(c) 4 methods: mortise machine, router, chisel and mallet, drilled holes and chisel Award 0–3 dependent on technical accuracy of method and tools stated 3 Machine methods require details for max.3 marks 12(d) Round wooden former 1 Saw cut to guide straight end of shape 1 Pegs to clamp start of bend and final inside bend 1 At least 4 pegs around outside of shape to hold against former 1 Correct tools and equipment stated 1 5 12(e) A facing off B taper turning C parting off 3  1 3 12(f)(i) Tap 1 12(f)(ii) Die, circular split die 1 12(g)(i) Paint, electroplating, dip-coating, powder coating, plastic coating 2  1 2 12(g)(ii) Clear finish allows grain characteristics to be seen 1

This question in 0445/31 May/June 2022

Q278 · An incomplete design for a wind gauge that could be made in a school workshop 0445/31 May/June 2022

13 Fig. 13.1 shows an incomplete design for a wind gauge that could be made in a school workshop. The cups and arms rotate when the wind blows. cup central connector arm Ø6.0 mm tube A column Ø10.0 mm rod base Ø150 × 10 mm thick Fig. 13.1 (a) State two benefits of using plastic materials for the parts of the wind gauge. 1 … 2 … [2] (b) Give two reasons why a designer would make a model of the wind gauge before making it from resistant materials. 1 … 2 … [2] (c) Fig. 13.2 shows details of the central connector. The central connector will be made from a 15 mm section of Ø20 acrylic rod. The Ø10.5 hole in the connector will be drilled while the acrylic rod is held in a three jaw chuck on a centre lathe. Ø6 Ø20 Ø10.5 15 Fig. 13.2 Fig. 13.3 shows a length of Ø20 acrylic rod held in a three jaw chuck. Fig. 13.3 (i) State one check that should be carried out before turning on the centre lathe. … [1] (ii) Fig. 13.4 shows the drill that will produce a small hole to act as a guide for the Ø10.5 drill. Fig. 13.4 Name the type of drill shown in Fig. 13.4. … [1] (iii) Fig. 13.5 shows the Ø10.5 drill that will be used. Fig. 13.5 Name the type of drill shown in Fig. 13.5. … [1] (iv) Fig. 13.6 shows a saw that could be used to cut a length of acrylic rod to make the connector. Fig. 13.6 Name the type of saw shown in Fig. 13.6. … [1] (d) The arms will be joined to the central connector and the cups by means of an ‘interference’ or ‘friction’ fit. Explain what is meant by the terms ‘interference’ or ‘friction’ fit. … … … [2] (e) Fig. 13.7 shows details of one of the cups. The cups will be vacuum formed. 20 60 80 2 mm thick polystyrene Fig. 13.7 Use sketches and notes to show four stages by which the cup could be vacuum formed. [6]

16 marks

Mark scheme: 13(a) 2 benefits: plastic materials are lightweight, can be used outdoors effectively, easily worked, self-coloured, easily shaped, weather resistant 2  1 13(b) 2 reasons: check sizes, appearance, test function, avoids mistakes and waste of materials 2  1 2 Accept any valid reasons 13(c)(i) Checks include: secure workpiece in chuck, remove chuck key, correct speed, guard in position 1 Accept any valid checks 13(c)(ii) Centre drill, slocombe drill 1 13(c)(iii) Twist drill 1 13(c)(iv) Hacksaw 1 Only acceptable answer 13(d) An interference or friction fit between two parts in which one part is forced under pressure into a slightly smaller hole in the other. 2 Award 0–2 dependent on accuracy of explanation 13(e) 4 stages include: place former on platen, clamp plastic sheet, turn on heater, check for pliability, raise platen, remove air, leave to cool 4  1 Award technical accuracy of sketches and notes 0–2 6 Accept any valid stages 13(f) Modification required: some sort of fastening to weather vane and column 0–3 Retained in position A 1 Fittings to allow rotation 1 5 Look for any practical method 13(g) Use of CAD to design the letters, model fonts and sizes 0–2 Use of CAM to transfer data to machine to engrave or cut out vinyl to apply 0–2 4 Reward an imbalance between information provided for CAD and CAM

This question in 0445/31 May/June 2022

Q279 · A wooden stand for a mobile phone 0445/32 May/June 2022

1 Fig. 1.1 shows a wooden stand for a mobile phone. Fig. 1.1 State two different processes that could be used to form the shape of the mobile phone stand. 1 … 2 … [2]

2 marks

Mark scheme: 1 2 processes: laminating, steam bending 2 Must include the term ‘steam’

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Q280 · Two pieces of hardwood prepared to take a countersunk head screw 0445/32 May/June 2022

2 Fig. 2.1 shows two pieces of hardwood prepared to take a countersunk head screw. pilot hole Fig. 2.1 Sketch onto Fig. 2.1 to show: (a) a countersunk hole (b) a clearance hole. [2]

2 marks

Mark scheme: 2(a) Correct position of countersunk hole 1 2(b) Correct position of clearance hole 1 2

This question in 0445/32 May/June 2022

Q281 · Products such as chisels and screwdrivers, made from high carbon steel, can be ‘hardened’ 0445/32 May/June 2022

3 Products such as chisels and screwdrivers, made from high carbon steel, can be ‘hardened’. Hardening makes the metal very brittle. Complete the sentence below by adding the correct term from the list. normalising tempering annealing alloying The process of removing the excess ‘hardness’ and improving the toughness of the steel is known as … . [1]

1 marks

Mark scheme: 3 Tempering 1

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Q282 · A type of sandwich packaging 0445/32 May/June 2022

6 Fig. 6.1 shows a type of sandwich packaging. Fig. 6.1 (a) Name a suitable plastic from which the packaging could be made. … [1] (b) Give one benefit of using plastic material for food packaging. … [1] (c) Give one drawback of using plastic material for food packaging. … [1]

3 marks

Mark scheme: 6(a) PETE, HDPE, PVC, LDPE, PET, Polythene, Polyethylene 1 Not HIPS, polystyrene, ABS, polypropylene 6(b) Benefits: hygienic, keeps food fresh, protects food, can withstand extremes of environment, maintains high quality produce, easily recycled, fast manufacturing process, water resistant, transparent, does not react with food, lightweight 1 Accept any valid benefit ‘Cheap’ must be qualified Not long lasting, attractive Question Answer Marks Guidance 6(c) Drawbacks: is a finite resource, non-biodegradable, wasteful, can cause pollution when thrown away, doesn’t decompose, references to landfill, not environmentally friendly, unsustainable 1 Accept any valid drawbacks

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Q283 · A knock-down (KD) fitting 0445/32 May/June 2022

7 Fig. 7.1 shows a knock-down (KD) fitting. Fig. 7.1 (a) Name the type of knock-down (KD) fitting shown in Fig. 7.1. … [1] (b) Use sketches and notes to show how the knock-down (KD) fitting could be used. [3]

4 marks

Mark scheme: 7(a) Corner block, bloc fitting, two-piece bloc, 2 piece connector 1 Accept authentic variations. 7(b) KD fitting joined/positioned against 2 sides 2  1 Technical accuracy/proportion 1 3 Do not accept fitting on outside of cabinet

This question in 0445/32 May/June 2022

Q284 · Two camping stools, A and B 0445/32 May/June 2022

8 Fig. 8.1 shows two camping stools, A and B. Stool A is made from oak and stool B is made from aluminium tube with a canvas seat. A B Fig. 8.1 State three advantages of stool B over stool A when in use. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 8 3 advantages: lightweight, less bulky to carry, more comfortable canvas seat, easier to clean, easier to open/close, packs away smaller, does not splinter, fewer moving parts 3 Not weatherproof, not more stable, durable, or attractive

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Q285 · The end of a length of softwood with a rebate marked out 0445/32 May/June 2022

9 Fig. 9.1 shows the end of a length of softwood with a rebate marked out. rebate 20 70 Fig. 9.1 (a) Name a power tool that could be used to cut out the rebate. … [1] (b) The rebate could also be cut out using hand tools only. Complete the names of two hand tools that could be used to cut out the rebate. 1 … saw 2 … chisel. [2]

3 marks

Mark scheme: 9(a) Router 1 9(b) Tenon saw, dovetail saw 1 Firmer, bevel-edge chisel, mortise chisel 1 2 Accept ‘bevel chisel’

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Q286 · An incomplete design for a trophy made from 1 mm thick brass 0445/32 May/June 2022

10 Fig. 10.1 shows an incomplete design for a trophy made from 1 mm thick brass. The trophy requires a wooden base to make it stable. T & AWARDD 100 30 Fig. 10.1 Use sketches and notes to show a design for a wooden base to which the trophy could be attached. Show a suitable method of attachment and give one important dimension. [4]

4 marks

Mark scheme: 10 Recognised base 1 Method of attachment 0–2 Dimension 1 4 Epoxy resin, ‘Araldite’ = 2 marks Contact adhesive = 1 mark Glued only = 1 mark

This question in 0445/32 May/June 2022

Q287 · Views and details of a garden lantern 0445/32 May/June 2022

11 Fig. 11.1 shows views and details of a garden lantern. The lantern has a plastic candle with a flickering bulb that imitates a real flame. lantern lid 1 mm thick mild steel sheet lantern body 5 mm thick acrylic 250 plastic candle 120 120 Fig. 11.1 (a) (i) State one property of mild steel sheet that makes it suitable for the lantern lid. … [1] (ii) The mild steel lantern lid requires a finish. State two suitable finishes that could be applied to the lantern lid. 1 … 2 … [2] (b) A card model of the garden lantern will be made before making it from resistant materials. (i) State one benefit of making a card model of the garden lantern. … [1] (ii) State one benefit of using CAD for on-screen modelling of the garden lantern. … [1] (c) Fig. 11.2 shows the development (net) of the lantern lid marked out on mild steel sheet. An additional view shows inside the lantern lid when the flaps have been bent and joined permanently to the sides. side flap side waste flaps 130 20 inside lantern lid Fig. 11.2 (i) Name two tools or items of equipment that could be used to mark out the development (net) of the lantern lid on the surface of the mild steel sheet. 1 … 2 … [2] (ii) Name the tool shown in Fig. 11.3 that could be used to cut out the mild steel sheet. Fig. 11.3 … [1] (iii) Name a permanent method of joining the flaps to the sides that uses heat. … [1] (iv) Name an adhesive that could be used to join the flaps to the sides of the lantern lid. … [1] (d) Fig. 11.4 shows the development (net) of the lantern body made from 5 mm thick acrylic. 120 250 side base Fig. 11.4 Use sketches and notes to show how the development (net) could be formed to produce the shape of the lantern body. [5] (e) Fig. 11.5 shows the garden lantern and part of a support from which it will be suspended. 1 mm thick mild steel sheet support Ø5 mm mild steel rod Fig. 11.5 Use sketches and notes to show a method of joining the lantern lid to the lantern body so that it could be easily removed to allow access to the plastic candle. Include details of the fittings and constructions used. [4] (f) Use sketches and notes to show modifications to the lantern lid and the end of the support shown in Fig. 11.5 so that the garden lantern could be suspended safely. The modifications must allow the garden lantern to be detached from the support. Include details of the materials, fittings and constructions used. [6]

25 marks

Mark scheme: 11(a)(i) Hardwearing, easily shaped, relatively cheap, takes a variety of finishes, malleable 1 Accept any valid property Not durable, weatherproof, heat resistant 11(a)(ii) Paint, dip-coated, electroplated, plastic coated, powder coated, galvanised, chrome plated 2  1 2 11(b)(i) Benefit: check sizes, appearance, prevent mistakes and waste of material, allows for modifications 1 Accept any valid benefit Must be different benefits for (bi) and (bii) 11(b)(ii) Benefit: 3D models can be created, editing can be carried out quickly, no materials used, designs can be replicated, designs can be transferred to CAM 1 Accept any valid benefit 11(c)(i) 2 marking out tools: scriber, odd-leg calipers, permanent marker, marker pen, engineers square, try square, [steel] rule, engineers blue, sliding bevel 2  1 2 11(c)(ii) Tinsnips, snips, hand shears 1 11(c)(iii) Brazing, soldering, welding, hard/silver soldering 1 11(c)(iv) Epoxy resin, ‘Araldite’ or equivalent trade names, Gorilla Weld 1 Not Gorilla generic, superglue 11(d) Use of strip heater/line bender/hot air gun/heat gun 1 Use of former to bend 4 sides to shape 1 Use of former to bend base to shape 1 Method of retention while acrylic cools 1 Technical accuracy of sketches/terms used 1 5 11(e) Practical idea: some form of pin, peg through top into body of lantern, clip, clasp, magnets 0–2 Details of construction/fittings used 0–2 4 Accept modifications to the lid and body of lantern Lid must lift off. Not hinged Parts (e) and (f) are not connected Mark these as completely separate questions Question Answer Marks Guidance 11(f) Method of suspension: Modification lid and/or support rod 0–2 Can be detached 1 Details of constructions/fittings 0–3 6 Reward any practical design that shows potential success Award 1 mark of 3 for use of string under ‘Details of constructions/fittings etc’.

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Q288 · An incomplete design for a pinball game 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

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Q289 · Two pieces of softwood that will be joined using panel pins 0445/33 May/June 2022

2 Fig. 2.1 shows two pieces of softwood that will be joined using panel pins. Fig. 2.1 (a) Add sketches to Fig. 2.1 to show how the two pieces of softwood could be joined by means of ‘staggered’ nailing. [2] (b) Name a tool that could be used to sink the panel pins below the surface of the wood. … [1]

3 marks

Mark scheme: 2(a) Minimum 2 nails shown 2 Maximum 5 nails Marks: 2 2 1 2 2 2(b) Nail or pin punch, hammer 1

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Question 290 0445/33 May/June 2022

3 Fig. 3.1 shows a workshop process. Fig. 3.1 (a) Name the process shown in Fig. 3.1. … [1] (b) State one item of Personal Protective Equipment (PPE), other than face protection, that must be worn when carrying out the process shown in Fig. 3.1. … [1]

2 marks

Mark scheme: 3(a) Casting, sand casting 1 Not die casting 3(b) Gauntlets [gloves], [leather] apron, spats 1

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Question 291 0445/33 May/June 2022

6 Fig. 6.1 shows a cabinet door. The door has a panel that is fitted inside the hardwood frame. 4 mm thick manufactured board panel hardwood frame 50 mm wide × 15 mm thick Fig. 6.1 Use sketches and notes to show how the panel could be fitted inside the hardwood frame of the cabinet door. [3]

3 marks

Mark scheme: 6 Rebate, applied beads or groove recognised 1 3 No marks for glued only Technical accuracy: accurate sizes/proportion of panel-frame 0–2

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Question 292 0445/33 May/June 2022

8 Fig. 8.1 shows a cycle helmet. inner cushioned lining outer shell Fig. 8.1 A list of plastics is given below. nylon polycarbonate polypropylene expanded polystyrene acrylic (a) Select from the list one plastic that is suitable for the outer shell. … [1] (b) Select from the list one plastic that is suitable for the inner lining. … [1]

2 marks

Mark scheme: 8(a) Polycarbonate 1 8(b) Expanded polystyrene 1

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Q293 · A list of metals is given below 0445/33 May/June 2022

9 A list of metals is given below. cast iron aluminium stainless steel duralumin copper Select from the list one metal that is a: (a) ferrous alloy … [1] (b) non-ferrous alloy. … [1]

2 marks

Mark scheme: 9(a) Stainless steel, cast iron 1 9(b) Duralumin 1

This question in 0445/33 May/June 2022

Q294 · An incomplete design for a table top organiser made from acrylic 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

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Q295 · A wall-mounted cycle rack made from mild steel 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

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Q296 · An incomplete design for a wall-mounted shelf unit for a bathroom 0445/33 May/June 2022

13 Fig. 13.1 shows an incomplete design for a wall-mounted shelf unit for a bathroom. The end frames are made from softwood. The shelves are made from manufactured board. 200 fixed shelf 12 mm thick 440 moveable shelf 12 mm thick fixed shelf 12 mm thick 600 end frame softwood 20 × 20 Fig. 13.1 (a) (i) Name a suitable softwood for the end frames. … [1] (ii) Name a suitable manufactured board for the shelves. … [1] (b) State two factors a designer would need to consider when designing products for use in a bathroom. 1 … 2 … [2] (c) A corner bridle joint will be used to join the parts of the frame. Fig. 13.2 shows one corner of an end frame. Complete Fig. 13.2 to show an exploded view of a corner bridle joint. Fig. 13.2 [3] (d) Fig. 13.3 shows one end of a fixed shelf and part of an end frame. Complete Fig. 13.3 to show a joint that could be used to join the fixed shelf to the end frame. fixed shelf 12 mm thick end frame 20 × 20 Fig. 13.3 [4] (e) Fig. 13.4 shows the end frame and moveable shelf. Use sketches and notes to show how the shelf could be supported at three different heights. The shelf must be prevented from sliding horizontally inside the end frame. Include details of the materials, constructions and fittings used. 160 12 mm thick 20 × 20 200 Fig. 13.4 [6]

17 marks

Mark scheme: 13(a)(i) Pine, red deal, redwood, spruce, fir, parana pine, yew, cedar 1 Accept any valid softwood 13(a)(ii) Plywood, MDF, chipboard 1 Not blockboard 13(b) 2 factors: moisture/steam resistant materials, corrosion resistant metal, 2 Accept any valid consideration colour co-ordination, attractive appearance, easy to clean, size of bathroom, Must relate to bathroom e.g. not ‘no sharp chemical resistance 2 × 1 edges’ 13(c) ‘Tenon’ shown on top part of frame 1 3 ‘Slot’ shown on upright part of frame 1 Accurate size/proportion 1 13(d) Recognised joint includes: dowel, biscuit, T&G, housing 1 4 Maximum numbers of dowels 4 Modification to end frame 1 Minimum of 2 biscuits Modification to shelf 1 Technical accuracy 1 13(e) Shelf joined to end frame 1 6 If shelf and/or frame size altered award no Can be moved to 3 different positions 1 marks. Shelf does not move horizontally 1 Appropriate named materials 1 Details of constructions and fittings used 0–2 13(f) Additional supporting rail, ‘back’ or brackets shown 1 4 Award one mark max for using screws to fix Method of fitting/joining additional rail, ‘back’ or brackets to existing shelf unit directly to wall. unit 1 Method of attaching unit to wall (screws/hooks etc.) 1 Technical accuracy 1 13(g) Advantage to manufacturer: quicker to produce, less labour involved 1 2 Accept any valid advantage or disadvantage Disadvantage to manufacturer: single sheet would be more expensive 1 for manufacturing 13(h) Explanations could include: 2 Reference could be made to either the Some (not all) manufactured boards can be made from recycled materials/ manufactured board or softwood waste products, Softwoods are fast growing so more readily available, Softwood trees can be replanted, to replace those cut down. 2 × 1

This question in 0445/33 May/June 2022

Q297 · A set of steps used in a swimming pool 0445/32 Oct/Nov 2022

1 Fig. 1.1 shows a set of steps used in a swimming pool. support rail step Fig. 1.1 Give the name of: (a) a suitable specific metal that could be used to make the support rails … [1] (b) a specific plastic for the steps. … [1]

2 marks

Mark scheme: Question Answer Marks Guidance 1(a) Stainless steel, aluminium, inox, duralumin 1 1(b) ABS, polypropylene, HDPE 1 Not polythene or polyethylene, PVC

This question in 0445/32 Oct/Nov 2022

Q298 · A card model of an adjustable lamp mechanism 0445/32 Oct/Nov 2022

3 Fig. 3.1 shows a card model of an adjustable lamp mechanism. paper fasteners card base Fig. 3.1 Give two benefits of making a card model when designing the adjustable lamp mechanism. 1 … 2 … [2]

2 marks

Mark scheme: 3 Benefits: check sizes, appearance, check movement of linkages, prevents waste 2 Not to test stability, easier to make of resistant materials, cheaper, quick to make

This question in 0445/32 Oct/Nov 2022

Q299 · A list of materials is given below 0445/32 Oct/Nov 2022

4 A list of materials is given below. ABS aluminium polypropylene brass mild steel melamine formaldehyde Select, from the list, one material that is a: (a) ferrous alloy … (b) non-ferrous alloy … (c) thermosetting plastic … [3]

3 marks

Mark scheme: 4(a) Mild steel 1 3 4(b) Brass 1 4(c) Melamine formaldehyde 1

This question in 0445/32 Oct/Nov 2022

Q300 · A battery that has been ‘blister packaged’ 0445/32 Oct/Nov 2022

6 Fig. 6.1 shows a battery that has been ‘blister packaged’. e5gr mAh567B 650 CCD Fig. 6.1 (a) State two benefits of blister packaging products. 1 … 2 … [2] (b) Describe one environmental problem caused by blister packaging. … … [2]

4 marks

Mark scheme: 6(a) Benefits: provides safe packaging of product, product is visible, material can be 2 Accept any valid benefit formed to shape of product, protects contents, easy to manufacture, airtight, Not cheap to manufacture lightweight, waterproof, dust free, no risk of oxidisation, difficult for children to open 6(b) Packaging can create litter, plastic is a non-renewable resource 2 Accept any valid environmental e.g. plastic is non-biodegradable = 1 therefore can cause pollution = 1 problem

This question in 0445/32 Oct/Nov 2022

Q301 · Two pieces of hardwood that will be joined by means of a dowel joint 0445/32 Oct/Nov 2022

7 Fig. 7.1 shows two pieces of hardwood that will be joined by means of a dowel joint. Ø9 20 70 Fig. 7.1 Use sketches and notes to show a design for a jig that would allow the holes to be drilled accurately in both pieces of hardwood. [3]

3 marks

Mark scheme: 7 Sheet with 2 holes drilled 1 3 Not two ends Sheet with 2 holes drilled and located against one end 2 Sheet with 2 holes drilled and located against one end and one side 3

This question in 0445/32 Oct/Nov 2022

Q302 · A length of 20 × 20 square tube and a length of Ø10 rod 0445/32 Oct/Nov 2022

8 Fig. 8.1 shows a length of 20 × 20 square tube and a length of Ø10 rod. tube Ø10 rod Fig. 8.1 State a method of joining the rod to the tube permanently when they were both made from: brass … mild steel … acrylic … [3]

3 marks

Mark scheme: 8 Silver soldering, hard soldering, soft soldering, soldering 1 3 Do not accept repeats Not Araldite, epoxy resin, contact Brazing, welding 1 adhesive Acrylic cement, Tensol cement 1

This question in 0445/32 Oct/Nov 2022

Q303 · A wooden drawer and the top of a desk 0445/32 Oct/Nov 2022

9 Fig. 9.1 shows a wooden drawer and the top of a desk. 15 mm thick desk top drawer slides in and out 12 mm thick side Fig. 9.1 Use sketches and notes to show how the drawer could be supported under the desk top and allowed to slide in and out. Show all constructional details. [3]

3 marks

Mark scheme: 9 Support joined to underside of desk top 1 3 Accept support in position [not joined] Some sort of ‘runner’ attached to drawer side 1 Accept whole ‘box’ added under Drawer ‘runner’ attached to support 1 desktop Look for use of groove and bead as a runner or use of applied beads

This question in 0445/32 Oct/Nov 2022

Q304 · A small table made from hardwood 0445/32 Oct/Nov 2022

11 Fig. 11.1 shows a small table made from hardwood. The table top has been removed to show details of the legs and rails. table top Ø450 × 20 thick B rail 40 × 20 A 450 leg 40 × 40 Fig. 11.1 (a) The rails are joined at A by means of a cross-halving joint. Complete the exploded drawing below to show a cross-halving joint. [3] (b) Sketch and name a permanent method of joining the rail to the leg shown at B in Fig. 11.1. Name of joint … [4] (c) The table top will be produced using a woodturning lathe. Fig. 11.2 shows the shape of the table top marked out on a hardwood board. waste corners to be sawn off 20 mm thick Fig. 11.2 (i) Name two machine saws that could be used to remove the waste wood shown in Fig. 11.2. 1 … 2 … [2] (ii) Circle , from the list below, the method of woodturning that would be used to produce the table top. taper parallel faceplate between-centres [1] (iii) State two checks that would need to be carried out after setting up the hardwood board on the woodturning lathe. 1 … 2 … [2] (d) The palm sander shown in Fig. 11.3 could be used to prepare the parts of the table to take a clear finish. Fig. 11.3 (i) State two advantages of using a palm sander to prepare the parts of the table rather than by hand using a cork block and glasspaper. 1 … 2 … [2] (ii) Explain why a clear finish rather than an opaque finish would be applied to the parts of the table. … … … [2] (iii) Name two suitable clear finishes that could be applied to the parts of the table. 1 … 2 … [2] (e) Solid wood contains moisture. Moisture loss can cause the wood to shrink and split. Fig. 11.4 shows the direction in which the hardwood table top could shrink. B shrinkage occurs across the grain Fig. 11.4 Use sketches and notes to show how the shrinkage plate shown below could be used to fasten the table top to rail B in such a way to prevent the hardwood from splitting. 3 mm thick mild steel 40 30 [3] (f) Fig. 11.5 shows details of a shelf that is to be fitted to the legs of the table at the height shown. 400 140 shelf Ø390 × 15 thick Fig. 11.5 Use sketches and notes to show how the shelf could be joined to the legs without the use of additional rails. Show all the constructions and any fittings used. [4]

25 marks

Mark scheme: 11(a) Halving cut out of top rail 1 3 Halving cut out of lower rail 1 Accurate size/proportion 1 11(b) Appropriate constructions at B: dowel, mortise and tenon, bridle named 1 4 Dowel joint must have Correct orientation 1 2 dowels = 2 marks Technical accuracy of joint 0–2 1 dowel = 1 mark 11(c)(i) Band saw, scroll saw, circular saw, jig saw, Hegner saw, table saw 2  1 2 Do not accept both circular saw and table saw 11(c)(ii) Faceplate 1 11(c)(iii) 2 checks: speed of lathe, position/tightening of tool rest, condition of turning tools, 2 Accept any valid checks secure the wood, free rotation of work piece 2  1 11(d)(i) 2 advantages: quicker, more even pressure, even finish, less effort, easier 2  1 2 Accept any valid advantages Not better finish 11(d)(ii) Explanation: clear finish allows the natural features of hardwood to be seen, 2 opaque finish hides them, aesthetic / attractive quality, grain and colour visible 2  1 11(d)(iii) White polish, French polish, Danish oil, lacquer, teak oil, varnish, sealer, wax 2 Accept any valid clear finishes 2  1 Not oil or polish 11(e) Position of shrinkage plate on top rail [where B is marked] 1 3 Shrinkage plate shown screwed to top rail 1 Plate overhangs rail 1 11(f) Method: use of brackets/blocks/dowel pegs/metal pins 1 4 Technical accuracy: e.g. materials Joined to legs 1 used for brackets, pegs, pins, blocks, Shelf shown at 140mm height 1 types of screws used Technical accuracy 1

This question in 0445/32 Oct/Nov 2022

Q305 · A book stand that will be used to display books in a school library 0445/32 Oct/Nov 2022

12 Fig. 12.1 shows a book stand that will be used to display books in a school library. The book stand is made from 5 mm thick acrylic and a batch of ten will be produced by hand in a school workshop. 40 40 100 100 Fig. 12.1 (a) Fig. 12.2 shows two templates that will be used to mark out the shapes onto acrylic sheet. foot support Fig. 12.2 (i) Give one reason why a template made from card would not be suitable when making a large batch of products. … [1] (ii) Name two different tools or items of equipment that could be used to draw around the templates to mark the surface of the acrylic sheet. 1 … 2 … [2] (b) Fig. 12.3 shows one support marked out on a sheet of acrylic. waste Fig. 12.3 Use sketches and notes to show how the waste material shown in Fig. 12.3 could be removed. Name all the tools and equipment used. Do not include any filing of the edges. [3] (c) Fig. 12.4 shows one support after all the waste has been removed. A B C Fig. 12.4 Name three different types of file that could be used when filing the parts of the support. Curve A … Corner B … Slot C … [3] (d) Twenty supports and twenty feet will be required to batch produce ten complete book stands. Use sketches and notes to show one method, other than by using templates, of ensuring that all twenty supports are made to an identical size and shape. [2] (e) Fig. 12.5 shows a different design for a book stand made from one length of Ø5 non-ferrous metal rod. 190 200 150 Fig. 12.5 (i) Name a suitable non-ferrous metal for the book stand. … [1] (ii) The non-ferrous metal used to make the book stand must be able to be bent to shape easily. Circle , from the list below, the term that describes the ability of a metal to be shaped without breaking. flexibility hardness malleability toughness [1] (iii) Use sketches and notes to show how a single length of Ø5 non-ferrous metal rod could be bent to the shape of the book stand shown in Fig. 12.5. Name all the tools and equipment used. [5] (iv) When hammering the metal into shape it can become ‘work hardened’. Name the process used to make the metal softer so that it can continue to be shaped without breaking. … [1] (v) The Ø5 rod will have a clear lacquer finish. Give two benefits of a clear lacquer finish for the non-ferrous metal book stand. 1 … 2 … [2] (f) Describe one different design feature of each of the book stands shown in Fig. 12.1 and Fig. 12.5. Acrylic book stand Fig. 12.1 … … Metal book stand Fig. 12.5 … … [4]

25 marks

Mark scheme: 12(a)(i) Card will become worn with use which will result in less accurate marking out 1 12(a)(ii) 2 tools: scriber, permanent marker, chinagraph pencil, felt tip pen, felt pen, water 2 soluble marker, marker 2  1 12(b) Drill hole for drill to access shape, insert saw blade and saw out shape 2  1 3 Appropriate saws: coping, jig, Hegner, Correctly named tools and equipment 1 scroll, abra file, junior hacksaw, router 12(c) A half round or round/rat tail 1 3 B hand, triangle, 3 square, half round 1 C warding, square, hand file, flat file 1 12(d) Method: tape several pieces together and cut/shape as one piece 2 Accept use of CNC machine = 1 mark Cut out one end piece then mark around it [as a template] = 1 mark only For 2 marks e.g. include references to software, file saved, data transferred to CNC machine 12(e)(i) Aluminium, brass, copper, nickel silver, duralumin 1 12(e)(ii) Malleability 1 12(e)(iii) Metal heated to soften 1 5 Use of formers, jigs to produce bends 0–2 Will it work? 1 Named tools and equipment 1 12(e)(iv) Annealing 1 12(e)(v) 2 benefits: attractive finish, natural colour of metal visible, prevents corrosion, 2 Accept any valid benefits prevents tarnishing, easier to clean 2  1 12(f) Acrylic book stand: adjustable and can take different size books, can be 4 Reward answers that state a point disassembled, and stored flat, attractive colours 0–2 then expand upon it Metal book stand: simple design, good/minimal use of materials, attractive lacquered finish, stackable 0–2

This question in 0445/32 Oct/Nov 2022

Q306 · An incomplete design for a table football game 0445/32 Oct/Nov 2022

13 Fig. 13.1 shows an incomplete design for a table football game. players handle end rod side base A goal area Fig. 13.1 (a) Table 13.1 shows a parts list for the table football game. Complete Table 13.1 by stating the name of a specific material that could be used for each part of the table football game. Table 13.1 Part No. Length × Width × Thickness General material Specific material Sides 2 480 × 60 × 15 Hardwood Ends 2 310 × 60 × 15 Base 1 480 × 290 × 4 Manufactured board Rods 4 490 × Ø8 Non-ferrous metal Players 12 80 Plastic [4] (b) Fig. 13.2 shows the corner joint A. Fig. 13.2 (i) Name the joint shown in Fig. 13.2. … [1] (ii) Add sketches and notes to Fig. 13.2 to show how the joint could be strengthened. [2] (c) Fig. 13.3 shows a rebate used to join the base and sides of the table football game. A power router will be used to cut out the shape of the rebate. side rebate basebase Fig. 13.3 State two settings that need to be made before the power router can be used. 1 … 2 … [2] (d) Fig. 13.4 shows details of one of the goal areas. 15 mm thick height of goal area 50 mm 110 Fig. 13.4 Use sketches and notes to show a method of retaining a ball when a goal is scored. Include details of the materials, fittings and constructions used. [4] (e) The players are made from a plastic. (i) Circle , from the list below, the method of manufacture used to produce the players. vacuum forming extrusion moulding injection moulding [1] (ii) The players could be joined to the non-ferrous rod by means of an adhesive. Name a suitable adhesive.

14 marks

Mark scheme: 13(a) Hardwood: wide variety of suitable hardwoods 1 4 Use internet to check obscure named Manufactured board: hardboard, plywood, MDF 1 woods Non-ferrous metal: aluminium, duralumin 1 Must be appropriate for use Plastic: ABS, HIPS, HDPE, nylon, polypropylene 1 Not chipboard Not acrylic, PVC 13(b)(i) Mitre 1 13(b)(ii) Use of veneer ‘feather’ in outer edge, use of solid wood insert across top of joint, 2 Award 0–2 dependent on technical wooden block, K-D corner block inside, corrugated metal fastener, angled bracket accuracy inside, use of staples 13(c) 2 settings: correct diameter/type of router bit, securely fitted, depth gauge, 2 Accept references to width and depth adjust fence to width, insert and tighten bit, correct speed 2  1 of rebate 13(d) Some sort of enclosed ‘box’ or ‘tray’ shown 1 4 Attached to side of cabinet or to base 1 Details of materials, fittings and constructions 0–2 13(e)(i) Injection moulding 1 13(e)(ii) Epoxy resin, ‘Araldite’ or equivalent trade name 1 13(f)(i) Use of strip heater/line bender, hot air gun 1 4 Method of heating must be stated Method of retention while acrylic cools 1 13(f)(ii) 3 processes to engrave numbers: data from file transferred to CNC machine, 3 Examples: use of laser cutter, place acrylic on bed of machine, set tool parameters, computer ‘print’, ‘run’ CAMM2 CNC machine 3  1 3 processes to apply numbers: data from file transferred to CNC machine, vinyl Example: CAMM1 vinyl cutter loaded into machine, set tool parameters, computer ‘print’, ‘run’ 3  1 Do not reward use of laser cutter or 3D printer to cut out numbers as they will not fit onto scoreboard with slider 13(g) Method of protection from impact: use of soft/flexible ‘washer’ or ‘spacer’ fitted 3 Protection can be shown inside or over rods 0–2 outside the cabinet Details of materials and fittings used 1

This question in 0445/32 Oct/Nov 2022

Q307 · Three fastenings, A, B and C, used to join materials 0445/33 Oct/Nov 2022

1 Fig. 1.1 shows three fastenings, A, B and C, used to join materials. A B C Fig. 1.1 Name an appropriate tool for use with each fastening. A … B … C … [3]

3 marks

Mark scheme: Question Answer Marks Guidance 1 A spanner, wrench 1 3 Not mole grips, B screwdriver 1 Not posidrive, Phillips screwdriver C allen key, hexagon wrench, hexagon screwdriver 1

This question in 0445/33 Oct/Nov 2022

Q308 · Part of a table top with an area to be cut out so that a container can fit inside 0445/33 Oct/Nov 2022

2 Fig. 2.1 shows part of a table top with an area to be cut out so that a container can fit inside. 150 200 waste wood to be removed 18 mm thick hardwood Fig. 2.1 Complete Table 2.1 by stating the name of a specific tool required for each process. Table 2.1 Process Specific tool Make a hole in corner of waste wood …………………………………. drill Cut out waste wood ………………………….……… saw Make cut edges smooth ……………………………..….. paper [3]

3 marks

Mark scheme: 2 Twist drill, hole saw 1 3 Hegner, bow, pad, jig, scroll, coping saw 1 Glasspaper, sandpaper, aluminium oxide, garnet paper 1 Not wet and dry paper, abrasive paper

This question in 0445/33 Oct/Nov 2022

Q309 · A set of hardwood skittles that have been made using a woodturning lathe 0445/33 Oct/Nov 2022

3 Fig. 3.1 shows a set of hardwood skittles that have been made using a woodturning lathe. Fig. 3.1 (a) State one benefit of using a close-grained hardwood for the skittles. … [1] (b) Name one tool that could be used to check the diameter of a skittle when it has been ‘turned’ on a woodturning lathe. … [1]

2 marks

Mark scheme: 3(a) Benefit: wood is less likely to split/splinter when turned or in use, tough, dense 1 Not durable, hardwearing, strong 3(b) [Outside], [external] calipers, vernier 1 Not calipers, micrometer

This question in 0445/33 Oct/Nov 2022

Q310 · A cycle rack used in a public park 0445/33 Oct/Nov 2022

4 Fig. 4.1 shows a cycle rack used in a public park. The wooden posts are made from oak and the metal tubes from mild steel. Fig. 4.1 (a) Give one property of oak that makes it suitable for outdoor use. … [1] (b) Name a suitable finish, other than paint, for the mild steel tubes. … [1]

2 marks

Mark scheme: 4(a) Hardwearing, weather resistant, long lasting, durable 1 4(b) Electroplated, galvanised 1 Not plastic coated

This question in 0445/33 Oct/Nov 2022

Q311 · An incomplete drawing of a mortise and tenon joint 0445/33 Oct/Nov 2022

6 Fig. 6.1 shows an incomplete drawing of a mortise and tenon joint. mortise Fig. 6.1 Complete Fig. 6.1 to show a tenon that would fit into the mortise. [3]

3 marks

Mark scheme: 6 Height of tenon 1 thickness of tenon 1 length of tenon 1 3 Tenon clearly drawn Equally proportioned shoulders

This question in 0445/33 Oct/Nov 2022

Q312 · A yoghurt pot with a plastic foldable spoon attached to the inside of the lid of the pot 0445/33 Oct/Nov 2022

7 Fig. 7.1 shows a yoghurt pot with a plastic foldable spoon attached to the inside of the lid of the pot. Fig. 7.1 (a) Give one benefit to consumers of supplying a spoon with the yoghurt pot. … [1] (b) State one negative impact on the environment of supplying a spoon with the yoghurt pot. … [1]

2 marks

Mark scheme: 7(a) No need to carry spoon, convenience 1 7(b) Uses material from finite source, spoon thrown away 1

This question in 0445/33 Oct/Nov 2022

Q313 · A barbecue made from 1.5 mm thick mild steel sheet 0445/33 Oct/Nov 2022

8 Fig. 8.1 shows a barbecue made from 1.5 mm thick mild steel sheet. 250 500 300 Fig. 8.1 Use sketches and notes to show a modification to the barbecue shown in Fig. 8.1 that would make it easier to carry. [2]

2 marks

Mark scheme: 8 Award 1 mark for practical design. Award 1 mark for supporting notes 2 Examples of notes: heatproof to hold, safe to carry, size, constructions, named materials

This question in 0445/33 Oct/Nov 2022

Q314 · A child’s counting toy that could be made in a school workshop 0445/33 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

Q315 · A picnic table made from recycled plastic 0445/33 Oct/Nov 2022

10 Fig. 10.1 shows a picnic table made from recycled plastic. Fig. 10.1 Give two benefits of using recycled plastic for the picnic table rather than softwood. 1 … 2 … [2]

2 marks

Mark scheme: 10 Benefits: more resistant to outdoor conditions, recycled materials save 2 Accept any valid benefit resources, does not require a finish, less maintenance, easy to clean, better for Not cheaper environment 2  1

This question in 0445/33 Oct/Nov 2022

Q316 · An incomplete design for a cabinet with a drawer 0445/33 Oct/Nov 2022

11 Fig. 11.1 shows an incomplete design for a cabinet with a drawer. The cabinet is made from 18 mm thick veneered chipboard and designed as flat pack for self- assembly. 400 400 top drawer 600 side base leg 120 × Ø30 Fig. 11.1 (a) Give two reasons why manufactured boards are often covered with veneer. 1 … 2 … [2] (b) The top and base of the cabinet are joined to the sides using dowels. (i) State a suitable diameter for the dowels … [1] (ii) State a suitable length for the dowels … [1] (iii) State the number of dowels used to join one side to the top of the cabinet … [1] (d) Working with chipboard can be difficult. Describe one problem that can be encountered when working with chipboard and how the problem could be solved. Problem … … Solution … … [2] (e) The drawer front will be joined to the sides of the drawer using cam lock knock-down (KD) fittings. Fig. 11.2 shows details of the drawer and a cam lock fitting. 120 80 drawer side 300 mm long drawer front 15 mm thick cam lock knock-down (KD) fitting Fig. 11.2 Use sketches and notes to show how one cam lock fitting could be used to join the drawer front to one of the sides. [3] (f) (i) Use sketches and notes to show a design for a handle that could be attached to the drawer front to enable the drawer to be opened and closed. Include: • the name of the material used for the handle • the method of attaching the handle to the drawer front. [4] (ii) Use sketches and notes to show how the drawer could be supported inside the cabinet. The drawer must be: • able to slide in and out of the cabinet • prevented from going too far inside the cabinet. Include details of fittings and fixings used. [4] (g) Fig. 11.3 shows one corner of the back of the cabinet and part of the hardboard back. top hardboard back 4 mm thick side Fig. 11.3 Use sketches and notes to show how the hardboard back could be fitted permanently to the cabinet so that the edges of the hardboard are not visible. [3] (h) Fig. 11.4 shows a box in which all the parts of the cabinet and drawer will fit for delivery to customers. depth CABINET length width Fig. 11.4 Add to Fig. 11.4 by stating an appropriate length, width and depth for the box to contain all the parts of the cabinet and drawer. [3]

25 marks

Mark scheme: 11(a) 2 reasons: to cover unattractive surface, to give the appearance of quality solid 2 wood, more cost effective than using expensive hardwood 2  1 11(b)(i) Minimum Ø6 – maximum Ø12 1 11(b)(ii) Length 15 mm – 30 mm 1 11(b)(iii) Minimum 3 – maximum 6 1 11(c) Benefit: easy to apply, quick drying, easy to remove surplus, strong 1 Accept any valid benefit 11(d) Problem: when sawing, planing or chiselling it can crumble, chip, break off 1 2 Accept any valid problem Solution: support chipboard whenever possible 1 Not references to non-water resistance 11(e) Correct position of cam in drawer side 1 3 Accept position of cam inside or Correct position of screw inside drawer front 1 outside drawer Cam locked explained 1 11(f)(i) Practical design of handle 0–2 4 Method of attachment to drawer front 1 Named specific material 1 11(f)(ii) Drawer slides in and out: 4 Award 1 mark only for use of pre- Use of ‘cut’ grooves or applied beads to side of drawer and inside cabinet or use manufactured runners, rails of single batten for drawer to ‘run’ on 0–2 Method of stopping drawer going too far 1 Details of fittings and fixings 1 11(g) Method: use of groove or rebate [cut out or applied beads] 1 3 Technical accuracy/correct size and proportion 0–2 11(h) Minimum dimensions of parts of cabinet 600  400  100 3  1 3 Maximum “ “ “ “ “ 700  500  200

This question in 0445/33 Oct/Nov 2022

Q317 · A tray made from 5 mm thick acrylic 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

Q318 · A jewellery stand made in a school workshop 0445/33 Oct/Nov 2022

13 Fig. 13.1 shows a jewellery stand made in a school workshop. The jewellery stand could be delivered to customers as flat pack for self-assembly. The tray and uprights are made from oak. The rail and support are made from brass. rail support 240 upright tray side 300 150 Fig. 13.1 (a) State two items of research the designer would need to consider when designing the jewellery stand. 1 … … 2 … … [2] (b) The sides of the tray will be joined by mitre joints at each corner. Fig. 13.2 shows part of one of the sides of the tray with the joint marked out. waste Fig. 13.2 (i) Name the tools, A and B, that could be used to mark out the joint. A B A … B … [2] (ii) Fig. 13.3 shows the sides of the tray ready to be glued at each corner. Fig. 13.3 Add sketches and notes to Fig. 13.3 to show how the sides could be held in position while the glue sets. [2] (c) Use sketches and notes to show how the space inside the tray could be divided into three unequal parts to keep different items of jewellery separate. Give details of the materials and constructions used. [5] (d) The support is made from 1.5 mm thick brass strip. Fig. 13.4 shows part of the support marked out ready for the holes to be drilled and the strip to be bent to shape. centres for holes bend line Fig. 13.4 (i) Name two marking out tools that could be used to mark out the centres and bend lines on the brass strip. 1 … 2 … [2]

13 marks

Mark scheme: 13(a) 2 items of research: specific types of jewellery, quantity, material jewellery is 2 Accept any valid item of research made from, specific sizes and best ways to store/support jewellery, ergonomics 2  1 13(b)(i) A mitre square 1 2 B sliding bevel 1 Accept ‘adjustable bevel’ 13(b)(ii) Use of string + dowel inserted to tighten or use of rubber bands, ‘ratchet straps’ 2 Traditional sash/G cramps not ‘corner blocks’ mitre cramps 0–2 appropriate 13(c) 3 unequal parts shown 1 5 Examples of method include solid Constructional details 0–3 wood partitions housed or a single Appropriate named materials 1 vacuum formed insert 13(d)(i) 2 marking out tools: scriber, odd leg calipers [odd-legs, Jenny calipers], steel rule, 2 Not use of dot or centre punch, engineers square, try square, engineers [marking] blue 2  1 markers, felt tip pens 13(d)(ii) 2 precautions: drill piece tightened in chuck, chuck key removed, correct speed 2 Accept references to drilling machine set, workpiece clamped securely, centre punched brass to assist drilling 2  1 only 13(d)(iii) Sketch showing use of mallet or hammer and scrap wood, vice as a former 0–2 3 Accept sheet metal bender: details Correctly named tools and equipment 1 must be given for max. 3 marks 13(e)(i) Wet and dry [silicon carbide] paper 1 Do not accept emery cloth 13(e)(ii) Explanation: too fine a grade will not remove marks and too coarse a grade will 2 scratch the surface 0–2 13(f) Some sort of screw/nut and bolt arrangement at A and B 2  1 4 Details of fitting: e.g. countersunk, type of head, length 0–2

This question in 0445/33 Oct/Nov 2022

Q319 · Views of a butt joint using softwood 60 mm wide × 15 mm thick 0445/31 May/June 2023

2 Fig. 2.1 shows views of a butt joint using softwood 60 mm wide × 15 mm thick. Fig. 2.1 Add sketches and notes to Fig. 2.1 to show how the butt joint could be strengthened. [3]

3 marks

Mark scheme: 2 Any 2 different appropriate methods: Use of wooden corner block / recognised KD fitting / dovetail nailing / dowels / screws / Pin & glue / screw & glue [3 marks] 3 Reward 2 different appropriate methods 3 marks Use of adhesive not required

This question in 0445/31 May/June 2023

Q320 · A hardwood block with a line measured and marked out 100 mm from the datum face 0445/31 May/June 2023

4 Fig. 4.1 shows a hardwood block with a line measured and marked out 100 mm from the datum face. 100 datum face Fig. 4.1 Describe the purpose of the datum face. … … [2]

2 marks

Mark scheme: 4 Datum face provides a perfectly flat surface [1] From which to measure, used to measure accurately [1] 2

This question in 0445/31 May/June 2023

Q321 · Select the plastic from the list below that corresponds to the description 0445/31 May/June 2023

5 Select the plastic from the list below that corresponds to the description. expanded polystyrene PVC nylon polyester resin phenol formaldehyde (a) Good chemical and weather resistance, used for pipes, guttering and window frames. … [1] (b) Hard, brittle, heat resistant, used for dark electrical fittings, saucepan and kettle handles. … [1]

2 marks

Mark scheme: 5(a) PVC 1 5(b) Phenol formaldehyde 1

This question in 0445/31 May/June 2023

Q322 · An incomplete design for a bracket made from 3 mm thick mild steel strip that will be… 0445/31 May/June 2023

6 Fig. 6.1 shows an incomplete design for a bracket made from 3 mm thick mild steel strip that will be fixed to a wall. weight is applied 150 25 Fig. 6.1 Use sketches and notes to show how the bracket could be strengthened. [3]

3 marks

Mark scheme: 6 Some form of strut [1] Method of joining strut to bracket: brazed / riveted] [1] Technical accuracy in notes and sketches [1]

This question in 0445/31 May/June 2023

Q323 · A hardwood rail, 40 × 25, with a recess cut out, ready to take a butt hinge 0445/31 May/June 2023

7 Fig. 7.1 shows a hardwood rail, 40 × 25, with a recess cut out, ready to take a butt hinge. Fig. 7.1 Fig. 7.2 Add sketches to Fig. 7.2 to show a complete butt hinge fitted into the recess. [3]

3 marks

Mark scheme: 7 Hinge drawn in correct position [1] 2 leaves [1] 2 or 3 holes in each leaf [1] 3

This question in 0445/31 May/June 2023

Q324 · Two components, A and B, that have been produced by different manufacturing processes 0445/31 May/June 2023

8 Fig. 8.1 shows two components, A and B, that have been produced by different manufacturing processes. Component A is made of plastic. Component B is made of metal. A B Fig. 8.1 Name the manufacturing process that has been used to produce each component. Component A … Component B … [2]

2 marks

Mark scheme: 8 A injection moulding / 3D printing [1] B die-casting [1] 2 Do not reward ‘casting’

This question in 0445/31 May/June 2023

Q325 · A sheet of 4 mm thick hardboard 0445/31 May/June 2023

10 Fig. 10.1 shows a sheet of 4 mm thick hardboard. 400 300 Fig. 10.1 Use sketches and notes to show how a softwood frame could be joined to the hardboard to make a ‘flush’ door. [4]

4 marks

Mark scheme: 10 Recognised frame: 4 softwood strips [1] Size/proportion of strips [1] Corner joint for strips; e.g. butt joint / mitre joint, named or shown [1] Method of joining frame to hardboard [1] Strips must be applied to ‘face of hardboard- not edges

This question in 0445/31 May/June 2023

Q326 · An incomplete design for a sweet dispenser 0445/31 May/June 2023

11 Fig. 11.1 shows an incomplete design for a sweet dispenser. The sweet dispenser is made from 5 mm thick MDF with a clear plastic window. The mechanism that allows sweets to fall when the handle is turned has been removed. 50 position for lid clear plastic window cut out shape 70 × 70 200 handle rotates 100 80 Fig. 11.1 (a) (i) State two properties of MDF that make it suitable for the sweet dispenser. 1 … 2 … [2] (ii) Name one other manufactured board that could be used to make the sweet dispenser. … [1] (iii) Name a suitable plastic, other than acrylic, that could be used for the window. … [1] (b) Give two reasons why it would be important to make a card model of the sweet dispenser before making it from MDF. 1 … 2 … [2] (c) Use sketches and notes to show how the window could be cut out and the edges made flat and smooth using hand and / or machine tools. Name all the tools and equipment used. State one safety precaution that must be taken. Safety precaution … [5] (d) Fig. 11.2 shows details of the handle. Two discs are needed to make the handle to turn the mechanism. One disc has a Ø5 hole drilled through it. The second disc has a ‘blind’ hole 8 mm deep. Ø5 hole for dowel two discs Ø40 × 10 mm thick front of dispenser 5 mm thick Fig. 11.2 Use sketches and notes to show how the two discs, including the holes, could be produced from 10 mm thick MDF sheet. Name all the tools and equipment used. [5] (e) The parts of the sweet dispenser will be joined using a contact adhesive. (i) State one benefit and one drawback of using a contact adhesive to join the parts of the sweet dispenser. Benefit … … Drawback … … [2] (ii) Describe how the contact adhesive would be used to join the parts of the sweet dispenser. … … [2] (f) Use sketches and notes to show a design for a lid that could be fitted in the position shown in Fig. 11.1. The lid must allow easy access to fill the dispenser. Show all constructional details and state two important sizes. [5]

25 marks

Mark scheme: 11(a)(i) 2 Accept any valid benefits 11(a)(ii) Plywood / hardboard 1 11(a)(iii) PVC / ABS / polycarbonate / PET / polythene 1 11(b) Any 2 reasons such as : reduces costs if mistakes are made / check appearance / sizes / test mechanism [2  1] 2 Accept any valid reasons Question Answer Marks Guidance 11(c) Marking out plastic [1] Saw plastic to shape: leaving small amount of waste to remove [1] Appropriate saws: band saw / Hegner saw / scroll saw / coping saw/ tenon saw [1] Edges made flat and smooth: files, disk sander, wet and dry paper [1] Accept any valid safety precaution relating to any correct process [1] 5 Do not accept jig saw Do not accept glasspaper/sandpaper 11(d) Mark out 40 x 40 piece of MDF [1] Cut to disk shape, leaving small amount of waste to remove [1] File/sand to finished shape [1] Holes drilled correctly [1] Correctly named tools and equipment [1] 5 Accept use of hole saw: Hole saw named [1] Hole saw drawn [1] Mark centres on 40  40 piece of MDF [1] Description of use [0 – 2] 11(e)(i) Benefit: quick to apply and join parts / no clamping required [1] Drawback: can be ‘messy’ / no adjustment of joints possible / not as strong as PVA type adhesives / difficult to remove excess adhesive /, toxic fumes [1] 2 11(e)(ii) Thin layer of contact adhesive applied evenly to both surfaces to be joined [1] Allow to ‘touch dry’ before joining two surfaces together [1] 2 2 clear stages 11(f) Recognised easy access ‘lid’ design [1] Appropriate constructions shown or named [0 – 2] Sizes to confirm lid fits [2  1] 5 Outside dimensions: 100  50 Inside dimensions: 80  30

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Q327 · An incomplete design for an adjustable stand to support a tablet 0445/31 May/June 2023

12 Fig. 12.1 shows an incomplete design for an adjustable stand to support a tablet. The stand is made of 4 mm thick acrylic and could be made in a school workshop. support base pivot Fig. 12.1 (a) Acrylic is a thermoplastic. State one advantage of making the stand from a thermoplastic rather than a thermosetting plastic. … [1] (b) Fig. 12.2 shows the development (net) of the base marked out on a sheet of acrylic. waste 160 centre for Ø10 hole 50 bend line 255 Fig. 12.2 (i) Name two tools or items of equipment that could be used to mark out the lines on the surface of the acrylic sheet. 1 … 2 … [2] (ii) Name two types of saw that could be used to remove the waste material. 1 … 2 … [2] (c) The Ø10 holes will be drilled before the acrylic is bent to the shape of the base. Use sketches and notes to show two precautions, other than Personal Protective Equipment (PPE), that need to be taken when using a drilling machine to drill the holes in the acrylic sheet. [3] (d) Fig. 12.3 shows an item of equipment that could be used to soften the acrylic so that it could be bent to the shape of the base. Fig. 12.3 (i) Name the item of equipment shown in Fig. 12.3. … [1] (ii) Use sketches and notes to show how the acrylic could be bent to the shape of the base. [3] (e) Fig. 12.4 shows a side view of the stand and the angles to which the support must be adjusted. 10° 20° support height 150 30° pivot base length 160 Fig. 12.4 Use sketches and notes to show how the support could be locked at four different positions, starting with the upright position, then at 10°, 20° and 30°. Give details of all materials and constructions used. [5] (f) The adjustable stand could also be made from 1.0 mm thick stainless steel sheet. (i) State two properties of stainless steel that make it suitable for the adjustable stand. 1 … 2 … [2] (ii) Use sketches and notes to show how the development (net) shown in Fig. 12.2 could be bent to form the base of the adjustable stand when made from stainless steel. Name all the tools and equipment used. [4] (g) The adjustable stand could be designed using CAD. State two benefits, other than speed and accuracy, of using CAD to design the adjustable stand. 1 … 2 … [2]

25 marks

Mark scheme: 12(a) Acrylic can be reheated and shaped whereas thermosets can only be heated and shaped once. 1 12(b)(i) Scriber / chinagraph pencil / marker pen [2  1] 2 12(b)(ii) Tenon saw / coping saw / Hegner saw or equivalent / band saw / hacksaw [2  1] 2 Question Answer Marks Guidance 12(c) Any 2 precautions such as: acrylic sheet must be clamped securely / high drill speed / sacrificial board under acrylic sheet / care taken with pressure applied [2  1] Technical accuracy showing acrylic on table of drilling machine [1] 3 Accept any valid precaution Do not accept PPE/safety glasses 12(d)(i) Strip heater 1 Accept line bender 12(d)(ii) Acrylic positioned on line bender or strip heater [1] Use of a former or equivalent to produce correct bend [1] Method of retention while acrylic cools [1] 3 12(e) Support locked at 4 positions [1] Method of locking [0 – 2] Named materials [1] Technical accuracy: e.g. constructions and fittings used [1] 5 Reward designs that focus on locking at the pivot point with discreet 10°, 20° and 30° positions or use a strut fitted against the back of the support to provide the tilted angles 12(f)(i) Any 2 benefits: stainless steel is attractive / extremely hardwearing / does not corrode / self-finished [2  1] 2 12(f)(ii) Stainless steel sheet is clamped appropriately [1] Use of a former or equivalent [1] Method of force: hammer and scrap wood or hide mallet [1] Correctly named tools and equipment [1] 4 Accept use of sheet metal folder with details described fully 12(g) Any 2 benefits of CAD such as: on-screen editing / on-screen modelling of ‘tilt’ positions / CAD drawing linked to CNC machine to transfer data / faster [2  1] 2 Accept any valid benefits

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Q328 · A desk organiser made from hardwood 0445/31 May/June 2023

13 Fig. 13.1 shows a desk organiser made from hardwood. partitions 10 mm thick ends 12 mm thick A 140 B 280 space at B 122 wide × 30 high × 100 deep 140 Fig. 13.1 (a) State two items of research the designer would have considered when designing the desk organiser. 1 … 2 … [2] (b) A questionnaire was given to 100 people asking them to list three main features of a well-designed desk organiser. Fig. 13.2 shows the results of the questionnaire in the form of a pie chart. From the pie chart shown in Fig. 13.2 state the three most important features. attractive finish 13% 24% made from quality materials easy to move around 6% strong constructions 14% 11% different storage compartments unique design 8% 4% other specification points easy access to equipment 20% Fig. 13.2 1 … 2 … 3 … [3] (c) Fig. 13.3 shows the ends and the centre piece of the desk organiser marked out on a length of hardwood ready to be cut and shaped. 140 5 mm waste 140 waste Fig. 13.3 (i) State one benefit of using a template to mark out the shapes of the ends and centre piece. … [1] (ii) State one reason why 5 mm waste has been marked out between each shape. … [1] (iii) Name a machine saw that could be used to cut each piece to the required shape. … [1] (d) Fig. 13.4 shows one of the end pieces after it has been sawn to the required shape. curved shape end grain Fig. 13.4 (i) Describe how the sawn edge of the curved shape could be made smooth. … … [2] (ii) When planing end grain there is a danger that the wood could split. Use sketches and notes to show how to prevent the wood from splitting when it is planed. [3] (e) Fig. 13.5 shows the partition and one end piece that will be joined at A shown in Fig. 13.1. end partition Fig. 13.5 Use sketches and notes to show a suitable method of joining the partition to the end piece. [3]

16 marks

Mark scheme: 13(a) Materials and equipment to store / their sizes / quantity of materials/equipment / location/environment [2  1] 2 Accept any valid items of research Do not accept one-word answers 13(b) 1 Made from quality materials [1] 2 Easy access to equipment [1] 3 Strong constructions [1] 3 13(c)(i) Benefit of template: speed / repetitive accuracy 1 13(c)(ii) 5mm waste marked out to allow for the thickness of the saw kerf 1 Do not accept ‘room for error’ 13(c)(iii) Band saw / jig saw / Hegner saw or equivalent 1 13(d)(i) Use of sanding disk / files / glasspaper / spokeshave [2  1] 2 13(d)(ii) Wood held securely in a vice or clamped securely [1] Planed to middle, stop and plane from opposite end or plane straight across with scrap wood at end of board [1] Technical accuracy of tools and equipment named [1] 3 Accept shooting board Look carefully at position of scrap wood 13(e) Suitable construction: mortise and tenon [variants] / dowel Award 0–3 marks dependent on technical accuracy: proportion, orientation Tenon with shoulders [max 3] Bareface (only mortise drawn) [max 2] 3 13(f) Drawer fits space B 122  30  100 [1] Constructions: corner joints named or shown [1] Constructions: base fitted to drawer [1] Appropriate hand hold clearly shown or identified [1] 4 13(g)(i) White polish / French polish / button polish / cellulose / Teak oil / Tung oil / wax / lacquer 1 Do not accept ‘oil’ 13(g)(ii) Provides even pressure applied to surface / faster than using individual fingers/hand / allows a flat/even finish 1 Question Answer Marks Guidance 13(g)(iii) To avoid scratching the surface 1 Do not accept ‘damages the wood’, ‘splinters’, ’chips’ 13(h) Check against original specification / give the product to a third party to ‘test’ it out / place items for storage in desk tidy to check fit and access 2 Accept any valid method

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Q329 · A shaped piece of hardwood 0445/32 May/June 2023

2 Fig. 2.1 shows a shaped piece of hardwood. A B Fig. 2.1 State from the list below the correct name for the types of grain labelled at A and B in Fig. 2.1. cross short patterned straight end Grain A … Grain B … [2]

2 marks

Mark scheme: 2 A end [1] B short [1]

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Q330 · One part, the yoke, of a two-piece former that is used to produce the press formed… 0445/32 May/June 2023

4 Fig. 4.1 shows one part, the yoke, of a two-piece former that is used to produce the press formed moulding. yoke press formed moulding plug Fig. 4.1 Complete Fig. 4.1 by drawing the plug over which the yoke will fit to produce the press formed moulding. [3]

3 marks

Mark scheme: 4 Shape of plug must fit inside yoke [1] Draft angle on plug [1] Dowel pegs to locate in yoke [1] 3 Award 1st mark without draft angle shown Accept drawing added to press form moulding

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Q331 · Circle from the list below one metal that is a pure metal 0445/32 May/June 2023

5 Circle from the list below one metal that is a pure metal. mild steel brass stainless steel aluminium [1]

1 marks

Mark scheme: 5 Aluminium [1] 1

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Q332 · The back of a shelf unit and details of two keyhole plates that will be used when fitting… 0445/32 May/June 2023

6 Fig. 6.1 shows the back of a shelf unit and details of two keyhole plates that will be used when fitting the shelf unit to a wall. keyhole plate back of shelf unit brass 25 × 25 × 1 mm thick Fig. 6.1 Fig. 6.2 shows a piece of 1 mm thick brass, marked out, ready to produce the keyhole shape. Use sketches and notes to show how the keyhole shape could be produced from the 1 mm thick brass. Name all the tools and equipment used. Fig. 6.2 [3]

3 marks

Mark scheme: 6 Drill holes at top and bottom centres [1] Insert blade of saw and remove waste [1] Use of files to finish keyhole shape [1] Accept use of chain drilling + file for 3 marks 3 Do not accept use of laser cutter, hole saw, jig saw, hacksaw Accept following: piercing, coping, Hegner and scroll saws with metal cutting blade, abra file saw

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Q333 · A table number stand used in a cafe and a development (net) of the stand 0445/32 May/June 2023

7 Fig. 7.1 shows a table number stand used in a cafe and a development (net) of the stand. 7 7 7 Fig. 7.1 (a) Name a suitable non-ferrous metal for the number stand. … [1] (b) A batch of 20 number stands will be made in a school workshop. Describe how 20 identical number stands could be marked out onto a sheet of metal. … … [2]

3 marks

Mark scheme: 7(a) Aluminium / brass / copper / gilding metal / duralumin [1] 1 7(b) Use of a template / tessellation / stencil / marking jig [1] Suitable marking out tool: scriber / chinagraph pencil / marker pen / felt tip pen [1] 2 Do not accept use of laser cutter

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Q334 · A through housing joint marked out on a length of hardwood 0445/32 May/June 2023

8 Fig. 8.1 shows a through housing joint marked out on a length of hardwood. 30 waste 20 80 Fig. 8.1 Complete Table 8.1 by describing the process each tool is used for when marking out and/or cutting out the through housing joint. Table 8.1 Tool Description of process Cutting gauge Tenon saw Bevel-edge chisel [3]

3 marks

Mark scheme: 8 Cutting gauge to mark out the lines of the housing across the grain [1] Tenon saw to saw down the lines of the housing, cutting out joint [1] Bevel-edge chisel to remove the waste wood [1] 3 Accept use of cutting gauge to mark out area to be cut out, provides a guide for tenon saw Do not accept to ‘smooth wood’

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Q335 · Circle from the list below one material that is biodegradable 0445/32 May/June 2023

9 Circle from the list below one material that is biodegradable. polystyrene hardboard tin nylon copper [1]

1 marks

Mark scheme: 9 Hardboard [1] 1

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Q336 · An incomplete design for a guitar stand 0445/32 May/June 2023

11 Fig. 11.1 shows an incomplete design for a guitar stand. protective padding A leg support rubber cap foot Fig. 11.1 Table 11.1 shows a parts list for the guitar stand. Table 11.1 Part No. reqd. Length × Width × Thickness Material leg 2 400 × 30 × 15 beech foot 2 280 × Ø30 beech support 2 250 × Ø6 aluminium (a) The designer of the guitar stand would consider a number of specification points when designing the guitar stand. Add two further specification points to the list below. The guitar stand must: • be adjustable to support different types of guitar • … • … [2] (b) Fig. 11.2 shows the end of a leg and part of the foot that will be joined together. leg 30 × 15 foot Ø30 Fig. 11.2 Sketch and name a suitable method of joining the leg to the foot permanently. [4] (c) The legs will be hinged at position A shown in Fig. 11.1. Sketch and name a suitable hinge that could be used at position A shown in Fig. 11.1. [4] (d) The feet will be produced using a woodturning lathe. Fig. 11.3 shows a length of beech ready to be turned on a woodturning lathe. beech A B tool rest Fig. 11.3 (i) State one property of beech that makes it suitable for woodturning. … [1] (ii) A saw cut has been made in the end of the length of beech at A in Fig. 11.3. State the purpose of the saw cut. … [1] (iii) Candle wax is often applied to the end of the length of beech at B in Fig. 11.3. State the purpose of the candle wax. … [1] (iv) State one reason why it is important to set the tool rest at the correct height before starting to turn the length of beech. … [1] (e) The supports of the guitar stand are made of Ø6 aluminium rod covered with a protective padding. Fig. 11.4 shows details of one support with the protective padding removed. R12 60 R6 40 25 90 30 Fig. 11.4 Use sketches and notes to show how a 250 mm length of aluminium rod could be formed to the shape of the support. Name all the tools and equipment used to produce the support. [4] (f) Fig. 11.5 shows a front view of the guitar stand. The guitar stand will be made adjustable to support different types and sizes of guitar. The hinged legs need to be opened or closed and locked apart at different distances. position for hinge legs 30 × 15 legs open and close Fig. 11.5 Use sketches and notes to show how the hinged legs could be locked apart at different distances. Give details of additional materials and constructions used. [5] (g) The guitar stand is made from two main materials: beech and aluminium. Explain why beech is a more sustainable material than aluminium. … … … [2]

25 marks

Mark scheme: 11(a) Any two from the list below: Protect the guitar from damage/scratches / stable in use / easy to place the guitar on the stand / attractive / hold guitar securely / ease of access / easily transported / easily stored / folds up small / size of guitar [2 x 1] 2 Accept any valid specification points Do not accept waterproof, lightweight Durable must be qualified 11(b) Suitable joint: dowel / mortise and tenon [variants] / biscuit [1] Through M&T with shoulder [3] Through M&T without shoulder [2] Mortise drawn only [1] Cut-out [flat recess] [1] Screw from underneath [with or without glue] [1] 4 Dependent on size, proportion and orientation Do not accept use of nails 11(c) Butt hinge named [1] 2 leaves [1] 2 or 3 holes [1] Size/proportion to legs [1] OR Back flap hinge named [1] 2 leaves [1] 3 holes [1] Size/proportion to legs [1] 4 Reference to, or shown in sketch to match width of leg [30mm] 11(d)(i) Close-grained / not liable to splitting/splintering/cracking [1] 1 Do not accept hard or durable 11(d)(ii) Saw cut to locate the end of the fork centre / support/hold wood being turned [1] 1 11(d)(iii) To provide lubrication for the dead centre in tailstock [1] 1 Accept smoother rotation 11(d)(iv) Correct height essential for lathe tool to cut safely and effectively / chisel does not get caught / prevents damage [1] 1 Question Answer Marks Guidance 11(e) Use of heat to make rod malleable [1] Use of at least one former [1] One end of rod secured to allow bending around formers [1] Method of force: hammer or hide mallet [1] 4 11(f) Some sort of ‘connecting strip’ or base between two legs [0 – 2] Method of locking in several dedicated or any positions [1] Named materials and constructions [0 – 2] 5 Do not accept 3D printer 11(g) Beech is more sustainable because it can be replaced by tree planting [1] Aluminium [bauxite] is a finite resource [1] 2

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Q337 · Views of an incomplete design for a coin box used by children 0445/32 May/June 2023

12 Fig. 12.1 shows views of an incomplete design for a coin box used by children. The coin box is made mainly from MDF. Coins are placed in the Ø30 holes, the handle is turned, the top disk rotates and coins fall into the box. slot 140 × 15 Ø30 holes 150 disk Ø120 170 100 disk Ø120 back of coin box with one side, front view of coin box back and part of the top removed Fig. 12.1 (a) Table 12.1 shows a parts list for the coin box. Complete Table 12.1 by providing the missing dimensions. Table 12.1 Part No. required Length × Width × Thickness Material front 1 MDF 170 × × 10 side 2 MDF × 10 base 1 170 × 100 × 10 MDF top 1 170 × 100 × 10 MDF [3] (b) Fig. 12.2 shows the top of the coin box marked out and cut to length. A small amount of waste remains and must be removed to make the ends flat and square. waste top 170 100 Fig. 12.2 (i) Use sketches and notes to show how the waste could be removed using a smoothing plane. Show clearly how the MDF could be held securely while it is planed. [3] (ii) Use sketches and notes to show how the ends could be checked for squareness after they have been planed. State the name of the tool used. [3] (c) Fig. 12.3 shows the slot in the front of the coin box. slot 140 × 15 Fig. 12.3 State the name of a machine that could be used to cut out the slot in the front of the coin box. … [1] (d) Fig. 12.4 shows part of the front, top and side of the coin box. All the parts of the coin box will be glued and nailed to produce the finished box. top 10 mm thick front side 170 Fig. 12.4 (i) State a suitable type of nail that could be used to join the top of the coin box to the front. … [1] (ii) State an appropriate length of nail that could be used to join the top of the coin box to the front. … [1] (iii) Draw on Fig. 12.4 to show the number of nails that could be used to join the top of the coin box to the front and the distance between each of the nails used. [2] (e) Fig. 12.5 shows two sheets of MDF from which the disks will be produced. The two sheets of MDF will be glued to each side of a sheet of drawing paper. MDF 3 mm thick Ø120 glue drawing paper glue MDF 10 mm thick Fig. 12.5 (i) State the purpose of the drawing paper that will be glued to each disk. … [1] (ii) Use sketches and notes to show how the disks could be cut out and shaped from the sheets of MDF. Name all the tools and equipment used. [3] (f) Fig. 12.6 shows a drill bit that could be used to drill the Ø30 holes in the 3 mm thick disk. Fig. 12.6 (i) Name the type of drill bit shown in Fig. 12.6. … [1] (ii) State one safety check, other than Personal Protective Equipment (PPE), that must be carried out before switching on the drilling machine. … [1] (g) Children need to access the coins that have fallen into the box. Fig. 12.7 shows details of the coin box with the back removed. Fig. 12.7 Use sketches and notes to show how a back could be made to fit the coin box but be removed easily and quickly. Show details of all materials and constructions used. [5]

25 marks

Mark scheme: 12(a) Front 130 wide [1] Side 130 long [1]  90 wide [1] 12(b)(i) MDF held securely in a vice / clamped to bench or table [1] Sketch showing plane positioned correctly [1] Method: Plane from end to middle-stop-plane to middle from other end [1] OR Clamp 10 mm scrap wood at end of MDF and plane across end [1] 3 12(b)(ii) Sketch showing tool [1] Correct position of tool [1] Try square, engineers square or combination square named [1] 3 12(c) Mortising machine / power router / table router [1] 1 Do not accept laser cutter 12(d)(i) Panel pins [1] 1 Do not accept any other answer 12(d)(ii) 20 mm – 25 mm / ¾” – 1” [1] 1 Accept any size between Question Answer Marks Guidance 12(d)(iii) Minimum 3 panel pins – maximum 6 [1] Evenly spaced [1] 2 12(e)(i) Drawing paper allows the MDF disks to be separated after they have been made [1] 1 12(e)(ii) Saw off waste leaving a small amount of MDF to remove up to the line [1] Use of sanding disk to make round [1] Correctly named tools and equipment [1] 3 Accepted: coping, jig, Hegner, scroll, band saws Use of hole saw must include relevant details including material clamped and diameter to access 3 marks 12(f)(i) Saw tooth bit/ Forstner bit [1] 1 12(f)(ii) Bit tightened securely / chuck key removed / work piece securely clamped / sacrificial board under work piece / guard in position / no loose clothing / hair tied back [1] 1 12(g) Some sort of back fits against or inside coin box [1] Details showing method of fitting the back [0-2] Method allows for quick and easy access [1] Technical accuracy [1] 5 Methods include use of hinges and brass ‘turns’ to keep in place or back is inserted with strips screwed to edge of box to retain back

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Q338 · A bird feeder made of 5 mm thick clear acrylic 0445/32 May/June 2023

13 Fig. 13.1 shows a bird feeder made of 5 mm thick clear acrylic. The bird feeder has an outer case made from one length of acrylic folded and joined at A. The bird feeder has an identical front and back, each joined to the edges of the outer case. outer case Ø5 perch B A 140 80 Fig. 13.1 (a) Give two benefits of using acrylic for the bird feeder. 1 … 2 … [2] (b) Fig. 13.2 shows the development (net) of the outer case marked out, ready to be bent to shape. 70 140 140 70 80 bend lines Fig. 13.2 (i) Name two tools or items of equipment that could be used to mark the bend lines on the surface of the acrylic sheet. 1 … 2 … [2] (ii) Use sketches and notes to show a bending jig or former that could be used when bending the acrylic to the shape of the outer case. [2] (iii) Describe in detail how the development (net) of the outer case could be bent to shape. … … … … [3] (c) Fig. 13.3 shows the front of the bird feeder with the Ø5 hole and shape B marked out. waste shape B R 25 15 30 Ø5 Fig. 13.3 (i) Use sketches and notes to show how the front part of the bird feeder could be held securely to prevent damage to the acrylic sheet when the Ø5 hole is drilled. [3] (ii) Name a suitable tool that could be used to mark out the arc section of shape B. … [1] (iii) Use sketches and notes to show how shape B could be cut out and the edges made smooth. Name all the tools and equipment used. [4] (d) (i) The front and back of the bird feeder will be joined to the outer case by means of acrylic cement. State two reasons why acrylic cement could be considered a potentially dangerous substance. 1 … 2 … [2]

19 marks

Mark scheme: 13(a) Any two benefits from the list below: Easy to shape / resistant to corrosion / easy to clean / low maintenance / transparent / water or weather resistant / self-finishing / variety of colours [2 x 1] 2 Accept any valid benefits Do not accept lightweight Durability and strong must be qualified 13(b)(i) Any two of: Scriber / chinagraph pencil / marker pen / felt tip pen [2 x 1] 2 Do not accept sharpie 13(b)(ii) Bending jig or former must show 60º angle [1] Additional notes [1] 2 Question Answer Marks Guidance 13(b)(iii) Acrylic heated: line bender, strip heater, hot air gun [1] Use of jig or former [1] 3rd mark accept any one from: Method of retention while acrylic cools / repeat process for other bends / leave to cool [1] 3 Do not accept oven 13(c)(i) Acrylic clamped securely [1] Sacrificial board under acrylic sheet [1] Scrap material to protect acrylic from pressure of cramp or retain protective sheet [1] 3 13(c)(ii) Dividers [1] 1 13(c)(iii) Drill small hole in corner of shape B [1] Undo blade of coping saw or scroll saw and insert to cut out shape [1] File to line or use of wet and dry paper [1] Minimum 2 correctly named tools [1] 4 Do not accept bobbin sander, laser cutter Do reward use of appropriate saw even if hole is not drilled 13(d)(i) Any two reasons for danger from: toxic fumes / fire risk / harmful to skin [2 x 1] 2 Do not accept burns skin 13(d)(ii) Use of cramps or weights [1] Use of scrap material either side of the feeder to distribute pressure evenly and to protect surfaces of feeder [1] Additional technical notes [1] 3 Award 1 mark for use of adhesive tape, rubber bands 13(e) Practical modification to feeder [1] Method of suspension: use of string / rope / wire / metal rod [1] Clarity of sketches and additional notes [1] 3

This question in 0445/32 May/June 2023

Q339 · A chair that can be used when camping 0445/33 May/June 2023

1 Fig. 1.1 shows a chair that can be used when camping. Fig. 1.1 State three specification points a designer would need to consider when designing a chair that will be used when camping. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 1 Any 3 specification points such as: Lightweight / corrosion resistant / easily stored/packed away / strong constructions / stable in use / comfortable / portable / safe to use / compact / include a cup holder / waterproof material / easy to clean [3  1] Do not accept ‘durable’ or ‘aesthetics’ without qualification

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Q340 · Two parts, A and B, of an incomplete tee bridle joint 0445/33 May/June 2023

2 Fig. 2.1 shows two parts, A and B, of an incomplete tee bridle joint. A B Fig. 2.1 Draw on part B in Fig. 2.1 to show the other part of the tee bridle joint. [3]

3 marks

Mark scheme: 2 Award 0–3 dependent on accuracy 3 Correct size/proportion to fit existing joint Shaded ‘waste’ area [max 1 mark]

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Q341 · A piece of sheet metal that will be folded to shape using a rawhide mallet 0445/33 May/June 2023

3 Fig. 3.1 shows a piece of sheet metal that will be folded to shape using a rawhide mallet. rawhide mallet sheet metal A engineer’s vice Fig. 3.1 (a) Name the item of equipment labelled A in Fig. 3.1. … [1] (b) Give one reason why a rawhide mallet is used to fold the sheet metal rather than a hammer. … [1]

2 marks

Mark scheme: 3(a) Folding bars / bending irons 1 3(b) To avoid damaging the surface of the mild steel sheet, e.g. dents / Greater surface area of mallet face, evenly distributed force 1

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Q342 · A watering can made of plastic 0445/33 May/June 2023

4 Fig. 4.1 shows a watering can made of plastic. ribs Fig. 4.1 (a) Name a suitable plastic for the watering can. … [1] (b) State the manufacturing process used to produce the plastic watering can. … [1] (c) State the purpose of the ribs shown in Fig 4.1. … [1]

3 marks

Mark scheme: 4(a) Polypropylene / PP / PVC / polyethylene / PET / HDPE / ABS / HIPS 1 4(b) Blow moulding / rotational moulding 1 4(c) Ribs add rigidity/strength to the structure of the watering can 1

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Q343 · Two different types of leg construction, A and B, for a small table made of hardwood 0445/33 May/June 2023

5 Fig. 5.1 shows two different types of leg construction, A and B, for a small table made of hardwood. legs 40 × 40 400 A B Fig. 5.1 (a) State the method of construction for leg type B. … [1] (b) Give two advantages to a manufacturer of producing leg type B rather than leg type A. 1 … 2 … [2]

3 marks

Mark scheme: 5(a) Lamination / steam bending 1 5(b) 2 advantages: quicker process / easier to make / greater production / more profit / less waste [2  1] 2 Must relate to manufacturer. Do not accept ‘stronger construction’.

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Question 344 0445/33 May/June 2023

6 Fig. 6.1 shows a mountain bike. Fig. 6.1 Identify three ways the designer of the mountain bike has considered anthropometric data. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 6 3 ways considered anthropometric data: accept any reference to body measurements and parts of the bike [3  1] 3 Example: design of frame dependent on arm reach length / leg length. Brake levers relates to hand dimensions Do not accept references to ‘weight’ or ‘wheel/tyre sizes’

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Q345 · Views of a coat rack with adjustable sliders 0445/33 May/June 2023

7 Fig. 7.1 shows views of a coat rack with adjustable sliders. The coat rack and the sliders are made of plastic and are produced by different methods of manufacture. slider 60 end view coat rack 500 mm long Fig. 7.1 (a) State a suitable method of manufacture for the coat rack. … [1] (b) State a suitable method of manufacture for the sliders. … [1] (c) Give one advantage of making the coat rack and sliders from plastic rather than wood. … [1]

3 marks

Mark scheme: 7(a) Extrusion 1 7(b) Injection moulding 1 7(c) Plastic requires no applied finish or fabrication / low maintenance / easier to make in large quantities / smoother to slide / self-finishing / variety of colours / more durable 1 Candidates may answer from the standpoint of the manufacturer

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Q346 · Select from the list below the material that corresponds to the description 0445/33 May/June 2023

9 Select from the list below the material that corresponds to the description. MDF parana pine beech blockboard ash Hardwood, close-grained, withstands wear and shocks, used to make toys and flooring. … [1]

1 marks

Mark scheme: 9 Beech 1

This question in 0445/33 May/June 2023

Q347 · Views of a photograph frame held in a stand 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

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Q348 · An incomplete design for a small table 0445/33 May/June 2023

12 Fig. 12.1 shows an incomplete design for a small table. The tabletop is made of hardwood. The frames are made from mild steel rectangular tube. tabletop 800 × 410 × 20 400 680 450 frame 50 × 20 view with tabletop removed Fig. 12.1 (a) The frame of the table is made from 50 × 20 mild steel rectangular tube shown in Fig. 12.2. Fig. 12.2 Fig. 12.3 shows two other standard metal forms, A and B. A B Fig. 12.3 State the correct term for each standard form A and B. A … B … [2] (b) The parts of the frame shown in Fig. 12.1 will be cut from the length of 50 × 20 rectangular tube shown in Fig.12.4. Each part has been marked out ready to be cut to length. lines marked out Fig. 12.4 Complete Table 12.1 by stating the name of the tools used for marking out the lengths of the mild steel rectangular tube. Table 12.1 Tool Name of tool [2] (c) The parts of the frame will be joined by brazing. Fig. 12.5 shows parts of the frame ready to be brazed. clamped Fig. 12.5 (i) State the type of cramp that could be used to clamp the frame together. … [1] (ii) Name two materials or items of equipment that could be used to prepare the ends of the mild steel rectangular tube to ensure the frame would be brazed successfully. 1 … 2 … [2] (iii) Explain why it is important to heat the ends of the mild steel rectangular tube to the correct temperature when brazing. … … … [2] (d) The tabletop is constructed from three hardwood boards. (i) Give one reason why three boards have been joined together rather than using one board 410 mm wide. … [1] (ii) The tabletop will be screwed to the frame. Fig. 12.6 shows one frame with three holes drilled to take three screws. slotted hole Fig. 12.6 Explain why the holes in the frame need to be slotted. … … … [2] (e) Use sketches and notes to show how the design of the table could be modified to include a shelf. The modified design must include the following details: • the length and width of the shelf • the names of additional materials used • all constructional details. [6] (f) Fig. 12.7 shows one end of a frame. The open ends of the mild steel rectangular tube are unattractive. A Fig. 12.7 (i) Use sketches and notes to show how the ends of the rectangular tube could be made to look attractive. State the names of any materials used and important sizes. [3] (ii) The frame of the table could be replaced with hardwood the same size as the 50 × 20 mild steel rectangular tube. Sketch and name a suitable construction that could be used at A shown in Fig. 12.7. [4]

25 marks

Mark scheme: 12(a) A round tube [1] B angle [1] 2 Do not accept any alternative for round tube A Must include the term ‘angle’ for B 12(b) Scriber [1] Try square/engineers square 2 Do not accept ‘square’ 12(c)(i) Sash cramp / ‘F’ cramp 1 12(c)(ii) Emery cloth / files / wet and dry / silicon carbide / steel/wire wool [2  1] 2 Do not accept use of flux 12(c)(iii) Correct temperature to ensure spelter melts [1] And joins the metal [1] 2 12(d)(i) Any 1 point such as: Boards from hardwood trees are not available in 400 mm+ widths / Cheaper than purchasing one wide board / Less liable to warping / more stable 1 12(d)(ii) Hardwoods shrink and expand [1] Slotted hole allows the screw fixed to the table top to ‘move’ [1] 2 12(e) Shelf shown fitted to end frames, suspended under table top [1] Length and width of shelf [2  1] Appropriate additional materials [1] Constructional details [0–2] 6 12(f)(i) Some form of ‘cap’ or ‘block’ insert [1] Specific suitable material [1] Important sizes [1] 3 Question Answer Marks Guidance 12(f)(ii) Suitable construction using 50  20 section hardwood: dowel / mortise and tenon / housing / biscuit named [1] Technical accuracy: correct size/proportion/orientation [0–3] 4 Accept K-D fittings: e.g. bloc fitting, cam lock

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Q349 · A paint palette made of 3 mm thick acrylic 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

Q350 · A length of wood being planed in two directions, A and B 0445/31 Oct/Nov 2023

2 Fig. 2.1 shows a length of wood being planed in two directions, A and B. grain A B Fig. 2.1 (a) State the name of the plane shown in Fig. 2.1. … [1] (b) State which direction of planing, A or B, would produce the smoother surface. … [1]

2 marks

Mark scheme: 2(a) Smoothing 1 2(b) A 1

This question in 0445/31 Oct/Nov 2023

Q351 · Details of a tabletop that will be fastened to the rails of a small table 0445/31 Oct/Nov 2023

3 Fig. 3.1 shows details of a tabletop that will be fastened to the rails of a small table. MDF tabletop 18 thick hardwood rail 40 × 15 Fig. 3.1 Draw on Fig. 3.1 to show how the tabletop could be fastened to the rails. [3]

3 marks

Mark scheme: 3 Method: 3 For ‘screws’: (counterbored, pocket KD fitting, screws / ‘buttons’ / brackets / added blocks / dowels / screws [1] screwed, directly into underside of Technical details [0 – 2] tabletop)

This question in 0445/31 Oct/Nov 2023

Q352 · The centre for a drilled hole marked out on 6 mm thick metal 0445/31 Oct/Nov 2023

6 Fig. 6.1 shows the centre for a drilled hole marked out on 6 mm thick metal. tool A lines showing the centre for a drilled hole Fig. 6.1 (a) State the name of tool A. … [1] (b) State the name of a tool that could be used to mark out the circular shape. … [1]

2 marks

Mark scheme: 6(a) Centre or dot punch 1 6(b) Dividers 1

This question in 0445/31 Oct/Nov 2023

Q353 · Two pieces of 5 mm thick acrylic that will be joined together 0445/31 Oct/Nov 2023

7 Fig. 7.1 shows two pieces of 5 mm thick acrylic that will be joined together. Fig. 7.1 (a) Name a suitable adhesive that could be used to join the acrylic. … [1] (b) Add sketches and notes to Fig. 7.1 to show how excess adhesive could be prevented from spoiling the finished surfaces. [2]

3 marks

Mark scheme: 7(a) Acrylic cement / Tensol cement / MMA [1] 1 Do not accept epoxy resin, contact adhesive 7(b) Sketch showing adhesive ‘tape’, scrap paper, scrap wood [1] 1 2 Accept line drawn showing area to be Applied 5 mm from end of bottom piece [1] 1 glued for 1 mark

This question in 0445/31 Oct/Nov 2023

Q354 · Two pieces of brass that will be soldered on a brazing hearth using a blow torch 0445/31 Oct/Nov 2023

8 Fig. 8.1 shows two pieces of brass that will be soldered on a brazing hearth using a blow torch. firebricks flame brass pieces gas and air control silver solder part of a brazing hearth blow torch Fig. 8.1 (a) Explain the purpose of the firebricks. … … … [2] (b) Indicate clearly on Fig. 8.1 the hottest part of the blow torch flame. [1]

3 marks

Mark scheme: 8(b) 1 Award 1 mark for anywhere in the darkest zone hottest

This question in 0445/31 Oct/Nov 2023

Q355 · A basic design for a wall-mounted shelf made from 10 mm thick MDF 0445/31 Oct/Nov 2023

10 Fig. 10.1 shows a basic design for a wall-mounted shelf made from 10 mm thick MDF. 200 600 150 Fig. 10.1 (a) Use sketches and notes to show one functional improvement to the wall-mounted shelf. [2] (b) Use sketches and notes to show one aesthetic improvement to the wall-mounted shelf. [2]

4 marks

Mark scheme: 10(a) Functional improvement: added bracket or strips to give greater support to the 2 Accept any valid functional shelf, lipping to prevent items falling off [1] improvement Added details [1] 10(b) Aesthetic improvement: slight curve applied to front edge of shelf, rounded 2 Accept any valid aesthetic corners, application of paint, veneer, laminate [1] improvement Accept change of material for shelf for Added details [1] 1 mark

This question in 0445/31 Oct/Nov 2023

Q356 · Views of an incomplete design for a desktop box easel 0445/31 Oct/Nov 2023

11 Fig. 11.1 shows views of an incomplete design for a desktop box easel. The outer frames of the box and lid are made of 15 mm thick hardwood. The top of the lid and the base of the box are made from 6 mm thick veneered plywood. adjustable arm lid paper or spaces for canvas A artists materials box 60 clamp 400 300 Fig. 11.1 (a) The sides of the box will be joined at each corner by means of finger (comb) joints. Complete Fig. 11.2 to show an assembled finger (comb) joint. 15 60 Fig. 11.2 [3] (b) Fig. 11.3 shows part of the length of hardwood from which the clamp will be made. The shape has been marked out and the waste will be removed by planing. waste hardwood 290 × 25 × 25 waste Fig. 11.3 (i) Give one advantage of supporting the length of hardwood against a bench stop rather than holding the length of hardwood in a woodworker’s vice. … [1] (ii) The clamp holds the paper or canvas in place against the lid. Use sketches and notes to show how the clamp could be attached to the lid and allow paper or canvas to be removed and replaced. Give details of any fittings and fixings used. [4] (c) Partitions have been added inside the box to provide compartments that could be used to store equipment and materials. Fig. 11.4 shows part of the sides of the compartment shown at position A in Fig. 11.1. Fig. 11.4 Complete Fig. 11.4 to show a suitable construction that could be used to join the sides at A. [3] (d) Fig. 11.5 shows the adjustable arm with the slot marked out. slot 10 mm wide adjustable arm 320 × 40 × 20 Fig. 11.5 (i) A power router could be used to cut out the slot. State two settings that must be made to the power router before using it to cut out the slot. 1 … 2 … [2] (ii) A power router may not be available in the school workshop to cut out the slot. An alternative method will need to be used. Complete Table 11.1 by adding two further stages and naming the tools and/or equipment required to cut out the slot. Table 11.1 Stages Tools and/or equipment Drill hole/holes in marked out shape Drilling machine, twist drill [4] (e) Circle from the list below the most suitable hinge that could be used to join the lid to the box. back flap tee piano adjustable concealed [1] (f) The lid must be capable of being locked at different angles. (i) Explain why an angled lid is an example of ergonomic design in the box easel. … … … [2] (ii) Use sketches and notes to show how the lid could be locked securely at a required angle. Give details of materials, fittings and fixings used. [5]

25 marks

Mark scheme: 11(a) Number of ‘fingers’ 5 or 7 [1] 3 Equal spacing [1] Overall accuracy [1] 11(b)(i) Bench stop allows the wood to be planed without interference with the vice. 1 Do not accept ‘stable’ Wood can be planed on a flat surface 11(b)(ii) Method: screws or nuts and bolts to provide method of clamping [0 – 2] 4 Award 1 mark for use of dowels, Details of fittings and fixings to the clamping strip [0 – 2] mortise and tenon joint, magnets. 11(c) Suitable constructions: dowel, mortise and tenon, domino, housing [0 – 2] 3 Use of adhesive only - 0 marks Technical accuracy of details [0 – 2] Dowels: min. 2 – max. 3. Max. Ø6 11(d)(i) 2 settings: 2 • correct size router cutter • locked in position • fence set to width • depth of cut • speed of router cutter [2  1] 11(d)(ii) Stage 2: insert saw blade and cut out shape leaving small amount of waste [1] 4 Accept ‘chain drilling’ and use of files Hegner saw or equivalent, jig saw, coping saw, mortising machine [1] and / or chisels Stage 3: remove waste and clean surfaces up to the line [1] Use of files and glasspaper [1] 11(e) Piano hinge 1 11(f)(i) Angled lid ergonomic feature: consideration of different users [1] 2 To angle the lid at a position that is best / most comfortable for them [1] 11(f)(ii) Some sort of practical ‘connection’ between lid and box: e.g. use of wood / metal 5 strip with cut out or pins to provide fixed position [0 – 2] Details of materials, fittings and fixings used [0 – 3]

This question in 0445/31 Oct/Nov 2023

Q357 · An incomplete design for a tape dispenser made mainly from 1.6 mm thick mild steel sheet 0445/31 Oct/Nov 2023

12 Fig. 12.1 shows an incomplete design for a tape dispenser made mainly from 1.6 mm thick mild steel sheet. The tape dispenser could be made in a school workshop. roll of tape disk upright support cutting plate base 15 200 100 Fig. 12.1 (a) Mild steel is a ferrous metal. (i) State what is meant by the term ‘ferrous metal’. … [1] (ii) Name one other ferrous metal. … [1] (b) Fig. 12.2 shows a development (net) of the base of the tape dispenser marked out on 1.6 mm thick mild steel sheet. 100 waste 200 15 Fig. 12.2 (i) Name two tools or items of equipment that could be used to cut out the development (net). 1 … 2 … [2] (ii) Use sketches and notes to show how a wooden former could be used when bending the development (net) to produce the base. Name all the tools and equipment used. [4] (c) Fig. 12.3 shows the disk onto which the roll of tape fits. The disk is made of hardwood and will be turned on a woodturning lathe. Ø 75 × 50 Fig. 12.3 (i) Circle from the list below the best type of grain structure found in hardwoods when used for woodturning. open grain interlocking grain close grain wide grain [1] (ii) Fig. 12.4 shows a length of hardwood set up on a woodturning lathe. hardwood Fig. 12.4 Give one safety check that must be carried out before switching on the lathe. … [1] (iii) Name one tool that could be used when shaping the disk on the lathe. … [1] (iv) Name one tool that could be used to check the diameter of the disk after it has been turned. … [1] (d) Fig. 12.5 shows details of the hardwood disk fastened between the upright supports. A screw thread is cut on the inside of the Ø10 mild steel tube so that screws can be inserted on both sides of the disk. hardwood disk hardwood disk screw upright support Ø 10 mild steel tube screw base upright support end view Fig. 12.5 (i) Name a tool that would be used to cut the screw thread on the inside of the mild steel tube. … [1] (ii) Name an adhesive that could be used to glue the mild steel tube inside the hardwood disk. (e) Fig. 12.6 shows the tape being pulled from the roll. In design A the tape is pulled at an angle over the cutting plate. It would be easier to cut the tape from the roll if it could be pulled flat over the cutting plate as shown in design B. cutting plate A B Fig. 12.6 Use sketches and notes to show a modification to the tape dispenser to enable the tape to be cut as shown in design B. State the name of any additional materials used and all constructional details. [5] (f) The mild steel parts of the tape dispenser will be given a dip coated finish. Complete Table 12.1 by adding three further stages in the dip coating process. Table 12.1 Stage Process 1 Remove grease and dirt from surfaces of mild steel parts 2 3 4 [3] (g) Use sketches and notes to show a modification to the tape dispenser so that it could be fixed securely to a workbench. State the names of any fittings and fixings used. [3]

25 marks

Mark scheme: 12(a)(i) A metal that contains iron 1 Do not accept ‘magnetic’ 12(a)(ii) Wide variety of ferrous metal available 1 12(b)(i) Hacksaw, junior hacksaw, tinsnips, bench shears / guillotine [2  1] 2 Accept ‘snips’, Hegner / scroll saws with metal cutting blade Do not accept ‘curved snips’ 12(b)(ii) Sketch showing a wooden former [1] 4 Sketch showing metal development clamped securely to former [1] Method of force: hammer or mallet [1] Correctly named tools and equipment [1] 12(c)(i) Close grain 1 12(c)(ii) Checks: hardwood securely held between centres, rotate hardwood to ensure 1 clear from Tee rest, Tee rest at correct height / position, check to see if hardwood Is centred 12(c)(iii) Scraper, chisel, gouge 1 12(c)(iv) Outside / external calipers, vernier calipers, micrometer 1 Do not accept ‘calipers’ 12(d)(i) Tap 1 12(d)(ii) Epoxy resin, Araldite 1 Check alternative trade names: must include the name ‘epoxy resin’. 12(e) Method of cutting tape efficiently: practical idea 5 If ‘bracket’ is not practical, award max. Some form of horizontal bracket in correct position [0 – 2] 2 marks for ‘joining’, ‘additional Joined to upright support or to base [1] materials’ and ‘constructional details’. Suitable additional materials named [1] Constructional details [1] 12(f) 3 processes include: 3 Must be in correct sequence • Plastic in fluidised state • Heat metal to 180 °C in an oven • Plunge metal into tank of fluidised polythene • Reheat metal in an oven then leave to cool [3  1] 12(g) Modification to base of dispenser [1] 3 Screw holes are not modifications. Secured to bench [1] Use of screws or bolts: max 2 marks. Technical details [1] Do not accept change of material; e.g. from mild steel to wood

This question in 0445/31 Oct/Nov 2023

Q358 · Views of a design for a novelty photograph holder made of 4 mm thick acrylic in the shape… 0445/31 Oct/Nov 2023

13 Fig. 13.1 shows views of a design for a novelty photograph holder made of 4 mm thick acrylic in the shape of a t-shirt. The t-shirt has a coat hanger suspended from a metal rail. Two photographs can be ‘sandwiched’ between the two acrylic frames. metal rail acrylic frames coat hanger photographs 150 × 100 overall height of t-shirt 190 overall width of t-shirt 170 Fig. 13.1 (a) Fig. 13.2 shows a paper template glued onto 4 mm thick acrylic sheet. paper template waste cut out shape 140 × 90 Fig. 13.2 (i) Give two advantages of using a paper template rather than drawing the shape directly onto the acrylic sheet. 1 … 2 … [2] (ii) The cut out shape will be produced using hand and machine tools. Complete Table 13.1 by stating the correct names for the tools and/or equipment used to produce the cut out shape. Table 13.1 Stage Process Tools and/or equipment Make a hole in corner of shape to be cut 1 out Cut out shape leaving small amount of 2 waste to be removed later Remove waste up to the line of the final 3 shape Smooth edges to a high quality finish 4 [4] (iii) Two identical acrylic frames are required to make the photograph holder. Describe how two identical acrylic frames could be produced by hand. … … … [2] (b) The acrylic frames could be produced by means of CAD/CAM. Fig. 13.3 shows a screen shot of a CAD drawing of part of one acrylic frame. Fig. 13.3 (i) Explain why the designer has drawn only half of the shape of the acrylic frame. … … … [2]

10 marks

Mark scheme: 13(a)(i) 2 advantages: quicker / repetitive accuracy [2  1] 2 13(a)(ii) Stage 1 hand drill, machine drill, drill bit [1] 4 Do not accept Jigsaw or Laser Cutter. Stage 2 coping saw, Hegner, scroll saw or equivalent, router [1] Stage 3 hand, flat or half round files [1] Do not accept sandpaper. Stage 4 scraper, wet and dry [silicon carbide] paper, polishing mop, polishing compound, buffing machine [1] 13(a)(iii) 2 methods: 2 Award 1 mark for appropriate method Tape 2 pieces of acrylic together and cut and shape as one piece [0 – 2] Award 1 mark for notes relating to the Or actual cutting / shaping. Cut out one frame, use as a template to draw round for the second frame [0 – 2] 13(b)(i) More accurate and quicker to draw half the frame, click ‘select all’ and then click 2 Award 0–2 marks dependent on level ‘mirror image’ to produce the opposite half to complete the frame of CAD understanding demonstrated 13(b)(ii) 3 stages: position acrylic sheet in CNC machine, set machine parameters, press 3 Accept any relevant individual stages START button on machine to produce shape of frame [3  1] within ‘set machine parameters’ 13(c) Practical idea: some form of clip, clamp, connecting pins or pegs [0 – 2] 6 Do not accept use of hinges – 0 Suitable materials [1] marks Constructional details [1] 2 important sizes [2  1] Do not accept repeats of measurements given in Figs. 13(d) Metal rail Ø20 tube extended [1] 6 Accept use of aluminium welding as a Some form of stable base [1] construction. Suitable materials named [1] Do not accept repeats of Metal rail joined to base [1] measurements given in Figs. 2 important sizes [2  1]

This question in 0445/31 Oct/Nov 2023

Question 359 0445/32 Oct/Nov 2023

1 Fig. 1.1 shows a garden wheelbarrow. polypropylene tray mild steel frame Fig. 1.1 Identify three design features that would help the consumer when using the garden wheelbarrow. 1 … 2 … 3 … [3]

3 marks

Mark scheme: Question Answer Marks Guidance 1 3 features: 3 Accept any valid good design features. • lightweight tray Accept written as a Specification. • strong frame Accept one-word answers but not • handle grips ‘mild steel frame’ and ‘polypropylene • large wheel for ease of movement tray’ given in Fig. 1.1. Ignore reference to mild steel frame being lightweight. [3  1]

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Q360 · Exploded views of a finger (comb) joint marked out and cut out 0445/32 Oct/Nov 2023

2 Fig. 2.1 shows exploded views of a finger (comb) joint marked out and cut out. waste marked out cut out Fig. 2.1 Name two different saws that could be used to remove the waste wood. 1 … 2 … [2]

2 marks

Mark scheme: 2 Any two of: 2 Accept only those listed. Tenon / Dovetail tenon / Coping / Band / Hegner / Scroll [2  1]

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Q361 · Two parts of a shelving system 0445/32 Oct/Nov 2023

3 Fig. 3.1 shows two parts of a shelving system. The upright is screwed to a wall and the bracket slots into the upright to support a wooden shelf. upright bracket Fig. 3.1 Use sketches and notes to show a modification to the bracket so that the shelf could be held more securely. [2]

2 marks

Mark scheme: 3 Modification includes ‘lip’ on front or side of bracket [0 – 2] 2 Award 0–2 dependent on quality of design, sketches and notes OR Holes drilled in horizontal face of bracket and screwed [0 – 2]

This question in 0445/32 Oct/Nov 2023

Q362 · A sink unit made from stainless steel 0445/32 Oct/Nov 2023

4 Fig. 4.1 shows a sink unit made from stainless steel. Fig. 4.1 (a) State one property of stainless steel that makes it suitable for the sink unit. … [1] (b) Stainless steel is an alloy. Give the name of one metal that is added to steel to make stainless steel. … [1]

2 marks

Mark scheme: 4(a) Corrosion resistant / resistant to chemicals / waterproof 1 4(b) Chrome, nickel 1

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Q363 · A gate fixed to a wall 0445/32 Oct/Nov 2023

5 Fig. 5.1 shows a gate fixed to a wall. The frame of the gate has started to collapse. A sides of gate 80mm wide × 30mm thick Fig. 5.1 (a) Name a suitable joint that could be used to join the sides of the gate at corner A. … [1] (b) Name a suitable type of hinge that could be used to ‘hang’ the gate. … [1] (c) Add sketches and notes to Fig. 5.1 to show how the frame of the gate could have been prevented from collapsing. [2]

4 marks

Mark scheme: 5(a) Mortise and tenon / dowel / halving 1 Accept ‘tenon joint’ and ‘mortise joint’. 5(b) Tee hinge 1 5(c) Sketch showing a brace fitted diagonally from bottom left to top right corner 2 1 mark 1 mark 2 marks

This question in 0445/32 Oct/Nov 2023

Q364 · Two pieces of 5 mm thick mild steel, A and B 0445/32 Oct/Nov 2023

6 Fig. 6.1 shows two pieces of 5 mm thick mild steel, A and B. file to line 40 file to line 65 A B Fig. 6.1 Name a specific file that could be used to remove the waste metal to the line shown in the mild steel: A … B … [2]

2 marks

Mark scheme: 6 A hand file [1] 2 Accept only those listed. No B half-round file, round or rat tail file [1] variations

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Q365 · An exploded view of a hand-held torch showing the different parts 0445/32 Oct/Nov 2023

7 Fig. 7.1 shows an exploded view of a hand-held torch showing the different parts. glass plastic steel plastic lens reflector spring body plastic rubber rubber end cap washer seal Fig. 7.1 Give two benefits to the environment of designing products that can be disassembled. 1 … 2 … [2]

2 marks

Mark scheme: 7 2 benefits: 2 Accept any valid benefits. • allows for maintenance and repair • allows for reuse of parts and components • helps material recycling • reduces landfill and pollution • less waste [2  1]

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Q366 · Legs of a small table that have been produced by laminating veneers 0445/32 Oct/Nov 2023

8 Fig. 8.1 shows legs of a small table that have been produced by laminating veneers. clamping blocks base board laminates Fig. 8.1 Add sketches and notes to Fig. 8.1 to show the remaining clamping blocks required to ensure that the legs are successfully laminated. [4]

4 marks

Mark scheme: 8 4 Accept ‘curved’ shape at corners. Where one piece is shown across top of laminate award 1 mark only. [4  1]

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Q367 · Select from the list below the metal that corresponds to the description 0445/32 Oct/Nov 2023

9 Select from the list below the metal that corresponds to the description. mild steel brass lead cast iron copper (a) Pure metal, good conductor of heat and electricity, easily soldered, corrosion resistant. … [1] (b) Pure metal, heaviest metal, soft, malleable, excellent chemical resistance. … [1]

2 marks

Mark scheme: 9(a) Copper 1 9(b) Lead 1

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Q368 · An incomplete design for a paint holder that will be used when painting from a ladder 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

Q369 · A Design and Technology student has been asked by a local nursery to design a chair… 0445/32 Oct/Nov 2023

12 A Design and Technology student has been asked by a local nursery to design a chair suitable for children aged 3–4 years old. A prototype of the chair made from 15 mm thick MDF is shown in Fig. 12.1. overall dimensions height 440 width 370 depth 370 Fig. 12.1 (a) Before designing the chair the student was invited to the nursery to discuss the design brief. State three questions that the student could have asked at the nursery before designing the chair. 1 … 2 … 3 … [3] (b) Give two examples where anthropometric data would need to be considered when designing the chair. 1 … 2 … [2] (c) The prototype chair has been made from MDF. The final chair will be made from 15 mm thick beech veneered plywood. Give two advantages of making the prototype chair from MDF rather than 15mm thick beech veneered plywood. 1 … 2 … [2] (d) Fig. 12.2 shows an exploded view, showing five layers (plies) of 15 mm thick plywood. 1 2 3 4 5 Fig. 12.2 (i) Add sketches to Fig. 12.2 to show the grain direction on layers (plies) 2, 3, 4 and 5. [1] (ii) Give one advantage of using plywood rather than solid wood for the chair. … [1] (iii) Give one disadvantage of using plywood rather than solid wood for the chair. … [1] (e) Fig. 12.3 shows one of the dowel pegs used to join parts of the prototype chair. chamfer grooves Fig. 12.3 (i) State the purpose of the grooves. … [1] (ii) State the purpose of the chamfer. … [1] (f) When the prototype chair was evaluated at the nursery, three improvements were recommended. Fig. 12.4 shows the positions for the improvements. 1 A hand hold is required at position A to make it easier to pick up and carry. 2 The dowel joint at B needs to be strengthened. 3 An attachment is required that could fit over either of the sides of the chair at positions C to hold a plastic cup. The final design of chair will be made from 15 mm thick beech veneered plywood. A C C B Fig. 12.4 (i) Use sketches and notes to show how a hand hold could be produced at A. Name all the tools and equipment used. [4] (ii) Use sketches and notes to show how a dowel joint, used to join the seat to the sides of the chair at B, could be strengthened. Name all materials and fittings used. [4] (iii) Use sketches and notes to show a design for an attachment that could fit over either of the sides at positions C to hold the plastic cup shown in Fig. 12.5. The attachment must be removable. Name all materials and fittings used. Ø80 90 Ø50 Fig. 12.5 [5]

25 marks

Mark scheme: 12(a) 3 questions: 3 Accept any valid questions asked at nursery • height • weight of 3–4-year-old children • activities undertaken seated • number of chairs required by nursery • stacking feature • safety in use • materials • budget [3  1] 12(b) Accept answers that ‘link’ body measurements e.g., distance from foot to behind 2 Do not reward references to weight knee to determine seat height or width across hips to determine seat width Award 2 marks for explanation OR Award 1 mark for each separate example stated: e.g., height of chair, depth of chair, height of backrest 12(c) 2 advantages: cheaper than plywood, easier to work 2 Accept any valid benefits 12(d)(i) Grain shown at 90° on each alternate layer 1 12(d)(ii) Advantage over solid wood: wide boards available, cheaper, more stable 1 12(d)(iii) Disadvantage: unattractive / limited methods of construction / difficult to work with 1 12(e)(i) Space for glue / increased gluing area / increased grip / more secure 1 12(e)(ii) Allows for easier entry 1 12(f)(i) Recognised hand hold marked out [1] 4 Details of cutting out shape (for maximum 2 marks a hole must be drilled for a saw blade) [0 – 2] Finishing shape [files / glasspaper] [1] 12(f)(ii) Strengthened using additional wooden strips, KD fittings, brackets, blocks [0 – 2] 4 Correct position [1] Method of fixing: use of pins or screws and adhesive [1] 12(f)(iii) Correct position of attachment that fits over / against side of chair [1] 5 Cup fits into holder [1] Details of constructions [0 – 2] Suitable named materials [0 – 2]

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Q370 · Views of an adjustable table lamp made of acrylic 0445/32 Oct/Nov 2023

13 Fig. 13.1 shows views of an adjustable table lamp made of acrylic. Ø5 lampshade Ø120 × 150 bracket 4 mm thick Ø5 tilts stem Ø20 × 300 base Ø150 × 20 Fig. 13.1 (a) Fig. 13.2 shows the development (net) of the bracket. A centre for Ø20 hole centre for Ø5 hole A 35 bend lines waste Fig. 13.2 (i) State one advantage of using a chinagraph pencil rather than a scriber to mark out the bend lines on the acrylic. … [1] (ii) Name a suitable marking out tool that could be used to mark the arcs shown at A in Fig. 13.2. … [1] (iii) Describe how the waste could be removed to produce an accurate semi-circular shape. … … [2] (b) When drilling holes in acrylic sheet there is a danger that the drill could ‘snag’, causing the acrylic to spin and crack. Use sketches and notes to show how the danger could be prevented. [3] (c) Fig. 13.3 shows the development (net) ready to be bent to the shape of the bracket. The edges of the acrylic will be finished to a high quality before it is bent to shape. Fig. 13.3 Name two tools, items of equipment or materials that could be used to produce a high quality finish on the edges of the acrylic. 1 … 2 … [2] (d) (i) The lampshade is made of Ø120 acrylic tube. Name a manufacturing process used to produce acrylic tube. … [1] (ii) The lampshade could be made by heating a sheet of acrylic and forming it to the shape of the lampshade. Fig. 13.4 shows a sheet of acrylic that could be formed to produce a lampshade with a diameter of approximately 120 mm. 400 150 Fig. 13.4 Use sketches and notes to show how the sheet of acrylic could be heated and formed to produce the lampshade. Name all the items of equipment required to carry out the process. [4]

14 marks

Mark scheme: 13(a)(i) Chinagraph pencil marks can be erased / a scriber leaves a permanent mark / 1 can damage the surface 13(a)(ii) Dividers 1 13(a)(iii) Named saws: coping, piercing, Hegner, scroll saw, tenon, hacksaw [1] 2 Use of files, sanding disk to finish to line [1] Do not reward use of abrasive paper 13(b) Acrylic shown clamped [1] 3 Sacrificial board underneath acrylic sheet [1] Technical accuracy of details and drawings [1] 13(c) 2 materials / items of equipment: 2 Accept, ‘polisher’, ‘buffer’. • wet and dry (silicon carbide) paper Do not accept use of files, emery cloth • polishing (buffing) wheel • polishing compound • acrylic polish [2  1] 13(d)(i) Extrusion 1 13(d)(ii) Acrylic sheet heated using an oven [1] 4 Use of a Ø120 former [1] Heated acrylic shown ‘draped’ or moulded around former [1] ‘Held’ in position while acrylic cools [1] 13(e) Use of screws, nuts and bolts [1] 4 Locked by means of hand only; use of wing nut [1] Named materials appropriate [1] Technical accuracy of details and drawings [1] 13(f) 4 layers of 5 mm thick acrylic sheet 150  150 cemented together to produce 4 4 layers may be cemented as one 20 mm thickness [1] 20 mm thick base at start of process Base Ø150 marked out using dividers [1] OR Base Ø150 cut out using variety of appropriate saws [1] Cut out separately and cemented later Edges self-finished to high quality [1] in process. 13(g) Electrical cable emerges through or under base [1] 3 Constructional details: holes drilled, channels cut out [0 – 2]

This question in 0445/32 Oct/Nov 2023

Q371 · A length of wood being planed in two directions, A and B 0445/33 Oct/Nov 2023

2 Fig. 2.1 shows a length of wood being planed in two directions, A and B. grain A B Fig. 2.1 (a) State the name of the plane shown in Fig. 2.1. … [1] (b) State which direction of planing, A or B, would produce the smoother surface. … [1]

2 marks

Mark scheme: 2(a) Smoothing 1 2(b) A 1

This question in 0445/33 Oct/Nov 2023

Q372 · Details of a tabletop that will be fastened to the rails of a small table 0445/33 Oct/Nov 2023

3 Fig. 3.1 shows details of a tabletop that will be fastened to the rails of a small table. MDF tabletop 18 thick hardwood rail 40 × 15 Fig. 3.1 Draw on Fig. 3.1 to show how the tabletop could be fastened to the rails. [3]

3 marks

Mark scheme: 3 Method: 3 For ‘screws’: (counterbored, pocket KD fitting, screws / ‘buttons’ / brackets / added blocks / dowels / screws [1] screwed, directly into underside of Technical details [0 – 2] tabletop)

This question in 0445/33 Oct/Nov 2023

Q373 · The centre for a drilled hole marked out on 6 mm thick metal 0445/33 Oct/Nov 2023

6 Fig. 6.1 shows the centre for a drilled hole marked out on 6 mm thick metal. tool A lines showing the centre for a drilled hole Fig. 6.1 (a) State the name of tool A. … [1] (b) State the name of a tool that could be used to mark out the circular shape. … [1]

2 marks

Mark scheme: 6(a) Centre or dot punch 1 6(b) Dividers 1

This question in 0445/33 Oct/Nov 2023

Q374 · Two pieces of 5 mm thick acrylic that will be joined together 0445/33 Oct/Nov 2023

7 Fig. 7.1 shows two pieces of 5 mm thick acrylic that will be joined together. Fig. 7.1 (a) Name a suitable adhesive that could be used to join the acrylic. … [1] (b) Add sketches and notes to Fig. 7.1 to show how excess adhesive could be prevented from spoiling the finished surfaces. [2]

3 marks

Mark scheme: 7(a) Acrylic cement / Tensol cement / MMA [1] 1 Do not accept epoxy resin, contact adhesive 7(b) Sketch showing adhesive ‘tape’, scrap paper, scrap wood [1] 1 2 Accept line drawn showing area to be Applied 5 mm from end of bottom piece [1] 1 glued for 1 mark

This question in 0445/33 Oct/Nov 2023

Q375 · Two pieces of brass that will be soldered on a brazing hearth using a blow torch 0445/33 Oct/Nov 2023

8 Fig. 8.1 shows two pieces of brass that will be soldered on a brazing hearth using a blow torch. firebricks flame brass pieces gas and air control silver solder part of a brazing hearth blow torch Fig. 8.1 (a) Explain the purpose of the firebricks. … … … [2] (b) Indicate clearly on Fig. 8.1 the hottest part of the blow torch flame. [1]

3 marks

Mark scheme: 8(b) 1 Award 1 mark for anywhere in the darkest zone hottest

This question in 0445/33 Oct/Nov 2023

Q376 · A basic design for a wall-mounted shelf made from 10 mm thick MDF 0445/33 Oct/Nov 2023

10 Fig. 10.1 shows a basic design for a wall-mounted shelf made from 10 mm thick MDF. 200 600 150 Fig. 10.1 (a) Use sketches and notes to show one functional improvement to the wall-mounted shelf. [2] (b) Use sketches and notes to show one aesthetic improvement to the wall-mounted shelf. [2]

4 marks

Mark scheme: 10(a) Functional improvement: added bracket or strips to give greater support to the 2 Accept any valid functional shelf, lipping to prevent items falling off [1] improvement Added details [1] 10(b) Aesthetic improvement: slight curve applied to front edge of shelf, rounded 2 Accept any valid aesthetic corners, application of paint, veneer, laminate [1] improvement Accept change of material for shelf for Added details [1] 1 mark

This question in 0445/33 Oct/Nov 2023

Q377 · Views of an incomplete design for a desktop box easel 0445/33 Oct/Nov 2023

11 Fig. 11.1 shows views of an incomplete design for a desktop box easel. The outer frames of the box and lid are made of 15 mm thick hardwood. The top of the lid and the base of the box are made from 6 mm thick veneered plywood. adjustable arm lid paper or spaces for canvas A artists materials box 60 clamp 400 300 Fig. 11.1 (a) The sides of the box will be joined at each corner by means of finger (comb) joints. Complete Fig. 11.2 to show an assembled finger (comb) joint. 15 60 Fig. 11.2 [3] (b) Fig. 11.3 shows part of the length of hardwood from which the clamp will be made. The shape has been marked out and the waste will be removed by planing. waste hardwood 290 × 25 × 25 waste Fig. 11.3 (i) Give one advantage of supporting the length of hardwood against a bench stop rather than holding the length of hardwood in a woodworker’s vice. … [1] (ii) The clamp holds the paper or canvas in place against the lid. Use sketches and notes to show how the clamp could be attached to the lid and allow paper or canvas to be removed and replaced. Give details of any fittings and fixings used. [4] (c) Partitions have been added inside the box to provide compartments that could be used to store equipment and materials. Fig. 11.4 shows part of the sides of the compartment shown at position A in Fig. 11.1. Fig. 11.4 Complete Fig. 11.4 to show a suitable construction that could be used to join the sides at A. [3] (d) Fig. 11.5 shows the adjustable arm with the slot marked out. slot 10 mm wide adjustable arm 320 × 40 × 20 Fig. 11.5 (i) A power router could be used to cut out the slot. State two settings that must be made to the power router before using it to cut out the slot. 1 … 2 … [2] (ii) A power router may not be available in the school workshop to cut out the slot. An alternative method will need to be used. Complete Table 11.1 by adding two further stages and naming the tools and/or equipment required to cut out the slot. Table 11.1 Stages Tools and/or equipment Drill hole/holes in marked out shape Drilling machine, twist drill [4] (e) Circle from the list below the most suitable hinge that could be used to join the lid to the box. back flap tee piano adjustable concealed [1] (f) The lid must be capable of being locked at different angles. (i) Explain why an angled lid is an example of ergonomic design in the box easel. … … … [2] (ii) Use sketches and notes to show how the lid could be locked securely at a required angle. Give details of materials, fittings and fixings used. [5]

25 marks

Mark scheme: 11(a) Number of ‘fingers’ 5 or 7 [1] 3 Equal spacing [1] Overall accuracy [1] 11(b)(i) Bench stop allows the wood to be planed without interference with the vice. 1 Do not accept ‘stable’ Wood can be planed on a flat surface 11(b)(ii) Method: screws or nuts and bolts to provide method of clamping [0 – 2] 4 Award 1 mark for use of dowels, Details of fittings and fixings to the clamping strip [0 – 2] mortise and tenon joint, magnets. 11(c) Suitable constructions: dowel, mortise and tenon, domino, housing [0 – 2] 3 Use of adhesive only - 0 marks Technical accuracy of details [0 – 2] Dowels: min. 2 – max. 3. Max. Ø6 11(d)(i) 2 settings: 2 • correct size router cutter • locked in position • fence set to width • depth of cut • speed of router cutter [2  1] 11(d)(ii) Stage 2: insert saw blade and cut out shape leaving small amount of waste [1] 4 Accept ‘chain drilling’ and use of files Hegner saw or equivalent, jig saw, coping saw, mortising machine [1] and / or chisels Stage 3: remove waste and clean surfaces up to the line [1] Use of files and glasspaper [1] 11(e) Piano hinge 1 11(f)(i) Angled lid ergonomic feature: consideration of different users [1] 2 To angle the lid at a position that is best / most comfortable for them [1] 11(f)(ii) Some sort of practical ‘connection’ between lid and box: e.g. use of wood / metal 5 strip with cut out or pins to provide fixed position [0 – 2] Details of materials, fittings and fixings used [0 – 3]

This question in 0445/33 Oct/Nov 2023

Q378 · An incomplete design for a tape dispenser made mainly from 1.6 mm thick mild steel sheet 0445/33 Oct/Nov 2023

12 Fig. 12.1 shows an incomplete design for a tape dispenser made mainly from 1.6 mm thick mild steel sheet. The tape dispenser could be made in a school workshop. roll of tape disk upright support cutting plate base 15 200 100 Fig. 12.1 (a) Mild steel is a ferrous metal. (i) State what is meant by the term ‘ferrous metal’. … [1] (ii) Name one other ferrous metal. … [1] (b) Fig. 12.2 shows a development (net) of the base of the tape dispenser marked out on 1.6 mm thick mild steel sheet. 100 waste 200 15 Fig. 12.2 (i) Name two tools or items of equipment that could be used to cut out the development (net). 1 … 2 … [2] (ii) Use sketches and notes to show how a wooden former could be used when bending the development (net) to produce the base. Name all the tools and equipment used. [4] (c) Fig. 12.3 shows the disk onto which the roll of tape fits. The disk is made of hardwood and will be turned on a woodturning lathe. Ø 75 × 50 Fig. 12.3 (i) Circle from the list below the best type of grain structure found in hardwoods when used for woodturning. open grain interlocking grain close grain wide grain [1] (ii) Fig. 12.4 shows a length of hardwood set up on a woodturning lathe. hardwood Fig. 12.4 Give one safety check that must be carried out before switching on the lathe. … [1] (iii) Name one tool that could be used when shaping the disk on the lathe. … [1] (iv) Name one tool that could be used to check the diameter of the disk after it has been turned. … [1] (d) Fig. 12.5 shows details of the hardwood disk fastened between the upright supports. A screw thread is cut on the inside of the Ø10 mild steel tube so that screws can be inserted on both sides of the disk. hardwood disk hardwood disk screw upright support Ø 10 mild steel tube screw base upright support end view Fig. 12.5 (i) Name a tool that would be used to cut the screw thread on the inside of the mild steel tube. … [1] (ii) Name an adhesive that could be used to glue the mild steel tube inside the hardwood disk. (e) Fig. 12.6 shows the tape being pulled from the roll. In design A the tape is pulled at an angle over the cutting plate. It would be easier to cut the tape from the roll if it could be pulled flat over the cutting plate as shown in design B. cutting plate A B Fig. 12.6 Use sketches and notes to show a modification to the tape dispenser to enable the tape to be cut as shown in design B. State the name of any additional materials used and all constructional details. [5] (f) The mild steel parts of the tape dispenser will be given a dip coated finish. Complete Table 12.1 by adding three further stages in the dip coating process. Table 12.1 Stage Process 1 Remove grease and dirt from surfaces of mild steel parts 2 3 4 [3] (g) Use sketches and notes to show a modification to the tape dispenser so that it could be fixed securely to a workbench. State the names of any fittings and fixings used. [3]

25 marks

Mark scheme: 12(a)(i) A metal that contains iron 1 Do not accept ‘magnetic’ 12(a)(ii) Wide variety of ferrous metal available 1 12(b)(i) Hacksaw, junior hacksaw, tinsnips, bench shears / guillotine [2  1] 2 Accept ‘snips’, Hegner / scroll saws with metal cutting blade Do not accept ‘curved snips’ 12(b)(ii) Sketch showing a wooden former [1] 4 Sketch showing metal development clamped securely to former [1] Method of force: hammer or mallet [1] Correctly named tools and equipment [1] 12(c)(i) Close grain 1 12(c)(ii) Checks: hardwood securely held between centres, rotate hardwood to ensure 1 clear from Tee rest, Tee rest at correct height / position, check to see if hardwood Is centred 12(c)(iii) Scraper, chisel, gouge 1 12(c)(iv) Outside / external calipers, vernier calipers, micrometer 1 Do not accept ‘calipers’ 12(d)(i) Tap 1 12(d)(ii) Epoxy resin, Araldite 1 Check alternative trade names: must include the name ‘epoxy resin’. 12(e) Method of cutting tape efficiently: practical idea 5 If ‘bracket’ is not practical, award max. Some form of horizontal bracket in correct position [0 – 2] 2 marks for ‘joining’, ‘additional Joined to upright support or to base [1] materials’ and ‘constructional details’. Suitable additional materials named [1] Constructional details [1] 12(f) 3 processes include: 3 Must be in correct sequence • Plastic in fluidised state • Heat metal to 180 °C in an oven • Plunge metal into tank of fluidised polythene • Reheat metal in an oven then leave to cool [3  1] 12(g) Modification to base of dispenser [1] 3 Screw holes are not modifications. Secured to bench [1] Use of screws or bolts: max 2 marks. Technical details [1] Do not accept change of material; e.g. from mild steel to wood

This question in 0445/33 Oct/Nov 2023

Q379 · Views of a design for a novelty photograph holder made of 4 mm thick acrylic in the shape… 0445/33 Oct/Nov 2023

13 Fig. 13.1 shows views of a design for a novelty photograph holder made of 4 mm thick acrylic in the shape of a t-shirt. The t-shirt has a coat hanger suspended from a metal rail. Two photographs can be ‘sandwiched’ between the two acrylic frames. metal rail acrylic frames coat hanger photographs 150 × 100 overall height of t-shirt 190 overall width of t-shirt 170 Fig. 13.1 (a) Fig. 13.2 shows a paper template glued onto 4 mm thick acrylic sheet. paper template waste cut out shape 140 × 90 Fig. 13.2 (i) Give two advantages of using a paper template rather than drawing the shape directly onto the acrylic sheet. 1 … 2 … [2] (ii) The cut out shape will be produced using hand and machine tools. Complete Table 13.1 by stating the correct names for the tools and/or equipment used to produce the cut out shape. Table 13.1 Stage Process Tools and/or equipment Make a hole in corner of shape to be cut 1 out Cut out shape leaving small amount of 2 waste to be removed later Remove waste up to the line of the final 3 shape Smooth edges to a high quality finish 4 [4] (iii) Two identical acrylic frames are required to make the photograph holder. Describe how two identical acrylic frames could be produced by hand. … … … [2] (b) The acrylic frames could be produced by means of CAD/CAM. Fig. 13.3 shows a screen shot of a CAD drawing of part of one acrylic frame. Fig. 13.3 (i) Explain why the designer has drawn only half of the shape of the acrylic frame. … … … [2]

10 marks

Mark scheme: 13(a)(i) 2 advantages: quicker / repetitive accuracy [2  1] 2 13(a)(ii) Stage 1 hand drill, machine drill, drill bit [1] 4 Do not accept Jigsaw or Laser Cutter. Stage 2 coping saw, Hegner, scroll saw or equivalent, router [1] Stage 3 hand, flat or half round files [1] Do not accept sandpaper. Stage 4 scraper, wet and dry [silicon carbide] paper, polishing mop, polishing compound, buffing machine [1] 13(a)(iii) 2 methods: 2 Award 1 mark for appropriate method Tape 2 pieces of acrylic together and cut and shape as one piece [0 – 2] Award 1 mark for notes relating to the Or actual cutting / shaping. Cut out one frame, use as a template to draw round for the second frame [0 – 2] 13(b)(i) More accurate and quicker to draw half the frame, click ‘select all’ and then click 2 Award 0–2 marks dependent on level ‘mirror image’ to produce the opposite half to complete the frame of CAD understanding demonstrated 13(b)(ii) 3 stages: position acrylic sheet in CNC machine, set machine parameters, press 3 Accept any relevant individual stages START button on machine to produce shape of frame [3  1] within ‘set machine parameters’ 13(c) Practical idea: some form of clip, clamp, connecting pins or pegs [0 – 2] 6 Do not accept use of hinges – 0 Suitable materials [1] marks Constructional details [1] 2 important sizes [2  1] Do not accept repeats of measurements given in Figs. 13(d) Metal rail Ø20 tube extended [1] 6 Accept use of aluminium welding as a Some form of stable base [1] construction. Suitable materials named [1] Do not accept repeats of Metal rail joined to base [1] measurements given in Figs. 2 important sizes [2  1]

This question in 0445/33 Oct/Nov 2023

Q380 · A tennis racket made from carbon fibre reinforced plastic (CFRP) 0445/31 May/June 2024

1 Fig. 1.1 shows a tennis racket made from carbon fibre reinforced plastic (CFRP). Fig. 1.1 State two properties of carbon fibre reinforced plastic (CFRP) that make it suitable for the tennis racket. 1 … 2 … [2]

2 marks

Mark scheme: 1 Any two properties: tough, lightweight, good wear resistance, durable, impact resistant, easily moulded [2x1] 2 Accept any other valid properties

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Q381 · The outline shape and a development (net) for a tray made from 1.5 mm mild steel sheet 0445/31 May/June 2024

3 Fig. 3.1 shows the outline shape and a development (net) for a tray made from 1.5 mm mild steel sheet. 120 Fig. 3.1 (a) Add flaps to the development (net) shown in Fig. 3.1 that would enable the sides of the tray to be joined correctly when bent to shape. [2] (b) The tray must have safe edges. Explain what is meant by the term ‘safe edge’ when working with sheet metal. … … … [2]

4 marks

Mark scheme: 3(a) Award 1 mark for 2 correct flaps. Award 2 marks for 4 correct flaps 2 3(b) Safe edge is made to prevent injury from sharp edges of metal [1] Safe edge made by folding back narrow edge of sheet material [1] 2

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Q382 · Two parts, A and B, of an incomplete housing joint 0445/31 May/June 2024

4 Fig. 4.1 shows two parts, A and B, of an incomplete housing joint. A B Fig. 4.1 Draw on part B in Fig. 4.1 to show the other part of the housing joint. [3]

3 marks

Mark scheme: 4 3 Accurate projection lines from given drawing

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Q383 · A length of brass that is to be heated to a dull red colour 0445/31 May/June 2024

6 Fig. 6.1 shows a length of brass that is to be heated to a dull red colour. 120 5 mm thick 20 Fig. 6.1 Complete the following sentences. (a) The process of heating the brass to a dull red colour and leaving it to cool is known as [1] (b) The process makes the metal ………………………………………...… so that it becomes easier to work. [1]

2 marks

Mark scheme: 6(a) Annealing 1 6(b) Softer, more pliable, malleable, less brittle 1

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Q384 · A paint pot holder made of wood 0445/31 May/June 2024

7 Fig. 7.1 shows a paint pot holder made of wood. manufactured board holes Ø50 softwood 40 240 140 Fig. 7.1 Use sketches and notes to show how the paint pot holder could be redesigned and made from one sheet of thermoplastic measuring 240 × 220. Do not include details of the holes. [3]

3 marks

Mark scheme: 7 Sketch showing one-piece plastic design [1] Heat applied [1] Use of strip heater, line bender, heat gun [1] 3

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Q385 · Detailed stages of a process that could be carried out on steel 0445/31 May/June 2024

8 Table 8.1 gives detailed stages of a process that could be carried out on steel. Table 8.1 Stage Process 1 Heat up steel to dull red 2 Dip steel into carbon powder 3 Repeat stages 1 and 2 three times 4 Reheat steel to dull red 5 Quench in water Name the process detailed in Table 8.1 … [1]

1 marks

Mark scheme: 8 Case hardening 1

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Q386 · Views of a small box made of hardwood 0445/31 May/June 2024

9 Fig. 9.1 shows views of a small box made of hardwood. The hardwood base has been glued and screwed to the sides of the box. base screw base Fig. 9.1 Explain what is likely to happen to the base of the box, over time, as a result of gluing and screwing it to the sides of the box. … … … [2]

2 marks

Mark scheme: 9 The hardwood could dry out and shrink [1] Causing the base to split [1] 2

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Q387 · Views of an incomplete design for a teaching aid that could be used to teach children… 0445/31 May/June 2024

11 Fig. 11.1 shows views of an incomplete design for a teaching aid that could be used to teach children addition and subtraction. The case is made from MDF and the feet are made from aluminium. 6 5 5 1 + 4 0 2 4 150 9 1 = 9 0 – 300 70 feet case rear view front view Fig. 11.1 (a) Fig. 11.2 shows the front of the case with the windows marked out, ready to be cut out. Use sketches and notes to show how one window could be cut out by hand. Name all the tools and equipment used. windows to be cut out 3 mm thick MDF 40 × 20 Fig. 11.2 [4] (b) Fig. 11.3 shows the front of the case and part of a length of MDF from which the four sides of the case are made. 1 metre length of 6 mm thick MDF for sides front 300 × 150 × 3 mm thick Fig. 11.3 Complete Table 11.1 by giving four additional stages required to make the case. Table 11.1 Stage Process 1 Mark out the sides to the required lengths 2 3 4 5 [4] (c) The case could be made from one piece of sheet material without the use of any joints. Name a suitable material and describe how the case could be produced. … … … … … [4] (d) Fig. 11.4 shows details of one of the discs made from MDF with the numbers 0–9 on the edge of the disc. 5 6 7 Ø100 x 20 mm thick Fig. 11.4 (i) Use sketches and notes to show how one disc could be produced using workshop tools and equipment. [3] (ii) Describe how the numbers 0–9 could be produced and applied to the edge of the disc using CAD/CAM. … … … … … … [4] (e) Fig. 11.5 shows details of the discs and the mild steel rod on which the discs rotate. The discs must be prevented from sliding along the mild steel rod. 7 clearance hole Ø6.5 6 5 mild steel rod Ø6 Fig. 11.5 Use sketches and notes to show how the discs could rotate freely and be prevented from sliding along the mild steel rod. Give details of all materials and constructions used. [3] (f) Fig. 11.6 shows details of one of the feet made from aluminium. Use sketches and notes to show how one foot could be produced from a length of aluminium 150 × 25 × 2 mm thick. 100 20 120 25 Fig. 11.6 [3]

25 marks

Mark scheme: 11(a) Drill hole, insert blade of saw, cut out waste, file edges, named tools and equipment [41] machine and other valid stages 11(b) Main stages: cut sides to length, join sides, join front to sides. [4x1] Accept ‘minor’ stages: e.g. square sawn ends, use of pins, glue, clamping 4 Accept any other valid stages Do not accept glasspaper 11(c) Method: vacuum forming, injection moulding [1] Named material: acrylic, HIPS, ABS [1] Description of appropriate method [02] 4 11(d)(i) Main stages: shape marked out, shape cut out ‘roughly’, sand/file to shape, woodturning between centres, held in chuck, hole saw [31] 3 Accept any other valid stages 11(d)(ii) Award marks for relevant stages in CAD and CAM. Design numbers, transfer data to ‘machine’, cut out numbers, apply to disc Use of CAMM 1 vinyl cutter [0-4] 4 Accept imbalance; i.e. more info. For CAD than CAM and vice versa. Accept any other valid stages 11(e) Use of ‘spacer’, metal or plastic tube, metal pin [1] Appropriately named material [1] ‘Spacer’ secured in position to prevent sliding [1] 3 11(f) Aluminium held securely: use of folding bars, vice, clamped [1] Use of hammer and scrap wood or mallet to bend [1] Correct tools and equipment named [1] 3

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Q388 · An incomplete design for a unit to store items used in a shower room 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

Q389 · Views of an incomplete design for an adjustable tray that could be used by a person… 0445/31 May/June 2024

13 Fig. 13.1 shows views of an incomplete design for an adjustable tray that could be used by a person sitting up in bed. The tray can be used in the flat position or tilted and locked at different angles. The tray is made of manufactured board. The rails and legs are made of hardwood. tray 15 mm thick tray rails 25 × 15 240 legs fold under 600 320 legs 15 mm thick Fig. 13.1 (a) (i) Name a suitable manufactured board for the tray. … [1] (ii) Many manufactured boards have veneered surfaces. State one benefit and one drawback of using veneers to cover the surfaces of manufactured boards used to make furniture products. Benefit … Drawback … [2] (b) The top surface of the tray is covered with a plastic laminate. State two benefits of covering the top surface of the tray with a plastic laminate. 1 … 2 … [2] (c) Fig. 13.2 shows one of the legs with the curved shape marked out, ready to be removed. waste 15 mm thick hardwood 320 Fig. 13.2 (i) Name a specific type of saw that could be used to remove the waste. … [1] (ii) Give the specific names of two tools or items of equipment that could be used to make the sawn edges smooth. 1 … 2 … [2] (d) In use, there is a danger that items could slide off the surface of the tray. Use sketches and notes to show a modification to the design of the tray that could prevent items from sliding off. Name any materials and constructions used. [3] (e) Fig. 13.3 shows an exploded view of the rails that will be joined at each corner of the adjustable tray. Fig. 13.3 Add sketches to Fig. 13.3 to show a suitable corner construction, other than a butt joint, that could be used to join the rails. [3] (f) Fig. 13.4 shows one of the legs of the tray in both an open and folded position. folded position open position Fig. 13.4 Use sketches and notes to show how the leg could be made to fold underneath in the direction of the arrow shown in Fig. 13.4. Name any materials and fittings used. [3]

17 marks

Mark scheme: 13(a)(i) Plywood, chipboard, MDF, blockboard 1 Do not accept hardboard 13(a)(ii) Any one benefit: cheaper than solid wood, appearance of solid wood, attractive [1] Any one drawback: damages easily, not easily repaired, less durable [1] 2 Accept any other valid benefits or drawbacks 13(b) Any two benefits: increased durability, easily cleaned, heat resistant, resistant to spillages, wide range of decorative finishes [21] 2 Accept any other valid benefits 13(c)(i) Coping saw, Hegner saw, scroll saw, band saw, jig saw 1 13(c)(ii) Half-round, round, rat tail files, spokeshave, sanding bobs, glasspaper [21] 2 13(d) Practical idea: complete raised lipping or additional surface strips [1] Suitable named materials [1] Constructions: adhesive, pin and glue, screw [1] 3 Do not accept plywood Lipping applied up to the edge or on top of tray 13(e) Suitable construction named: mitre, half lap, dovetail, finger, dowels [1] Award 02 dependent on technical accuracy, proportion [02] 3 Question Answer Marks Guidance 13(f) Some form of pin or bolt to act as a pivot [1] Pin or bolt secured in position [1] Details of fittings/materials used [1] 3 13(g) Recognised butt hinge: 2 or 3 holes [1] Knuckle and pin [1] 2 equal leaves [1] 3 13(h) Practical idea: some form of ‘arm/s’ attached to tray or rails [02] Locking method: added strips, use of nuts and screws [1] Locks at 4 different angles [1] Named materials [1] 5

This question in 0445/31 May/June 2024

Q390 · Parts A and B of an incomplete drawing of a twin mortise and tenon joint 0445/32 May/June 2024

1 Fig. 1.1 shows parts A and B of an incomplete drawing of a twin mortise and tenon joint. A B Fig. 1.1 Draw on part B in Fig. 1.1 to show the twin tenons. [3]

3 marks

Mark scheme: 1 2 tenons [1] Correct width [1] Correct thickness [1] 3 Do not accept incorrect orientation or guidelines drawn only. Ignore length of tenons.

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Q391 · A label from the front of a box of steel bolts 0445/32 May/June 2024

2 Fig. 2.1 shows a label from the front of a box of steel bolts. M10 × 50 A B C Fig. 2.1 State what is meant by each item of information labelled A, B and C. A … B … C … [3]

3 marks

Mark scheme: 2 A metric [1] B diameter [1] C length [1] 3

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Q392 · CFRP and GRP are examples of composite materials 0445/32 May/June 2024

5 CFRP and GRP are examples of composite materials. Complete the names of the composite materials. (a) C………………………………... Fibre Reinforced Plastic [1] (b) G………………………………... Reinforced Plastic [1]

2 marks

Mark scheme: 5(a) Carbon 1 5(b) Glass 1

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Q393 · A copper dish being beaten into shape 0445/32 May/June 2024

7 Fig. 7.1 shows a copper dish being beaten into shape. When the copper is beaten it becomes ‘work hardened’. A Fig. 7.1 (a) Complete the sentence by adding the correct term from the list. soaked alloyed annealed tempered To make the copper softer and easier to work, it must be … [1] (b) Name the item of equipment labelled A. … [1]

2 marks

Mark scheme: 7(a) Annealed 1 7(b) Sand bag, sand pad 1 Accept variations including ‘sand…..’

This question in 0445/32 May/June 2024

Q394 · A portable toolbox made of softwood 0445/32 May/June 2024

11 Fig. 11.1 shows a portable toolbox made of softwood. handle tray lifts out hinge hinged side 400 600 200 end Fig. 11.1 (a) Name a suitable softwood for the toolbox. … [1] (b) Fig. 11.2 shows part of one of the hinged sides which is made by gluing together two softwood boards. 325 175 15 mm thick Fig. 11.2 (i) Give one reason why two boards are glued together rather than making the side from one board only. … … [1] (ii) Use sketches and notes to show how the two boards could be glued and clamped together. Name the type of cramps used. [3] (iii) State two checks that should be carried out after the boards have been glued and clamped together. 1 … 2 … [2] (c) Fig. 11.3 shows two types of hinge that could be screwed to the toolbox to allow the sides to open and close. A B Fig. 11.3 (i) Name each type of hinge, A and B. Hinge A … Hinge B … [2] (ii) Explain why hinge B would be more suitable than hinge A. … … (d) Fig. 11.4 shows details of a set of screwdrivers that will be stored on the inside of one of the hinged sides of the toolbox. 100 Fig. 11.4 Use sketches and notes to show how the set of screwdrivers could be stored on the inside of a hinged side. The method of storage must: • hold six screwdrivers safely and securely when the toolbox is carried • allow for ease of access. Give details of all materials and constructions used. [5] (e) Use sketches and notes to show how the hinged sides shown in Fig. 11.1 could be held securely and prevented from opening when the toolbox is carried. [3] (f) The handle enables the toolbox to be carried. Fig. 11.5 shows a method of joining the handle to the ends of the toolbox. handle 40 × 25 end Fig. 11.5 (i) Name the joint shown in Fig. 11.5. … [1] (ii) Explain why the method shown in Fig. 11.5 has considerable strength when joining the handle to the ends of the toolbox. … … … [2] (g) Fig. 11.6 shows a commercially manufactured toolbox made from plastic. Fig. 11.6 Give three advantages of using a toolbox made from plastic rather than the toolbox made from softwood shown in Fig. 11.1. 1 … 2 … 3 … [3]

25 marks

Mark scheme: 11(a) Wide variety of softwoods available: pine, parana pine, redwood, fir, whitewood, [western red] cedar, larch, spruce [1] 1 11(b)(i) Softwood trees do not produce wide enough boards, two boards glued together are more resistant to warping [1] 1 11(b)(ii) Minimum 2 cramps shown across boards [1] Use of scrap wood between cramps and boards [1] Named cramps: sash, F cramps, ‘fast’, ‘quick’ [1] 3 Maximum 3 cramps used. 11(b)(iii) Any two checks: cramps tight, boards flat boards in line, removal of surplus glue [21] 2 11(c)(i) A butt [1] B tee [1] 2 11(c)(ii) The ‘arm’ of hinge B is longer than that of hinge A [1] and will cover a greater surface area of the wood, support more weight [1] 2 11(d) Method to locate screwdriver blades: Use of wooden block, spring clips, ‘box’ [0–2] Holds 6 screwdrivers [1] Attached to inside of hinged side [1] Named materials appropriate [1] 5 Look for practical ‘principle’. 11(e) Some form of purchased ‘catch’; e.g. toggle catch. Use of ‘made’ catch, clasp, strap, clips [that swivel across and is secured to handle], magnets, hasp and staple, string 3 Award 0–2 for a practical idea. Accept use of Velcro. Award 1 for notes describing how it works. 11(f)(i) Dovetail 1 Question Answer Marks Guidance 11(f)(ii) The dovetail shape prevents the handle from being pulled out when the toolbox is lifted [1] Wider at bottom than top preventing upward movement [1] 2 Do not accept ‘more surface area’. 11(g) Any three advantages: moulded shape with no sharp corners, lightweight, more durable, waterproof, weather resistant, easy to clean [31] 3 Must relate to USE. Accept any valid advantages.

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Q395 · An incomplete design for a desk that could be made in a school workshop 0445/32 May/June 2024

12 Fig. 12.1 shows an incomplete design for a desk that could be made in a school workshop. The materials list gives details of the materials from which the desk is made. 500 300 X 700 X desk top adjustable leg 700–800 leg height rail 600 foot 400 Materials List leg, foot, rail mild steel tube 50 × 25 adjustable leg mild steel tube 45 × 20 desk top veneered plywood 20 mm thick Fig. 12.1 (a) The rectangular mild steel tube used for parts of the desk is a standard metal form. Fig. 12.2 shows two other standard metal forms, A and B. A B Fig. 12.2 Complete the names of the standard metal forms A and B. A ………………….. strip B ………………….. bar [2] (b) State two different methods that could be used to join the rail and legs to the feet permanently. 1 … 2 … [2] (c) Use sketches and notes to show how the desk top could be joined to the rails labelled X in Fig. 12.1. The method of joining must be carried out using only basic tools such as screwdrivers and / or Allen / hex keys. [4] (d) The height of the desk can be adjusted between 700–800 mm. Fig. 12.3 shows part of one of the adjustable legs. mild steel tube 45 × 20 mild steel tube 50 × 25 Fig. 12.3 Use sketches and notes to show how the adjustable leg could be locked securely at any height between 700–800 mm. Give details of any fixings and fittings used. [4] (e) Fig. 12.4 shows details of one of the plugs that will be inserted into the ends of the 50 × 25 mild steel tube. The plugs are made of hardwood. Fig. 12.4 (i) Give two reasons for the plugs. 1 … 2 … [2] (ii) The hardwood plugs will be glued into the ends of the mild steel tube. Name a suitable adhesive that could be used to glue the hardwood plugs into the mild steel tube. … [1] (f) A small drawer will be added to the desk and supported below the desk top. Fig. 12.5 shows details of the drawer and its position. 12 mm thick desk top 20 mm thick 100 450 drawer 200 Fig. 12.5 Use sketches and notes to show how the drawer could be supported below the desk top and allowed to be opened and closed. Give details of additional materials used and the constructions carried out to support the drawer in use. [6] (g) Fig. 12.6 shows a palm sander that could be used to make the veneered surface of the desk top smooth before applying a clear varnish finish. Fig. 12.6 (i) State two reasons why care must be taken when using a palm sander on the veneered surface of the plywood. 1 … 2 … [2] (ii) Describe how a clear varnish could be applied to the desk top to achieve a high quality finish. … … … [2]

25 marks

Mark scheme: 12(a) A flat [1] B square [1] 12(b) Brazing [1] Welding [1] 2 Do not accept soldering , rivets. 12c practical idea [0–2] Detailed notes describing method [0–2] 4 Some type of bracket or screwed from inside the rail. Large hole for screwdriver blade to fit Do not reward ‘long’ screw through entire 45 mm wide rail. 12(d) Hole drilled in outer tube [1] Slot removed in inner tube [1] Some form of pin, screw, bolt through hole and slot, ‘push- button’ [1] Method of locking/securing pin, screw, bolt in position [1] 4 Award max.2 if a number of holes are drilled rather than a slot 12(e)(i) The plugs: provide an attractive appearance [1] hide the sharp ends of the steel tube/are safer [1] prevent dust and dirt from entering [1] are easier to clean [1] 2 12(e)(ii) Epoxy resin, ‘Araldite’ 1 Question Answer Marks Guidance 12(f) Wooden or metal ‘supports’ attached to underside of desk top [0–2] Added beads applied to supports or grooves cut in supports and added beads applied to drawer sides [0–2] Appropriately named materials and constructions [0–2] 6 Give credit to any practical method 12(g)(i) Any two reasons: Do not apply extreme pressure which could cut through veneer, damage to veneer, scratch the veneer, make surface uneven [21] 2 Accept any other valid reasons 12(g)(ii) Description to include: use of a paint brush, brush strokes in same direction, applied evenly, along the grain, multiple (more than 1) coats, thin layers [21] 2

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Q396 · Views of a desk tidy that will be batch produced in a school workshop 0445/32 May/June 2024

13 Fig. 13.1 shows views of a desk tidy that will be batch produced in a school workshop. The desk tidy is made from acrylic. Ø40 acrylic tubes base Ø120 × 20 deep heights of acrylic tubes 100 70 60 55 40 Fig. 13.1 (a) State two properties of acrylic that make it suitable for the desk tidy. 1 … 2 … [2] (b) Fig. 13.2 shows a sectional view of a machine used to manufacture the acrylic tube. A B C Fig. 13.2 (i) Name the process used to manufacture the acrylic tube. … [1] (ii) Complete the words for each of the labels, A, B and C, shown in Fig. 13.2. A plastic g ………………………. B h ………………………………. C d ……………………………… [3] (c) Fig. 13.3 shows part of a length of acrylic tube from which five different lengths, 100, 70, 60, 55 and 40 will be sawn. Ø40 Fig. 13.3 Use sketches and notes to show a design for a sawing jig to be used during batch production that could: • be held in a vice • hold the acrylic tube securely while it is sawn • allow the five different lengths to be sawn without the need for measuring and marking out. Name the materials used to make the sawing jig. [6] (d) The base of the acrylic desk tidy could be produced by the vacuum forming process. Fig. 13.4 shows the mould used to make the base. rounded edges mould Ø120 × 20 mm thick tapered sides Fig. 13.4 Explain why the mould has rounded edges and tapered sides. … … … [2] (e) The base of the desk tidy could also be made by press forming a sheet of 1.5 mm thick acrylic. Fig. 13.5 shows the yoke and plug used in the press forming process. yoke plug guide pegs Fig. 13.5 (i) Describe how the base of the acrylic desk tidy could be produced by the press forming process. … … … … … [3]

17 marks

Mark scheme: 13(a) Any two properties: variety of colours, attractive, easy to work, durable material, easily cleaned, self-finishing, easily shaped when heated [21] 2 Do not accept corrosion resistant, lightweight. Accept any other valid properties. 13(b)(i) Extrusion 1 13(b)(ii) A granules [1] B heater/heating element/heat source/heating plate, heating chamber [1] C die [1] 3 Reward variations including reference to ‘heater’ or ‘heating’. Question Answer Marks Guidance 13(c) Jig has saw cuts to guide saw for 5 different lengths or measurements marked out on jig [0–2] Adapting jig to secure in vice [1] Method of holding acrylic tube securely when sawn [0–2] Appropriately named materials [1] 6 13(d) Rounded edges to help plastic to form to shape without thinning/splitting [1] Tapered sides allow the mould to be released from the formed plastic [1] 2 13(e)(i) Three clear stages such as: Plastic sheet is heated in an oven Sheet is positioned on top of the ‘plug’ ‘Yoke’ is pressed down onto the plug [guide pegs] Clamp in position until plastic has cooled down [31] 3 Accept any other valid stages in process Stages must start with heating plastic. If no heating is given anywhere in answer award 0 marks. If heating appears elsewhere in answer only mark correct stages after heating is stated. 13(e)(ii) Any two advantages: much quicker process, more accurate [21] 2 Accept ‘easier’ only if it is qualified. Question Answer Marks Guidance 13(f) 4 methods: 1 Woodturning between centres. Stages include: prepare square section length of wood by planing off corners, saw cuts made in one end, centre marked on other end, one end inserted into fork centre in headstock, other end inserted into tailstock, tool rest set up, use of gouges, chisels to turn to shape, glasspaper to make smooth, check with calipers, part off, saw off and use glasspaper to remove sharp edges. [61] 2 Hole saw. Details to include: Hole saw sketch and name, holes marked out, workpiece clamped securely, use of sacrificial board or drill ½ way and turn workpiece over, glasspaper to remove sharp edges. [61] 3 Laser cutter. Details to include: Disks drawn using CAD software, material into laser cutter, export CAD programme to laser cutter, set parameters, set laser cutter to cut out shapes. [61] 4 Cutting disks from wooden board. Details to include: Mark out disks on board, cut out using appropriate saw, [coping, Hegner, scroll], use of disk sander, files, glasspaper. [51] 6 Accept any relevant stages. Accept any relevant details. Accept any relevant details. Accept any relevant details. Maximum 5 marks for this method as it would not produce 5 identical disks.

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Question 397 0445/33 May/June 2024

1 Fig. 1.1 shows a small table. The tabletop could be made from plywood or chipboard. tabletop Fig. 1.1 Give two advantages of using plywood rather than chipboard for the tabletop. 1 … 2 … [2]

2 marks

Mark scheme: 1 Any two advantages: better quality, less likely to split/chip/crumble, more hardwearing, more durable, stronger, more attractive (not aesthetically pleasing) [21] Do not accept ‘prevents splinters’

This question in 0445/33 May/June 2024

Q398 · An incomplete drawing of two pieces of metal being riveted together 0445/33 May/June 2024

2 Fig. 2.1 shows an incomplete drawing of two pieces of metal being riveted together. hammer head rivet Fig. 2.1 (a) Name the type of hammer used to rivet the two pieces of metal together. … [1] (b) Complete the shape of the hammer head that is about to strike the rivet in Fig. 2.1. [2]

3 marks

Mark scheme: 2(a) Ball pein, engineer’s hammer 1 2(b) Completed ‘dome’ shape [0–2] Dependent on technical accuracy 2 ‘semi-circular’ end drawn = 2 ‘round’ = 1

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Q399 · Details of a length of 8 mm thick hardwood that has been bent to shape 0445/33 May/June 2024

3 Fig. 3.1 shows details of a length of 8 mm thick hardwood that has been bent to shape. 8 mm thick 80 160 500 Fig. 3.1 Use sketches and notes to show how formers could have been used to produce the final curved shape. [3]

3 marks

Mark scheme: 3 Male and female formers shown clearly [21] Added descriptive notes; e.g. clamping, reference to steam bending [1] 3

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Q400 · A menu stand made from acrylic 0445/33 May/June 2024

4 Fig. 4.1 shows a menu stand made from acrylic. MENU Fig. 4.1 Explain how the designer has used the flexible property of acrylic in the design of the menu stand. … … … [2]

2 marks

Mark scheme: 4 Flexible property: ability to prise sides of menu stand apart [1] to insert menu [1] 2

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Q401 · Explain the term ‘alloy’ 0445/33 May/June 2024

5 Explain the term ‘alloy’. … … … [2]

2 marks

Mark scheme: 5 A mixture of two or more pure metals with other elements [1] To create a metal with special properties (not found in a single metal) [1]

This question in 0445/33 May/June 2024

Q402 · A wooden box with a ‘lift-off’ lid 0445/33 May/June 2024

6 Fig. 6.1 shows a wooden box with a ‘lift-off’ lid. 10 mm thick 10 mm thick 80 200 120 Fig. 6.1 Use sketches and notes to show a modification to the lid so that it could be fitted to either the inside of the box or to the outside of the box, without the use of hinges. [3]

3 marks

Mark scheme: 6 Inside box: block of wood glued to underside of lid or added small strips or rebated edges to locate inside box OR Outside of box: strips of wood [pinned and] glued to edge of lid or corner pieces added to the edges of the box Practical idea [1] Added details: e.g. sizes, constructions [0–2] Do not accept sliding lids. Do not accept lids joined on top; e.g. finger joints

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Q403 · Three wood screws, A, B and C, with different types of head 0445/33 May/June 2024

9 Fig. 9.1 shows three wood screws, A, B and C, with different types of head. A B C Fig. 9.1 Name the type of head for each of the wood screws A, B and C. A … B … C … [3]

3 marks

Mark scheme: 9 A round [1] B raised [1] C countersunk/countersink [1]

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Q404 · A piercing saw that will be used to cut out the curved shape in a piece of 1 mm thick… 0445/33 May/June 2024

10 Fig. 10.1 shows a piercing saw that will be used to cut out the curved shape in a piece of 1 mm thick brass sheet. brass sheet Fig. 10.1 Use sketches and notes to show how the brass sheet would be held securely while the curved shape is cut out. [3]

3 marks

Mark scheme: 10 Brass sheet flat [1] Over edge of bench [1] Clamped in position [1] 3 Accept board with ‘V’ shape cut out

This question in 0445/33 May/June 2024

Q405 · Views of an incomplete design for a trophy 0445/33 May/June 2024

11 Fig. 11.1 shows views of an incomplete design for a trophy. The trophy has three main parts made from the following materials: • front part – 5 mm thick acrylic • middle part – 2 mm thick brass • back part – 12 mm thick mahogany. 200 D&T D&T Award 2024 Award 2024 130 Fig. 11.1 (a) State two specification points a designer would have considered when designing the trophy. The trophy must: 1 … 2 … [2] (b) Fig. 11.2 shows a template that could be used to mark out the shape of one of the parts of the trophy. waste template Fig. 11.2 (i) State one benefit of using a template to mark out the shape of one of the parts of the trophy. … [1] (ii) Use sketches and notes to show how the shape could be cut out from either acrylic or mahogany and the edges made smooth. Name all the tools and equipment used. Chosen material … [4] (iii) Acrylic and brass are materials that can be self-finished. Explain what is meant by the term ‘self-finished’. … … … [2] (c) Holes will be drilled in the three parts of the trophy to allow the Ø5 rod to pass through. Give two reasons why sheet material must be clamped securely before holes are drilled through the material. 1 … 2 … [2] (d) Fig. 11.3 shows details of the caps, spacers and rod that are used to keep the three parts of the trophy held securely in position. cap Ø15 × 10 mm thick spacer Ø10 × 10 mm long screw thread rod Ø5 cap cap spacers material: aluminium Fig. 11.3 Use sketches and notes to show how the Ø5 screw thread could be cut either inside the cap or on the rod. Give details of all the tools and equipment used. [4] (e) Describe, in detail, how the words ‘D&T Award 2024’ could be engraved into the surface of the acrylic using CAD / CAM. … … … … … … [4] (f) Use sketches and notes to show a design for a base onto which the trophy could be mounted. Give details of all materials and constructions used. [4] (g) Explain why mahogany could be considered the most sustainable of the three materials used for the trophy. … … … [2]

25 marks

Mark scheme: 11(a) Any two specification points: attractive, represents D&T ‘theme’, stable as a freestanding award, title of award bold and clear, no sharp edges, fit in a person’s hand, colourful [2x1] 2 Accept any other valid points Do not accept lightweight. Do not accept durable. 11(b)(i) Speed, accuracy, easy to mark out ‘unusual’ shapes [1] 1 Accept any other valid benefits 11(b)(ii) Cut out acrylic and mahogany: Hegner saw, scroll saw, band saw, coping saw [1] Held securely: use of woodworkers, engineers vice, G cramp [1] Edges made smooth: combination of files, glasspaper, wet and dry [silicon carbide] paper [1] Quality of communication: [1] 4 Award 1 mark for ‘Held securely’ if Hegner saw, scroll saw, band saw is used to cut as this method is held by hands and is not clamped in position. 11(b)(iii) Materials that are prepared for but do not require an applied finish [1] Their appearance is enhanced by cleaning and polishing [1] 2 11(c) To prevent the sheet from ‘snagging’, spinning and cracking To prevent the underside of the sheet from splintering as the drill passes through the sheet To ensure that the hole is drilled in the correct position, accurate [2x1] 2 Accept references to personal safety Question Answer Marks Guidance 11(d) Both the cap and the rod: held in a vice [1] Die or tap named [1] Die or tap drawn [1] Technique used to cut threads [1] 4 Use of a centre lathe named only [1 mark] 11(e) Any four stages: design letters using software, transfer data to CNC machine, set up acrylic work piece in machine, set tool parameters to engrave letters [4x1] 4 Accept any valid stages. Accept imbalance between CAD and CAM. Do not reward laser cutter ‘on its own’. 11(f) Practical idea [1] Constructional details: making the ‘stand’ + joining the trophy to it [0–2] Named materials appropriate [1] 4 11(g) Mahogany trees can be replaced/replanted [1] Brass and acrylic are finite resources [1] 2

This question in 0445/33 May/June 2024

Q406 · An incomplete design for a bird feeder made from 1.5 mm thick mild steel sheet 0445/33 May/June 2024

12 Fig. 12.1 shows an incomplete design for a bird feeder made from 1.5 mm thick mild steel sheet. 30 150 perch base Fig. 12.1 (a) Mild steel is a ferrous metal. State what is meant by the term ‘ferrous metal’. … [1] (b) Fig. 12.2 shows a screenshot of part of the bird feeder designed using CAD. Fig. 12.2 State two advantages of on-screen modelling of the bird feeder rather than making a card model. 1 … 2 … [2] (c) Fig. 12.3 shows the development (net) of the bird feeder marked out on 1.5 mm thick mild steel sheet. 150 80 120 30 15 15 70 base 100 front flap bend lines waste Fig. 12.3 (i) Fig. 12.4 shows two tools, A and B, that could be used to cut out the waste metal. A B Fig. 12.4 Name tools A and B. A … B … [2] (ii) Fig. 12.5 shows part of a guillotine that could also be used to cut sheet metal. Fig. 12.5 Explain why the guillotine shown in Fig. 12.5 would only be partly successful in cutting out the waste metal in the development (net) of the bird feeder. … … … [2] (iii) Use sketches and notes to show how the development (net) could be bent to the shape of the bird feeder shown in Fig. 12.1. Name all the tools and equipment used to produce the shape. [5] (d) Fig. 12.6 shows the perch that will be joined to the bird feeder by means of a screw threaded mild steel rod and nut. Fig. 12.7 shows the end of the mild steel rod before the screw thread is cut. nut screw thread chamfer perch Ø8 mild steel rod Fig. 12.6 Fig. 12.7 (i) State the purpose of the chamfer on the end of the Ø8 mild steel rod. … [1] (ii) State the purpose of applying cutting compound (grease) to the screw cutting tool. … [1] (e) Fig. 12.8 shows part of a Ø25 mild steel tube that will be fixed into the ground and joined to the base of the bird feeder. Additional materials are needed to join the Ø25 mild steel tube permanently to the base of the bird feeder. base Ø25 mild steel tube Fig. 12.8 Use sketches and notes to show how additional materials and constructions could be used to join the Ø25 mild steel tube permanently to the base of the bird feeder. [6] (f) Fig. 12.9 shows a plastic tray that will fit inside the base of the bird feeder. 20 140 60 Fig. 12.9 Use sketches and notes to show how the plastic tray could be made. Name the type of plastic used and show the method of construction. [5]

25 marks

Mark scheme: 12(a) Metal that contains iron 1 12(b) Any two advantages: variety of editing tools available, speed of edit, more realistic image, files saved/shared electronically, more precise, transfer data to CAM, less waste of resources [2x1] 2 Accept any other valid advantages Do not accept quicker, easier 12(c)(i) A hacksaw [1] B tin snips, snips, shears [1] 2 12(c)(ii) Guillotine is limited to straight cuts [1] Not be able to cut diagonal lines or into corners without damaging the material [1] 2 Question Answer Marks Guidance 12(c)(iii) Use of tools & equipment including: former, vice, soft jaws, clamp, mallet, hammer + scrap wood [3x1] Technical accuracy of named tools + equipment used [1] Quality of communication [1] 5 Accept any other correctly named tools or equipment 12(d)(i) Chamfer makes it easier for the cutting tool to start cutting the thread [1] 1 12(d)(ii) Grease lubricates the cutting tool to make it easier to cut the mild steel rod [1] 1 12(e) Practical idea: Some form of plate/bracket [0–2] Attached to underside of base of bird feeder [0–2] Attached to top of Ø25 mild steel tube [0–2] 6 Award 0 marks if no additional materials are shown. Accept use of nuts & bolts or screws: award 1 mark maximum for each of the ‘headings’ in the answer column. 12(f) Five specific stages in the manufacture of the tray [5x1] 5 Tray can be vacuum formed or fabricated after sides and base are cut from acrylic sheet or acrylic development [net] is cut out and bent to shape.

This question in 0445/33 May/June 2024

Q407 · A design for a stand for a hot melt glue gun 0445/33 May/June 2024

13 Fig. 13.1 shows a design for a stand for a hot melt glue gun. The stand is made from plywood and a batch of 12 stands will be produced in a school workshop. support 9 mm thick position for handle Ø30 × 5 mm deep base 12 mm thick drip tray 200 70 Fig. 13.1 (a) State two specification points a designer would have considered when designing the hot melt glue gun stand. 1 … 2 … [2] (b) (i) Plywood is a manufactured board. Explain what is meant by the term ‘manufactured board’. … … … [2] (ii) Name a different manufactured board that would be suitable for the glue gun stand. … [1] (iii) Give two advantages of making the glue gun stand from plywood rather than using hardwood. 1 … 2 … [2] (c) Fig. 13.2 shows a drill bit that could be used to drill the Ø30 hole in the plywood base. Fig. 13.2 (i) Name the type of drill bit shown in Fig. 13.2. … [1] (ii) State two checks that should be made before switching on the drilling machine to drill the Ø30 hole in the plywood base. 1 … 2 … [2] (d) Fig. 13.3 shows the waste that needs to be removed to produce the shape of the support. 15 waste 25 R15 9 mm thick 70 Fig. 13.3 Use sketches and notes to show how the waste could be removed to produce the shape. Name all the tools and equipment used. [4] (e) A batch of 12 stands will be made in a school workshop Fig. 13.4 shows details of the dowel joint used to join the support to the base of the glue gun stand. The support has been strengthened by a softwood block glued to the support. 9 15 30 softwood block Ø5 dowel 70 Fig. 13.4 (i) Use sketches and notes to show how the holes for the dowels could be drilled accurately in the bases without the need for marking out. [4]

18 marks

Mark scheme: 13(a) Any two specification points: gun must sit safely in stand, stand must be stable, made from durable material not affected by heat from gun, heat resistant, safe in use [2x1] Do not accept easy to clean or reference to aesthetics/appearance 13(b)(i) Wood-based material made by compressing and bonding thin sheets of wood, pulp or particles with an adhesive [1] 2 Accept reference to use of ‘waste’ materials 13(b)(ii) MDF 1 Do not accept chipboard, blockboard Question Answer Marks Guidance 13(b)(iii) Any two advantages: more stable, less likely to shrink or warp, cheaper, no grain direction to consider [2x1] 2 Accept any other valid advantages Do not accept easier to work, lighter in weight 13(c)(i) Forstner, saw tooth 1 13(c)(ii) Work piece secure, guard in position, drill tight in chuck, chuck key removed, correct speed for drill, set depth gauge to 5 mm[2x1] 2 Accept any other valid checks Not PPE 13(d) Workpiece held securely [at any stage] [1] Use of Ø30 drill bit [1] Saw down straight lines into hole [1] Use of files/glasspaper to make sawn edges smooth [1] 4 Award maximum 3 marks if hole is not drilled 13(e)(i) Drilling jig: Metal ‘plate’ or sheet [template] with 2 holes drilled in correct position [1] Fits on top of plywood base [1] Jig secured + 1 ‘location’ [1] Jig secured + 2 ‘locations’ [1] 4 Award marks for any practical method that gives accurate positions 13(e)(ii) Saw cut to guide saw blade or 15 mm measurement marked on jig [1] Dowel held securely while cut to length [1] Jig held securely in vice or clamp [1] 3 13(f) Some form of container, block, bracket, grooves to fit into or onto the stand [0–2] Added details [1] Appropriately named materials [1] 4

This question in 0445/33 May/June 2024

Q408 · The label from a box of wood screws 0445/31 Oct/Nov 2024

1 Fig. 1.1 shows the label from a box of wood screws. B A 5.0 x 40mm 5.0 x 40mm 200 200 C Fig. 1.1 State what is meant by each item labelled A, B and C. A … B … C … [3]

3 marks

Mark scheme: Question Answer Marks Guidance 1 A diameter [gauge] of screw [1] 3 Not width of screw, height, type of screw B length of screw [1] C type of head [1]

This question in 0445/31 Oct/Nov 2024

Q409 · A block of softwood 20 mm thick 0445/31 Oct/Nov 2024

3 Fig. 3.1 shows a block of softwood 20 mm thick. Fig. 3.1 Draw a groove on the softwood block shown in Fig. 3.1. [2]

2 marks

Mark scheme: 3 Recognised groove drawn [1] 2 Housing across grain = [1] Groove drawn along the grain [1] Groove in end grain=1 ‘Stopped’ groove =1

This question in 0445/31 Oct/Nov 2024

Q410 · A mobile phone holder made from aluminium 0445/31 Oct/Nov 2024

4 Fig. 4.1 shows a mobile phone holder made from aluminium. Fig. 4.1 Identify three design features of the mobile phone holder shown in Fig. 4.1. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 4 Any 3 features such as: attractive appearance, easy to 3 Accept any other valid features clean, compact design, good use of material, holds phone Accept one-word answers; e.g. stable, portable, attractive safely, wide base for stability, gap for charger cable, pad on back to protect surface, portable, ergonomic viewing, lightweight [3  1]

This question in 0445/31 Oct/Nov 2024

Q411 · A sign holder made from 1.5 mm thick mild steel sheet 0445/31 Oct/Nov 2024

5 Fig. 5.1 shows a sign holder made from 1.5 mm thick mild steel sheet. 15 80 120 20 Fig. 5.1 Use sketches and notes to show how a batch of ten identical sign holders could be produced in a school workshop. Name all the tools and equipment used. [4]

4 marks

Mark scheme: 5 Use of a former [1] 4 Accept folding bars/bending irons as a former Use of mallet or hammer [1] Do not reward marking/cutting out & use of heat Held securely [1] Quality of communication (sketches and notes) [1]

This question in 0445/31 Oct/Nov 2024

Q412 · A split pattern made of wood 0445/31 Oct/Nov 2024

6 Fig. 6.1 shows a split pattern made of wood. The split pattern will be used to make an aluminium handle for a hacksaw. Fig. 6.1 Name the process that will be used to make the hacksaw handle using the split pattern. … [1]

1 marks

Mark scheme: 6 Sand casting, casting 1

This question in 0445/31 Oct/Nov 2024

Q413 · A dish that has been shaped from thin copper sheet and a process that is carried out… 0445/31 Oct/Nov 2024

7 Fig. 7.1 shows a dish that has been shaped from thin copper sheet and a process that is carried out during its manufacture. Fig. 7.1 (a) Name the process shown in Fig. 7.1. … [1] (b) Give two reasons why the process is carried out on the copper sheet. 1 … 2 … [2]

3 marks

Mark scheme: 7(a) Planishing 1 7(b) To induce hardness into the metal to prevent deformation [1] 2 Accept ‘smooth out imperfections’ To give an attractive appearance [1] Accept ‘strengthens the copper sheet’

This question in 0445/31 Oct/Nov 2024

Q414 · Two lengths of softwood glued together 0445/31 Oct/Nov 2024

9 Fig. 9.1 shows two lengths of softwood glued together. 40 × 40 Fig. 9.1 Add sketches and notes to Fig. 9.1 to show how the joint could be strengthened. State how any additional materials are attached to the softwood. [3]

3 marks

Mark scheme: 9 Blocks or brackets added to the 2 corners [0 – 2] 3 The joint must remain assembled Both corners/faces must be strengthened OR One face strengthened = [1] Accept nails or screws inserted underneath or at an angle ‘Plates’ attached to the front and back faces [0 – 2] above =1 Method of attaching additional materials [1]

This question in 0445/31 Oct/Nov 2024

Q415 · A condiment holder that has been designed and made by a group of Design & Technology… 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

Q416 · Views of an incomplete design for a freestanding clock made from acrylic 0445/31 Oct/Nov 2024

12 Fig. 12.1 shows views of an incomplete design for a freestanding clock made from acrylic. The clock mechanism and the clock hands have been removed. support 40 × 5 mm thick clock face Ø200 × 5 mm thick 12 12 3 9 3 9 6 6 base Ø200 × 20 mm deep Fig. 12.1 (a) Table 12.1 shows a list of statements. Complete Table 12.1 by indicating with a tick (3) the two statements that apply to acrylic. Table 12.1 Statement Tick (3) Impact resistant A thermosetting plastic Scratch resistant Can be self-finished Does not splinter [2] (b) The support shown in Fig. 12.1 is made by bending a strip of acrylic 500 × 40 × 5 to shape. The strip will be finished to a high quality before it is bent to shape. (i) Complete Table 12.2 by stating three processes that need to be carried out to the edges of the strip to produce a high-quality finish. Table 12.2 Stage Processes 1 2 3 [3] (ii) Use sketches and notes to show how the 500 mm length of acrylic could be bent to the shape of the support. Name all the tools and equipment used. [4] (c) Fig. 12.2 shows the clock face marked out on a sheet of 5 mm thick acrylic. centre for hole for clock mechanism clock face Ø200 waste Fig. 12.2 Give the name of each tool that could be used when carrying out the following processes to produce the clock face: (i) marking out the circular shape. … [1] (ii) cutting out the circular shape. … [1] (d) A Ø5 hole will be drilled through the clock face shown in Fig. 12.2 for the clock mechanism. State two precautions that must be taken to prevent damage to the clock face when drilling the hole. 1 … 2 … [2] (e) The numbers 3, 6, 9 and 12 will be designed using CAD. Describe how CAM could be used to produce the numbers 3, 6, 9 and 12 on the clock face. … … … … … [4] (f) The base of the clock will be vacuum formed. Fig. 12.3 shows the mould for the base of the clock positioned on the platen, ready to be vacuum formed. heater clamp acrylic sheet mould platen vacuum pump Fig. 12.3 Complete Table 12.3 by stating four additional processes that need to be carried out to vacuum form the base. Table 12.3 Stage Processes 1 Turn the heater on 2 3 4 5 [4] (g) Fig. 12.4 shows views of the side and back of the clock. The clock face will be joined to the base and support using two Ø5 acrylic rods labelled A and B. support rod Ø5 A clock face 5 mm thick clock mechanism B rod Ø5 base Fig. 12.4 Use sketches and notes to show how the clock face could be joined to the Ø5 acrylic rods. Give details of all materials and constructions used. [4]

25 marks

Mark scheme: 12(a) Impact resistant, can be self-finished [2  1] 2 Award 0 if more than 2 statements are ticked 12(b)(i) (Draw) file edges, use of ‘scraper’, use of wet and dry 3 Not abrasive paper [silicon carbide] paper, various grades, apply polishing Accept ‘polish compound to mop and buff to high quality [3  1] 12(b)(ii) Use of an oven to heat and soften acrylic [1] 4 Use of a former [1] Drape softened acrylic around former [1] Method of retention while acrylic cools [1] 12(c)(i) Dividers 1 Accept use of compass with chinagraph pencil or marker pen 12(c)(ii) Coping, Hegner, scroll, band saws 1 Accept use of laser cutter, CNC router 12(d) High drill speed, acrylic clamped, sacrificial board under 2 Accept any other valid precautions acrylic, apply tape to surface [2  1] 12(e) 2 methods: engraved or applied 4 Accept any valid stages in processes Accept ONE stage from CAD: ‘transfer of data’ to CNC Engraved: transfer file data to CNC machine, set up acrylic machine in machine (laser, router/engraver), set tool parameters, start machine [4  1] OR Applied: transfer file data to CNC machine (CAMM vinyl cutter), set up vinyl in machine, set tool parameters, start machine, cut out numbers, peel off and apply numbers to clock face [4  1] 12(f) Stages: heat up plastic until pliable, raise platen, turn on 4 Do not reward any stages before heating vacuum pump, switch off pump, lower platen, remove Accept any other valid stages in process heater, remove moulded plastic, leave to cool [4  1] 12(g) Some form of blocks with Ø5 holes drilled or brackets [0 – 2] 4 Do not reward use of nuts and bolts/screws through clock Method of joining to clock face [1] face for ‘method of joining to clock face’ Appropriate materials [1]

This question in 0445/31 Oct/Nov 2024

Q417 · A photo frame made of hardwood supported on a stand made from mild steel 0445/31 Oct/Nov 2024

13 Fig. 13.1 shows a photo frame made of hardwood supported on a stand made from mild steel. frame 30 × 15 hardwood stand 5 × 5 mild steel 210 160 Fig. 13.1 (a) Circle , from the list below, two hardwoods that could be used to make the photo frame. cedar parana pine beech whitewood oak [2] (b) Fig. 13.2 shows one of the sides of the frame with mitres marked out on each end. 15 waste 160 30 Fig. 13.2 Fig. 13.3 shows two tools, A and B, that could be used to mark out the mitres. A B Fig. 13.3 (i) State the name of tool A and tool B. A … B … [2] (ii) Use sketches and notes to show how the waste shown in Fig. 13.2 could be removed and the surfaces made flat to produce an accurate mitre joint. Name all the tools and equipment used. [3] (c) Fig. 13.4 shows the sides of the frame glued together and held in place using string. (i) Add sketches and notes to Fig. 13.5 to show how the string could be tensioned to hold the sides of the frame in place. string Fig. 13.4 Fig. 13.5 [2] (ii) Fig. 13.6 shows one corner of the photo frame. Fig. 13.6 Add sketches and notes to Fig. 13.6 to show how the mitre joint could be strengthened. The method must make the joint look attractive. [3]

12 marks

Mark scheme: 13(a) Beech, oak 2 13(b)(i) A sliding bevel [1] 2 B mitre square [1] 13(b)(ii) Mitres sawn off [1] 3 Use of sanding disc, linisher, band facer ONLY award max.1 Sawn ends flat: use of sanding disc, linisher, band facer or mark plane [1] Available saws: coping, tenon, band, Hegner, scroll, jig, Additional sketch to show tools/equipment [1] mitre box [with saw] Do not reward use of files, glasspaper 13(c)(i) Principle: insert dowel or ‘strips’ of wood between the frame 2 and string [1] 2 inserts at each corner [1] 13(c)(ii) Methods: ‘feather’ of veneer, saw cut across corner and 3 Award 0–3 for practical idea with additional notes to (contrasting coloured) wood inserted, ‘key’ inserted across describe method clearly corner on face of mitre joint 13(d)(i) Scriber [1] 2 Do not accept ‘square’ Engineer’s try square, engineer’s square, try square [1] 13(d)(ii) Hold leg in vice [1] 4 Hacksaw to saw down vertical sides of recess [1] File out waste [1] All 4 legs either marked out or cut out together [1] 13(e) Emery cloth to clean the joint before brazing [1] 4 Accept ‘to clean off rust’ Flux to prevent oxidisation and help spelter to flow [1] Blow torch to heat up the joint [1] Accept ‘to heat up brazing rod’ Brazing rod used to make the permanent joint [1] 13(f) Practical idea: add a base on which legs could be attached, 3 Accept any valid practical idea add 2 feet to the bottom of the legs [0 – 2] Additional notes to explain idea [1]

This question in 0445/31 Oct/Nov 2024

Q418 · Carbon fibre reinforced plastic (CFRP) is used to build many different aircraft parts 0445/32 Oct/Nov 2024

1 Carbon fibre reinforced plastic (CFRP) is used to build many different aircraft parts. State two benefits of using carbon fibre reinforced plastic (CFRP) to build aircraft parts. 1 … 2 … [2]

2 marks

Mark scheme: Question Answer Marks Guidance 1 Any 2 benefits such as: lightweight, tough, corrosion resistance, durable, 2 Accept any valid benefits weather / water resistant, low density, good strength-weight ratio, Not strong, malleable impact / shock resistant, shaped easily, stronger, lasts longer, does not conduct electricity [2  1]

This question in 0445/32 Oct/Nov 2024

Q419 · Pipes used for plumbing being joined together 0445/32 Oct/Nov 2024

2 Fig. 2.1 shows pipes used for plumbing being joined together. blowtorch metal pipe Fig. 2.1 (a) Name the metal used for the pipes. … [1] (b) Name the method used to join the metal pipes together. … [1]

2 marks

Mark scheme: 2(a) Copper 1 2(b) (soft) soldering 1 Not hard soldering

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Q420 · A through mortise and tenon joint 0445/32 Oct/Nov 2024

3 Fig. 3.1 shows a through mortise and tenon joint. Fig. 3.1 Add sketches and notes to Fig. 3.1 to show how the joint could be prevented from being pulled apart in the directio the arrow shown. [3]

3 marks

Mark scheme: 3 Some sort of wedge inserted into tenon, dowel, screw/s, nail/s inserted or 3 Max 1 glue only, if gluing is only method through edge of upright stated Max 2 if nail, pin, screw, dowel etc. is not long enough to go through edge and tenon Max 2 if nail, pin, screw, dowel etc. is not flush against upright Max 3 if nail, pin, screw, dowel etc. is shown vertically through tenon or horizontally through edge Max 3 for use of wooden blocks / KD fittings, brackets in either the front of or behind the vertical piece

This question in 0445/32 Oct/Nov 2024

Q421 · Three products made of different materials 0445/32 Oct/Nov 2024

4 Fig. 4.1 shows three products made of different materials. mild steel wheelbarrow body silver pendant brass tap Fig. 4.1 State a suitable different finish for each product: mild steel wheelbarrow body … silver pendant … brass tap … [3]

3 marks

Mark scheme: 4 Wheelbarrow body: zinc, galvanised, painted [1] 3 Silver pendant: self-finished, polished, buffing [1] Brass tap: chrome plated, electroplated [1]

This question in 0445/32 Oct/Nov 2024

Q422 · 4 mm thick acrylic sheet that has been shaped 0445/32 Oct/Nov 2024

5 Fig. 5.1 shows 4 mm thick acrylic sheet that has been shaped. 130 40 Fig. 5.1 Use sketches and notes to show how the curved shape could be produced. [3]

3 marks

Mark scheme: 5 Plastic heated [1] 3 Use of former or bending jig [1] Shape retained while cooling [1]

This question in 0445/32 Oct/Nov 2024

Q423 · Part of a length of mild steel square tube and an engineer’s vice 0445/32 Oct/Nov 2024

7 Fig. 7.1 shows part of a length of mild steel square tube and an engineer’s vice. A hacksaw will be used to cut the tube to make a 90° bend. area to be cut out tube 20 × 20 Fig. 7.1 Draw on Fig. 7.1 to show how the mild steel tube would be held in the engineer’s vice while the saw cuts are made. [2]

2 marks

Mark scheme: 7 Steel tube shown in vice at 45º [1] 2 Correct height to make saw cut [1]

This question in 0445/32 Oct/Nov 2024

Q424 · A body shell for a car made from glass reinforced plastic (GRP) 0445/32 Oct/Nov 2024

8 Fig. 8.1 shows a body shell for a car made from glass reinforced plastic (GRP). Fig. 8.1 Explain what is meant by the term ‘glass reinforced plastic’ (GRP). … … … [2]

2 marks

Mark scheme: 8 Glass fibre mat [1] 2 (Polyester) resin used [1]

This question in 0445/32 Oct/Nov 2024

Q425 · Two hardwood stools, A and B 0445/32 Oct/Nov 2024

10 Fig. 10.1 shows two hardwood stools, A and B. Stool A has been fabricated and stool B has been made by steam bending. A B Fig. 10.1 Explain why stool B would be cheaper to mass produce than stool A. … … … [2]

2 marks

Mark scheme: 10 B the manufacturing processes required could be carried out more quickly 2 than stool A which requires fabrication, less materials used More manufacturing time increases the cost of the stool [0 – 2]

This question in 0445/32 Oct/Nov 2024

Q426 · An incomplete design for a tablet stand made of hardwood 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

Q427 · An incomplete design for a coat hook used by children 0445/32 Oct/Nov 2024

12 Fig. 12.1 shows an incomplete design for a coat hook used by children. The coat hook is made from 2 mm thick mild steel sheet. Fig. 12.1 (a) Fig. 12.2 shows a card template of the coat hook shape glued onto mild steel sheet. The waste between the legs, labelled A, will be removed by drilling a hole and then using a saw to cut out the remaining sheet metal. 300 B 200 A A centre for Ø15 hole Fig. 12.2 (i) State one reason why a centre punch would be used to mark the centre where the holes will be drilled. … [1] (ii) State one reason why a Ø6 pilot hole would be drilled before using a Ø15 drill. … [1] (iii) Name a suitable saw that could be used to remove the remaining waste after the Ø15 hole has been drilled. … [1] (iv) Name a suitable tool that could be used to cut out the curved shapes of the coat hook. … [1] (v) Name a suitable type of file that could be used to make the curved edge shown at B in Fig. 12.2 smooth. … [1] (b) Fig. 12.3 shows details of the bend that needs to be made to the legs. 15 Ø15 Fig. 12.3 Use sketches and notes to show how one of the legs could be bent to shape. Name all the tools and equipment used. [4] (c) Fig. 12.4 shows a screenshot of the outline shape of the coat hook drawn using CAD software. When using CAD, changes to a design can be made quickly and accurately. Fig. 12.4 (i) Give three additional ways the CAD drawing could be modified. 1 Apply different colours to the outline shape 2 … 3 … 4 … [3] (ii) Give two benefits of using CAM to batch produce the coat hooks. 1 … 2 … [2] (d) Fig. 12.5 shows the coat hook that will be fixed to the wall using two screws. gap wall screw wall coat hook position screw of screws Fig. 12.5 Use sketches and notes to show a design for a bracket that will be attached to the back of the coat hook. The coat hook and bracket will then be fixed to the wall by the screws. Give details of all materials and constructions used. [6] (e) Paint could be applied to the coat hook to improve the appearance of the mild steel sheet. (i) Name a suitable finish, other than paint, that could be applied to the mild steel sheet. … [1] (ii) Describe how the surfaces of the mild steel sheet could be prepared to take an applied finish. … … … [2] (f) The coat hook could be made from aluminium sheet. Give two advantages of using aluminium rather than mild steel for the coat hook. 1 … 2 … [2]

25 marks

Mark scheme: 12(a)(i) To provide a guide for the tip of the drill, to prevent the drill from slipping 1 Accept any valid reasons. Not accurate 12(a)(ii) To make it easier for the Ø15 drill to produce a hole, provide a guide for the 1 Ø15 drill 12(a)(iii) Hacksaw, junior hacksaw, Hegner saw, band saw, piercing saw 1 Hegner and band saws must have metal cutting blades stated for marks 12(a)(iv) Tin snips, Hegner saw, band saw, piercing saw 1 Hegner and band saws must have metal cutting blades stated for marks 12(a)(v) Half round, round or rat tail 1 Not rounded 12(b) Sketches showing use of a former, held in a vice, mallet or hammer [3  1] 4 Do not reward heating of metal sheet Quality / clarity of communication [1] 12(c)(i) Any 3 modifications such as: enlarge view, erase / delete, fill colour, add 3 Accept any other valid modifications texture, 3D view [3  1] 12(c)(ii) Any 2 benefits such as: repetitive accuracy, speed, consistency of product, 2 Accept any other valid benefits machines can run constantly on repetitive tasks 12(d) ‘Bracket’ attached to back of coat rack [0 – 2] 6 Metal to metal bracket: soldering / brazing Allowance in bracket to fit over or on the 2 screws [0 – 2] Metal to wooden bracket: epoxy resin Named materials and constructions [0 – 2] 12(e)(i) Dip coated / plastic / powder coated finish, electroplated chrome, zinc, 1 galvanising, oil blue finish 12(e)(ii) Clean the metal [1] 2 Accept use of alcohol to degrease Method of cleaning metal: degrease, use different grades of emery cloth, wet and dry (silicon carbide) paper, steel / wire wool [1] 12(f) Any 2 advantages such as: can be self-finished, anodised, does not corrode, 2 Accept any other valid advantages easier to bend, easier to work [2  1] Not lightweight

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Q428 · An incomplete design for a case to store and carry a selection of artist’s materials and… 0445/32 Oct/Nov 2024

13 Fig. 13.1 shows an incomplete design for a case to store and carry a selection of artist’s materials and equipment. lid 4 mm thick manufactured board side 12 mm thick hardwood partition 9 mm thick hardwood 50 lift-out tray 2 mm thick plastic 330 240 Fig. 13.1 (a) (i) Name a suitable hardwood for the sides of the case. … [1] (ii) Name a suitable manufactured board for the lid. … [1] (b) The sides of the case will be joined at each corner by means of a half lap joint. Add to Fig. 13.2 to show an exploded view of a half lap joint. Fig. 13.2 [2] (c) Fig. 13.3 shows details of the lift-out tray. The tray is made of a thermoplastic and produced by vacuum forming. 100 9 compartments 25 mm wide × 10 mm deep 240 lipping 7.5 mm wide Fig. 13.3 (i) Use sketches and notes to show a design for a mould that could be used to vacuum form the lift-out tray. [4] (ii) Circle , from the list below, the most suitable material from which to make the mould. hardboard pine MDF chipboard oak [1] (d) Fig. 13.4 shows details of an artist’s palette that will be stored inside the lid of the case. The palette is made from acrylic. R10 Ø40 R50 200 4 mm thick 280 Fig. 13.4 (i) Use sketches and notes to show how the outline shape of the palette and the Ø40 hole could be cut out and the edges made smooth. Name all the tools and equipment used. [4]

13 marks

Mark scheme: 13(a)(i) Wide variety of suitable hardwoods available 1 Internet search for obscure named hardwoods 13(a)(ii) Plywood, hardboard, MDF 1 13(b) Half lap cut out of one piece [1] 2 Do accept assembled half lap joints End completed on second piece [1] 13(c)(i) Base on which ‘strips’ will be attached [1] 4 Shaped strips [1] Accurate sizes / proportions [1] Quality of communication / technical accuracy [1] 13(c)(ii) MDF 1 13(d)(i) Use of coping, Hegner, scroll, band saws to cut out shape [1] 4 Stage 1 reward use of laser cutter: Use of files, wet and dry [silicon carbide] paper to make edges smooth [1] named only for 1 mark max. Drill ‘pilot’ hole and insert blade of saw to cut out hole, use of hole saw [1] Details required to access max. 4 marks Stage 2 reward only one from the list Accuracy of named tools and equipment [1] Stage 3 do not reward router to cut hole Award 1 mark if most tools and equipment are named correctly 13(d)(ii) Clamp acrylic sheet securely to drill table or any flat surface [1] 2 Sacrificial board positioned under acrylic sheet [1] 13(d)(iii) Practical idea: use of ‘clips’, ‘turn buttons’ to secure palette [0–2] 3 Accept use of Velcro, magnets, rubber Materials / fittings named [1] bands, fabric pockets 13(e) Practical design of handle [0 – 2] 4 Award 1 mark only if handle is attached to Attached to case [1] lid, not side of case Named material appropriate [1] 13(f) Part A shown in correct position on lid [1] 3 Award 1 mark for accuracy / alignment Part B shown in correct position on base [1] even if parts A and B are upside down on Overall accuracy / alignment [1] the case

This question in 0445/32 Oct/Nov 2024

Q429 · The label from a box of wood screws 0445/33 Oct/Nov 2024

1 Fig. 1.1 shows the label from a box of wood screws. B A 5.0 x 40mm 5.0 x 40mm 200 200 C Fig. 1.1 State what is meant by each item labelled A, B and C. A … B … C … [3]

3 marks

Mark scheme: Question Answer Marks Guidance 1 A diameter [gauge] of screw [1] 3 Not width of screw, height, type of screw B length of screw [1] C type of head [1]

This question in 0445/33 Oct/Nov 2024

Q430 · A block of softwood 20 mm thick 0445/33 Oct/Nov 2024

3 Fig. 3.1 shows a block of softwood 20 mm thick. Fig. 3.1 Draw a groove on the softwood block shown in Fig. 3.1. [2]

2 marks

Mark scheme: 3 Recognised groove drawn [1] 2 Housing across grain = [1] Groove drawn along the grain [1] Groove in end grain=1 ‘Stopped’ groove =1

This question in 0445/33 Oct/Nov 2024

Q431 · A mobile phone holder made from aluminium 0445/33 Oct/Nov 2024

4 Fig. 4.1 shows a mobile phone holder made from aluminium. Fig. 4.1 Identify three design features of the mobile phone holder shown in Fig. 4.1. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 4 Any 3 features such as: attractive appearance, easy to 3 Accept any other valid features clean, compact design, good use of material, holds phone Accept one-word answers; e.g. stable, portable, attractive safely, wide base for stability, gap for charger cable, pad on back to protect surface, portable, ergonomic viewing, lightweight [3  1]

This question in 0445/33 Oct/Nov 2024

Q432 · A sign holder made from 1.5 mm thick mild steel sheet 0445/33 Oct/Nov 2024

5 Fig. 5.1 shows a sign holder made from 1.5 mm thick mild steel sheet. 15 80 120 20 Fig. 5.1 Use sketches and notes to show how a batch of ten identical sign holders could be produced in a school workshop. Name all the tools and equipment used. [4]

4 marks

Mark scheme: 5 Use of a former [1] 4 Accept folding bars/bending irons as a former Use of mallet or hammer [1] Do not reward marking/cutting out & use of heat Held securely [1] Quality of communication (sketches and notes) [1]

This question in 0445/33 Oct/Nov 2024

Q433 · A split pattern made of wood 0445/33 Oct/Nov 2024

6 Fig. 6.1 shows a split pattern made of wood. The split pattern will be used to make an aluminium handle for a hacksaw. Fig. 6.1 Name the process that will be used to make the hacksaw handle using the split pattern. … [1]

1 marks

Mark scheme: 6 Sand casting, casting 1

This question in 0445/33 Oct/Nov 2024

Q434 · A dish that has been shaped from thin copper sheet and a process that is carried out… 0445/33 Oct/Nov 2024

7 Fig. 7.1 shows a dish that has been shaped from thin copper sheet and a process that is carried out during its manufacture. Fig. 7.1 (a) Name the process shown in Fig. 7.1. … [1] (b) Give two reasons why the process is carried out on the copper sheet. 1 … 2 … [2]

3 marks

Mark scheme: 7(a) Planishing 1 7(b) To induce hardness into the metal to prevent deformation [1] 2 Accept ‘smooth out imperfections’ To give an attractive appearance [1] Accept ‘strengthens the copper sheet’

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Q435 · Two lengths of softwood glued together 0445/33 Oct/Nov 2024

9 Fig. 9.1 shows two lengths of softwood glued together. 40 × 40 Fig. 9.1 Add sketches and notes to Fig. 9.1 to show how the joint could be strengthened. State how any additional materials are attached to the softwood. [3]

3 marks

Mark scheme: 9 Blocks or brackets added to the 2 corners [0 – 2] 3 The joint must remain assembled Both corners/faces must be strengthened OR One face strengthened = [1] Accept nails or screws inserted underneath or at an angle ‘Plates’ attached to the front and back faces [0 – 2] above =1 Method of attaching additional materials [1]

This question in 0445/33 Oct/Nov 2024

Q436 · A condiment holder that has been designed and made by a group of Design & Technology… 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

Q437 · Views of an incomplete design for a freestanding clock made from acrylic 0445/33 Oct/Nov 2024

12 Fig. 12.1 shows views of an incomplete design for a freestanding clock made from acrylic. The clock mechanism and the clock hands have been removed. support 40 × 5 mm thick clock face Ø200 × 5 mm thick 12 12 3 9 3 9 6 6 base Ø200 × 20 mm deep Fig. 12.1 (a) Table 12.1 shows a list of statements. Complete Table 12.1 by indicating with a tick (3) the two statements that apply to acrylic. Table 12.1 Statement Tick (3) Impact resistant A thermosetting plastic Scratch resistant Can be self-finished Does not splinter [2] (b) The support shown in Fig. 12.1 is made by bending a strip of acrylic 500 × 40 × 5 to shape. The strip will be finished to a high quality before it is bent to shape. (i) Complete Table 12.2 by stating three processes that need to be carried out to the edges of the strip to produce a high-quality finish. Table 12.2 Stage Processes 1 2 3 [3] (ii) Use sketches and notes to show how the 500 mm length of acrylic could be bent to the shape of the support. Name all the tools and equipment used. [4] (c) Fig. 12.2 shows the clock face marked out on a sheet of 5 mm thick acrylic. centre for hole for clock mechanism clock face Ø200 waste Fig. 12.2 Give the name of each tool that could be used when carrying out the following processes to produce the clock face: (i) marking out the circular shape. … [1] (ii) cutting out the circular shape. … [1] (d) A Ø5 hole will be drilled through the clock face shown in Fig. 12.2 for the clock mechanism. State two precautions that must be taken to prevent damage to the clock face when drilling the hole. 1 … 2 … [2] (e) The numbers 3, 6, 9 and 12 will be designed using CAD. Describe how CAM could be used to produce the numbers 3, 6, 9 and 12 on the clock face. … … … … … [4] (f) The base of the clock will be vacuum formed. Fig. 12.3 shows the mould for the base of the clock positioned on the platen, ready to be vacuum formed. heater clamp acrylic sheet mould platen vacuum pump Fig. 12.3 Complete Table 12.3 by stating four additional processes that need to be carried out to vacuum form the base. Table 12.3 Stage Processes 1 Turn the heater on 2 3 4 5 [4] (g) Fig. 12.4 shows views of the side and back of the clock. The clock face will be joined to the base and support using two Ø5 acrylic rods labelled A and B. support rod Ø5 A clock face 5 mm thick clock mechanism B rod Ø5 base Fig. 12.4 Use sketches and notes to show how the clock face could be joined to the Ø5 acrylic rods. Give details of all materials and constructions used. [4]

25 marks

Mark scheme: 12(a) Impact resistant, can be self-finished [2  1] 2 Award 0 if more than 2 statements are ticked 12(b)(i) (Draw) file edges, use of ‘scraper’, use of wet and dry 3 Not abrasive paper [silicon carbide] paper, various grades, apply polishing Accept ‘polish compound to mop and buff to high quality [3  1] 12(b)(ii) Use of an oven to heat and soften acrylic [1] 4 Use of a former [1] Drape softened acrylic around former [1] Method of retention while acrylic cools [1] 12(c)(i) Dividers 1 Accept use of compass with chinagraph pencil or marker pen 12(c)(ii) Coping, Hegner, scroll, band saws 1 Accept use of laser cutter, CNC router 12(d) High drill speed, acrylic clamped, sacrificial board under 2 Accept any other valid precautions acrylic, apply tape to surface [2  1] 12(e) 2 methods: engraved or applied 4 Accept any valid stages in processes Accept ONE stage from CAD: ‘transfer of data’ to CNC Engraved: transfer file data to CNC machine, set up acrylic machine in machine (laser, router/engraver), set tool parameters, start machine [4  1] OR Applied: transfer file data to CNC machine (CAMM vinyl cutter), set up vinyl in machine, set tool parameters, start machine, cut out numbers, peel off and apply numbers to clock face [4  1] 12(f) Stages: heat up plastic until pliable, raise platen, turn on 4 Do not reward any stages before heating vacuum pump, switch off pump, lower platen, remove Accept any other valid stages in process heater, remove moulded plastic, leave to cool [4  1] 12(g) Some form of blocks with Ø5 holes drilled or brackets [0 – 2] 4 Do not reward use of nuts and bolts/screws through clock Method of joining to clock face [1] face for ‘method of joining to clock face’ Appropriate materials [1]

This question in 0445/33 Oct/Nov 2024

Q438 · A photo frame made of hardwood supported on a stand made from mild steel 0445/33 Oct/Nov 2024

13 Fig. 13.1 shows a photo frame made of hardwood supported on a stand made from mild steel. frame 30 × 15 hardwood stand 5 × 5 mild steel 210 160 Fig. 13.1 (a) Circle , from the list below, two hardwoods that could be used to make the photo frame. cedar parana pine beech whitewood oak [2] (b) Fig. 13.2 shows one of the sides of the frame with mitres marked out on each end. 15 waste 160 30 Fig. 13.2 Fig. 13.3 shows two tools, A and B, that could be used to mark out the mitres. A B Fig. 13.3 (i) State the name of tool A and tool B. A … B … [2] (ii) Use sketches and notes to show how the waste shown in Fig. 13.2 could be removed and the surfaces made flat to produce an accurate mitre joint. Name all the tools and equipment used. [3] (c) Fig. 13.4 shows the sides of the frame glued together and held in place using string. (i) Add sketches and notes to Fig. 13.5 to show how the string could be tensioned to hold the sides of the frame in place. string Fig. 13.4 Fig. 13.5 [2] (ii) Fig. 13.6 shows one corner of the photo frame. Fig. 13.6 Add sketches and notes to Fig. 13.6 to show how the mitre joint could be strengthened. The method must make the joint look attractive. [3]

12 marks

Mark scheme: 13(a) Beech, oak 2 13(b)(i) A sliding bevel [1] 2 B mitre square [1] 13(b)(ii) Mitres sawn off [1] 3 Use of sanding disc, linisher, band facer ONLY award max.1 Sawn ends flat: use of sanding disc, linisher, band facer or mark plane [1] Available saws: coping, tenon, band, Hegner, scroll, jig, Additional sketch to show tools/equipment [1] mitre box [with saw] Do not reward use of files, glasspaper 13(c)(i) Principle: insert dowel or ‘strips’ of wood between the frame 2 and string [1] 2 inserts at each corner [1] 13(c)(ii) Methods: ‘feather’ of veneer, saw cut across corner and 3 Award 0–3 for practical idea with additional notes to (contrasting coloured) wood inserted, ‘key’ inserted across describe method clearly corner on face of mitre joint 13(d)(i) Scriber [1] 2 Do not accept ‘square’ Engineer’s try square, engineer’s square, try square [1] 13(d)(ii) Hold leg in vice [1] 4 Hacksaw to saw down vertical sides of recess [1] File out waste [1] All 4 legs either marked out or cut out together [1] 13(e) Emery cloth to clean the joint before brazing [1] 4 Accept ‘to clean off rust’ Flux to prevent oxidisation and help spelter to flow [1] Blow torch to heat up the joint [1] Accept ‘to heat up brazing rod’ Brazing rod used to make the permanent joint [1] 13(f) Practical idea: add a base on which legs could be attached, 3 Accept any valid practical idea add 2 feet to the bottom of the legs [0 – 2] Additional notes to explain idea [1]

This question in 0445/33 Oct/Nov 2024

Q439 · Timber being seasoned naturally in the open air 0445/31 May/June 2025

1 Fig. 1.1 shows timber being seasoned naturally in the open air. roof to protect from sun and rain timber boards battens brick piers Fig. 1.1 Explain why timber needs to be seasoned. … … … [2]

2 marks

Mark scheme: Question Answer Marks Guidance 1 Trees contain moisture, timber needs to be dried, reduce 2 moisture content, prevent shrinkage, warping and rotting [2  1]

This question in 0445/31 May/June 2025

Q440 · Strips of hardwood glued and clamped together to make a chopping board 0445/31 May/June 2025

3 Fig. 3.1 shows strips of hardwood glued and clamped together to make a chopping board. chopping board hardwood strips scrap wood cramp Fig. 3.1 (a) Name the type of cramps used. … [1] (b) Give two reasons for the use of scrap wood. 1 … 2 … [2]

3 marks

Mark scheme: 3(a) Sash cramp 1 3(b) Reasons: to protect the hardwood from ‘bruising’, to 2 distribute pressure [2  1]

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Q441 · A basic design for a letter rack made from 4 mm thick acrylic 0445/31 May/June 2025

5 Fig. 5.1 shows a basic design for a letter rack made from 4 mm thick acrylic. 50 70 200 60 Fig. 5.1 (a) Draw a former that could be used when bending the acrylic to the shape of the letter rack. [2] (b) Give one advantage of using a line bender/strip heater rather than an oven to heat the acrylic so that it could be bent to shape. … … … [1]

3 marks

Mark scheme: 5(a) Former must ‘match’ shape of bends [1] 2 Accuracy and proportion [1] 5(b) Strip heater/line bender heats specific area. Oven heats 1 whole sheet.

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Question 442 0445/31 May/June 2025

7 Complete Fig. 7.1 to show a tee halving joint. Fig. 7.1 [3]

3 marks

Mark scheme: 7 Award 1 mark for each ‘halving’ shown 3 [2  1] Technical accuracy/proportion [1]

This question in 0445/31 May/June 2025

Q443 · Two office chairs, A and B 0445/31 May/June 2025

10 Fig. 10.1 shows two office chairs, A and B. A B Fig. 10.1 Identify one design feature on each chair. Chair A … [1] Chair B … [1]

2 marks

Mark scheme: 10 Chair A castors move, armrests, adjustable & padded seat 2 Accept any valid features and back [1] Chair B lightweight tube construction, minimal use of materials, fewer parts to replace, folds up [1]

This question in 0445/31 May/June 2025

Q444 · A drill rack that will be attached to the pillar of a pillar drill 0445/31 May/June 2025

11 Fig. 11.1 shows a drill rack that will be attached to the pillar of a pillar drill. The drill rack is made from 15 mm thick plywood. collar holes for drill bits 12mm deep pillar 400 140 Fig. 11.1 (a) State two specification points that a designer would need to consider when designing the drill rack. 1 … 2 … [2] (b) (i) Use sketches and notes to show the construction of plywood. [2] (ii) Explain why plywood is more suitable than solid wood for the drill rack. … … … [2] (c) Fig. 11.2 shows details of the recess and hole that need to be cut out. waste hole Ø80 collar recess 70 × 50 × 12 deep 15 mm thick Fig. 11.2 (i) Name a tool that could be used to cut out the Ø80 hole. … [1] (ii) Name a machine tool that could be used to cut out the recess. … [1] (iii) Use sketches and notes to show how the waste plywood could be removed and the edges made smooth to produce the shape of the collar. Name all the tools and equipment used. [4] (d) The holes in the rack to take the drill bits shown in Fig. 11.1 are drilled to a depth of 12 mm. Describe how the holes could be drilled to a depth of 12 mm. … … … [2] (e) Fig. 11.3 shows the scan fitting that will be used to join the collar to the drill rack when the collar is fitted around the pillar of the pillar drill. barrel nut 14 mm long screw 60 long × Ø6 mm Fig. 11.3 (i) Name the type of tool that would be used to tighten the scan fitting. … [1] (ii) Fig. 11.4 shows the positions for the scan fitting to join the collar to the drill rack. Use sketches and notes to show how the scan fitting could be used to join the collar to the drill rack. collar rack Fig. 11.4 [4] (f) Fig. 11.5 shows a pair of safety glasses that will be worn when using the pillar drill. 60 150 40 sizes of safety glasses when folded Fig. 11.5 Use sketches and notes to show a design for a container to store the safety glasses. Include the following: • a method to show how the safety glasses could be kept clean and free from dust • a method to show how the container could be fixed to a wall • details of all materials and constructions used to make the container. [6]

25 marks

Mark scheme: 11(a) 2 Specification points include: 2 Accept any valid spec. points must not interfere with operation of machine, must be secure on pillar of machine, hold different types of drill, allow for easy access, easy to adjust [2  1] 11(b)(i) Number of separate plies shown (minimum 3) [1] 2 Grain shown in opposite directions on plies [1] 11(b)(ii) Explanation: grain structure cancels out movement making 2 board stable [0 – 2] 11(c)(i) Hole saw, hole cutter, tank cutter, Forstner bit, saw tooth bit 1 11(c)(ii) Mortising machine, router 1 11(c)(iii) Saw off waste [1] 4 Coping, Hegner, scroll, band saws. jig saw Edges filed smooth [1] Hand, flat, half round files ‘Sand’ edges [1] Glasspaper, sandpaper, bobbin sander, disk sander Accuracy of named tools and equipment [1] 11(d) Depth stop can be set to 12 mm on portable, bench or 2 Accept references to milling machine setting pedestal drills Use of tape or equivalent wrapped around drill Collars can be fitted to twist drill bits set to 12 mm 11(e)(i) Allen key, hex key, hexagonal head screwdriver 1 11(e)(ii) Screw shown through collar and rack 4 [2  1] Barrel nut shown in side or top of rack [1] Quality of sketches and notes [1] 11(f) Suitable materials named [1] 6 Fixing to wall: Constructions used to make the container 2 screw holes inside box = 1, slot screws = 2 [0 – 2] 2 screw holes in ‘backboard’ (extends beyond box) = 2 Do not accept use of magnets Some sort of ‘lid’ to keep glasses clean [1] Method of fixing to wall [0 – 2]

This question in 0445/31 May/June 2025

Q445 · A child’s xylophone that could be made in a school workshop 0445/31 May/June 2025

12 Fig. 12.1 shows a child’s xylophone that could be made in a school workshop. bar 50 peg support stand 400 110 Fig. 12.1 (a) The stand is made by laminating beech veneers. Describe what is meant by the term ‘veneer’. … … [2] (b) Use sketches and notes to show how veneers could be laminated to make the shape of the stand. Give details of all the tools, materials and equipment used. [4] (c) Fig. 12.2 shows one of the bars marked out on part of a length of mild steel strip. A C B Fig. 12.2 (i) Name a tool that could be used to mark out line A. … [1] (ii) Name a tool that could be used to mark out line B. … [1] (iii) Name a tool that could be used to make an indentation in the metal at point C. … [1] (iv) Name an appropriate saw that could be used to saw off the bar to the required length along line A. … [1] (v) Name a specific file that could be used to make the sawn edge flat and square. … [1] (d) Each of the mild steel bars will be spray painted a different colour. (i) Give the names of two abrasives that could be used to prepare the bars for painting. 1 … 2 … [2] (ii) Give two advantages of spraying the paint onto the bars rather than by using a brush. 1 … 2 … [2] (iii) State two safety precautions that must be taken when spray painting. 1 … 2 … [2] (e) There are 16 pegs made of Ø9 beech dowel that need to be cut to length. Use sketches and notes to show a design for a jig that could be used when sawing 16 pegs, each 25 mm long, from a length of Ø9 beech dowel. [3] (f) Fig. 12.3 shows the beater that will be used to strike the bars of the xylophone. Ø25 Ø6 250 long Fig. 12.3 Use sketches and notes to show a modification to the xylophone so that the beater could be stored safely and securely. Give details of sizes, materials and constructions used. [3] (g) The main materials used to make the xylophone are mild steel and beech. Compare both materials and decide which of the two could be considered more sustainable. … … … [2]

25 marks

Mark scheme: 12(a) Thin layer of solid wood, cut from logs, used to cover 2 Accept references to uses for veneer manufactured boards to make attractive [2  1] 12(b) Veneers glued together [1] 4 Accept references to ‘vacuum bag’ Use of male and female formers [2  1] Veneers clamped around former [1] 12(c)(i) Scriber, felt tip pen 1 12(c)(ii) Odd-leg calipers 1 12(c)(iii) Centre or dot punch 1 12(c)(iv) Hacksaw, junior hacksaw 1 12(c)(v) Hand, flat or half round file 1 12(d)(i) 2 abrasives: emery cloth, wet and dry (silicon carbide 2 paper), aluminium oxide paper, steel/wire wool [2  1] 12(d)(ii) 2 advantages: more even finish, no brush strokes, quicker 2 [2  1] 12(d)(iii) 2 safety precautions: well ventilated area, no naked flames, 2 Accept mask and goggles as 2 different answers goggles, mask to prevent inhalation of fumes, face mask, gloves [2  1] 12(e) Length of 25 mm marked or cut on jig [1] 3 Dowel held securely while sawn [1] Quality of sketches and notes [1] 12(f) Modification example: 3 Hole in one end of stand with support underneath, some sort of hook or bracket attached to stand Safe and secure storage of ‘beater’ [1] Sizes, materials and constructions used [reward any 2 from 3] [0–2] 12(g) Beech is more sustainable than mild steel [1] 2 Beech trees can be replaced when felled OR Mild steel comes from a finite source [1]

This question in 0445/31 May/June 2025

Q446 · Parts of two wooden boards that will be joined using a tongue and groove joint 0445/32 May/June 2025

2 Fig. 2.1 shows parts of two wooden boards that will be joined using a tongue and groove joint. Fig. 2.1 Complete Fig. 2.1 to show a tongue and groove joint. [3]

3 marks

Mark scheme: 2 Tongue shown [1] 3 Accept freehand or ruler-drawn joint. Groove shown [1] Accept exploded or closed joint. Technical accuracy/proportion [1] Look at length and thickness of ‘tongue’

This question in 0445/32 May/June 2025

Q447 · Three hardwood boards glued together to make a table top 0445/32 May/June 2025

4 Fig. 4.1 shows three hardwood boards glued together to make a table top. 140 A B C Fig. 4.1 (a) Draw the end grain on boards B and C. [2] (b) Give one reason why three boards have been used to make the table top rather than one wide board. … [1]

3 marks

Mark scheme: 4(a) B end grain opposite to A [1] 2 Award 1 mark for end grain drawn as on A C end grain same as A [1] 4(b) Reason: wide board not available, greater stability, less 1 Do not accept ‘stops breaking’, ‘snapping’, more durable, warping cheaper Do not accept references to ‘length’ of boards

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Q448 · A bucket made from a thermoplastic 0445/32 May/June 2025

5 Fig. 5.1 shows a bucket made from a thermoplastic. Fig. 5.1 (a) Name a suitable thermoplastic for the bucket. … [1] (b) Give one advantage of the plastic bucket in use when compared to a bucket made from steel. … [1]

2 marks

Mark scheme: 5(a) HDPE, PP, ABS 1 5(b) Advantages: lightweight, non-corrosive 1 Accept any valid advantages in use

This question in 0445/32 May/June 2025

Q449 · The end grain of hardwood being planed 0445/32 May/June 2025

6 Fig. 6.1 shows the end grain of hardwood being planed. When planing end grain there is a danger that it could split. split Fig. 6.1 Use sketches and notes to show how the end grain could be planed without it splitting. [2]

2 marks

Mark scheme: 6 Methods include: scrap wood clamped at end of board, 2 Award 0–2 dependent on technical accuracy plane to centre from both ends [0 – 2]

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Q450 · A strip of metal that has been work hardened 0445/32 May/June 2025

7 Fig. 7.1 shows a strip of metal that has been work hardened. cracks Fig. 7.1 Explain what is meant by the term ‘work hardened’. … … … [2]

2 marks

Mark scheme: 7 Beaten or hammered [1] 2 Do not accept references to ‘heating’ metal Continuously or repeatedly [1]

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Question 451 0445/32 May/June 2025

8 Complete Fig. 8.1 to show an exploded view of a stopped housing joint. Fig. 8.1 [3]

3 marks

Mark scheme: 8 Stopped housing shown in lower board [1] 3 Do not accept through or double-stopped housings Stopped housing shown in upper board [1] Technical accuracy [1]

This question in 0445/32 May/June 2025

Q452 · A design for a rack to hold whiteboard marker pens and a board rubber 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

Q453 · A design for a holder to contain salt and pepper shakers 0445/32 May/June 2025

12 Fig. 12.1 shows a design for a holder to contain salt and pepper shakers. A batch of 12 holders will be produced for use in a local café. hardwood dowel handle Ø15 sheet metal support A plastic tube container 70 100 50 Fig. 12.1 (a) Name a suitable material for each of the parts of the holder. (i) a hardwood for the dowel handle … [1] (ii) a thermoplastic for the container … [1] (iii) a ferrous metal for the support … [1] (b) The containers will be connected at position A shown in Fig. 12.1. Use sketches and notes to show how the containers could be connected while allowing them to be taken apart quickly. The method of connection must not interfere with the salt and pepper shakers. Give details of all materials and constructions used. [4] (c) Fig. 12.2 shows the shape of the support marked out on 1.6 mm thick ferrous metal sheet. B arc R8 centre for Ø5 hole C 90 line A 50 Fig. 12.2 Name the marking out tools that could be used to mark out the following: (i) line A … [1] (ii) arc B … [1] (iii) centre for hole C … [1] (d) The supports will be ‘dip coated’ to provide an attractive finish. The surfaces of the metal must be prepared before dip coating. (i) Name two types of abrasive that could be used to prepare the metal. 1 … 2 … [2] (ii) Give the name of the plastic used in the dip coating process. … [1] (iii) State two other finishes that could be applied to the supports. 1 … 2 … [2] (e) Fig. 12.3 shows the hardwood dowel handle with its centre marked out on the end. A Ø3 mm hole will be drilled in the centre of the dowel. Ø15 50 centre for Ø3 hole Fig. 12.3 Describe how the Ø3 mm hole could be drilled accurately in the centre of the dowel. … … … … [3] (f) Fig. 12.4 shows one of the containers made from plastic tube. 4 mm thick 50 50 Fig. 12.4 Use sketches and notes to show how a base could be fitted inside the tube. Show clearly the method of fitting and name any materials used. [3] (g) Three different materials have been used to produce the holder for the salt and pepper shakers. The only material that could be considered sustainable is the dowel used for the handle. Explain why: (i) sheet metal could not be considered a sustainable material. … … … [2] (ii) plastic could not be considered a sustainable material. … … … [2]

25 marks

Mark scheme: 12(a)(i) Wide variety of hardwoods available: e.g. birch, beech, 1 ramin 12(a)(ii) ABS, acrylic, HDPE,polypropylene, PLA 1 Do not accept PVC 12(a)(iii) Mild steel, stainless steel, steel 1 Do not accept iron 12(b) Practical idea 4 Award max 2 marks for some sort of ‘clip’ [0 – 2] Award max 1 mark for use of magnet, velcro Award max.2 for some sort of ‘clip’ Award max.1 for use of magnet, Velcro Award max 1 mark for use of contact or epoxy resin adhesive with magnet, velcro Constructional details [0 – 2] 12(c)(i) Scriber, felt tip marker pen 1 12(c)(ii) Dividers 1 12(c)(iii) Centre/dot punch 1 12(d)(i) Emery cloth, wet and dry [silicon carbide] paper, steel/wire 2 wool [2  1] 12(d)(ii) Polyethylene, polythene, PET 1 Accept trade names: e.g. ‘Plastisol’ 12(d)(iii) 2 finishes include: lacquer, paint, galvanise, electroplating, 2 Do not accept polish, varnish chrome plating [2  1] 12(e) Dowel fitted into chuck of lathe [1] 3 Centre drill fitted into tailstock chuck and drill provides ‘start’ [1] Ø3 mm twist drill fitted into tailstock chuck to drill reqd. hole [1] OR Use of pedestal/bench drilling machines to drill vertically [1] Dowel secured in machine vice [or similar] [1] OR Centre punch end of dowel to guide drill [1] 12(f) Square base shown fits inside container [1] 3 If base is not fitted inside award 0 marks Suitable material for base named [1] Base glued into tube [1] 12(g)(i) Ferrous metals are produced from a non-renewable, finite 2 Reward 1 point expanded or several points made source Production of metals uses a lot of energy 12(g)(ii) Plastics are produced by processing oil, gas or coal which 2 Reward 1 point expanded or several points made are non-renewable, finite sources Many plastics cannot be recycled

This question in 0445/32 May/June 2025

Q454 · Views of a desk made of wood 0445/32 May/June 2025

13 Fig. 13.1 shows views of a desk made of wood. desktop drawer A end frame overall dimensions length 900 height 750 width 480 desk with top removed Fig. 13.1 (a) (i) Name a suitable hardwood for the end frame. … [1] (ii) Give two reasons why the designer of the desk has decided to use hardwood rather than softwood for the desk. 1 … 2 … [2] (iii) Name a suitable manufactured board for the desktop. … [1] (iv) The surface of the manufactured board has a thin decorative wood covering. State the term to describe the thin decorative wood covering. … [1] (v) Give one reason why a thin decorative wood covering has been applied to the desktop. … [1] (b) Fig. 13.2 shows part of the rail and leg at corner A in Fig. 13.1. The rail and leg will be joined using dowels. Centre lines for the dowels have been marked out . 25 50 50 centre line rail leg Fig. 13.2 (i) Give the name of a gauge that could be used to draw the centre lines for the dowels. … [1] (ii) State the number of dowels required to join the rail to the leg. … [1] (iii) State an appropriate diameter for the dowels. … [1] (c) Fig. 13.3 shows parts of an end frame ready to be glued and clamped. Fig. 13.3 (i) Add sketches and notes to Fig. 13.3 to show how the frame could be clamped. [4] (ii) Name the type of cramps used. … [1] (iii) State two checks that should be carried out immediately after gluing and clamping the frame. 1 … 2 … [2] (d) Fig. 13.4 shows the drawer removed from its support. support 15 mm thick drawer sides 15 mm thick Fig. 13.4 Use sketches and notes to show some sort of ‘runners’ or drawer guides that would allow the drawer to slide in and out of the support more easily. Do not use pre-manufactured metal or plastic drawer guides. Give details of all materials and constructions used. [4]

20 marks

Mark scheme: 13(a)(i) Wide variety of hardwoods available: for example, oak, 1 Check unfamiliar named woods which may be indigenous to beech, mahogany, birch, walnut centre’s country 13(a)(ii) Reasons: hardwood more attractive, more durable, can be 2 Do not accept ‘more stable’, ‘better quality’ easier to work, tougher [2  1] 13(a)(iii) Plywood, blockboard, chipboard, MDF, laminboard 1 13(a)(iv) Veneer 1 13(a)(v) To give the appearance of solid wood, more attractive, 1 Do not accept ‘gives protection’ cheaper than making desktop from oak 13(b)(i) Marking gauge 1 13(b)(ii) 2 only 1 13(b)(iii) Ø6 mm minimum--- Ø12 mm maximum 1 Accept any number between min. and max. 13(c)(i) 2 cramps shown: 1 at top of frame, 1 at bottom of frame* 4 Award 2 cramps shown: 1 at top of frame, 1 at bottom of [2  1] frame even if cramps shown are not the correct type of Cramps shown in centre of rails [1] cramp Use of scrap wood [1] 13(c)(ii) Sash, F cramp, quick grip, quick release cramps 1 13(c)(iii) 2 checks: wipe off surplus glue, check for tightness of 2 cramps, check for square, check for winding / frame lies flat [2  1] 13(d) Use of groove on inside of support [1] 4 Accept use of rebates Use of bead [to fit in groove] fitted to outside of drawer [1] OR Use of groove on outside of drawer [1] Use of bead [to fit in groove] fitted to inside of support [1] Materials [1] Constructions [1] 13(e) 3 divisions [1] 5 Sizes of partitions - any 2 Material for partitions named [1] Sizes of partitions to fit inside drawer Length of partition front to back max.400–415 [0 – 2] Constructions [1] Height of partition max. 90 Maximum length of partition along the inside length of drawer 770

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Q455 · Timber being seasoned naturally in the open air 0445/33 May/June 2025

1 Fig. 1.1 shows timber being seasoned naturally in the open air. roof to protect from sun and rain timber boards battens brick piers Fig. 1.1 Explain why timber needs to be seasoned. … … … [2]

2 marks

Mark scheme: Question Answer Marks Guidance 1 Trees contain moisture, timber needs to be dried, reduce 2 moisture content, prevent shrinkage, warping and rotting [2  1]

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Q456 · Strips of hardwood glued and clamped together to make a chopping board 0445/33 May/June 2025

3 Fig. 3.1 shows strips of hardwood glued and clamped together to make a chopping board. chopping board hardwood strips scrap wood cramp Fig. 3.1 (a) Name the type of cramps used. … [1] (b) Give two reasons for the use of scrap wood. 1 … 2 … [2]

3 marks

Mark scheme: 3(a) Sash cramp 1 3(b) Reasons: to protect the hardwood from ‘bruising’, to 2 distribute pressure [2  1]

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Q457 · A basic design for a letter rack made from 4 mm thick acrylic 0445/33 May/June 2025

5 Fig. 5.1 shows a basic design for a letter rack made from 4 mm thick acrylic. 50 70 200 60 Fig. 5.1 (a) Draw a former that could be used when bending the acrylic to the shape of the letter rack. [2] (b) Give one advantage of using a line bender/strip heater rather than an oven to heat the acrylic so that it could be bent to shape. … … … [1]

3 marks

Mark scheme: 5(a) Former must ‘match’ shape of bends [1] 2 Accuracy and proportion [1] 5(b) Strip heater/line bender heats specific area. Oven heats 1 whole sheet.

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Question 458 0445/33 May/June 2025

7 Complete Fig. 7.1 to show a tee halving joint. Fig. 7.1 [3]

3 marks

Mark scheme: 7 Award 1 mark for each ‘halving’ shown 3 [2  1] Technical accuracy/proportion [1]

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Q459 · Details of a jig used when bending a brass strip to shape 0445/33 May/June 2025

9 Fig. 9.1 shows details of a jig used when bending a brass strip to shape. brass strip steel peg Ø6 base 18 mm thick Fig. 9.1 Add sketches and notes to Fig. 9.1 to show how three additional steel pegs could be used so that the brass strip could be bent to the shape shown. [3]

3 marks

Mark scheme: 9 3 [3  1]

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Q460 · Two office chairs, A and B 0445/33 May/June 2025

10 Fig. 10.1 shows two office chairs, A and B. A B Fig. 10.1 Identify one design feature on each chair. Chair A … [1] Chair B … [1]

2 marks

Mark scheme: 10 Chair A castors move, armrests, adjustable & padded seat 2 Accept any valid features and back [1] Chair B lightweight tube construction, minimal use of materials, fewer parts to replace, folds up [1]

This question in 0445/33 May/June 2025

Q461 · A drill rack that will be attached to the pillar of a pillar drill 0445/33 May/June 2025

11 Fig. 11.1 shows a drill rack that will be attached to the pillar of a pillar drill. The drill rack is made from 15 mm thick plywood. collar holes for drill bits 12mm deep pillar 400 140 Fig. 11.1 (a) State two specification points that a designer would need to consider when designing the drill rack. 1 … 2 … [2] (b) (i) Use sketches and notes to show the construction of plywood. [2] (ii) Explain why plywood is more suitable than solid wood for the drill rack. … … … [2] (c) Fig. 11.2 shows details of the recess and hole that need to be cut out. waste hole Ø80 collar recess 70 × 50 × 12 deep 15 mm thick Fig. 11.2 (i) Name a tool that could be used to cut out the Ø80 hole. … [1] (ii) Name a machine tool that could be used to cut out the recess. … [1] (iii) Use sketches and notes to show how the waste plywood could be removed and the edges made smooth to produce the shape of the collar. Name all the tools and equipment used. [4] (d) The holes in the rack to take the drill bits shown in Fig. 11.1 are drilled to a depth of 12 mm. Describe how the holes could be drilled to a depth of 12 mm. … … … [2] (e) Fig. 11.3 shows the scan fitting that will be used to join the collar to the drill rack when the collar is fitted around the pillar of the pillar drill. barrel nut 14 mm long screw 60 long × Ø6 mm Fig. 11.3 (i) Name the type of tool that would be used to tighten the scan fitting. … [1] (ii) Fig. 11.4 shows the positions for the scan fitting to join the collar to the drill rack. Use sketches and notes to show how the scan fitting could be used to join the collar to the drill rack. collar rack Fig. 11.4 [4] (f) Fig. 11.5 shows a pair of safety glasses that will be worn when using the pillar drill. 60 150 40 sizes of safety glasses when folded Fig. 11.5 Use sketches and notes to show a design for a container to store the safety glasses. Include the following: • a method to show how the safety glasses could be kept clean and free from dust • a method to show how the container could be fixed to a wall • details of all materials and constructions used to make the container. [6]

25 marks

Mark scheme: 11(a) 2 Specification points include: 2 Accept any valid spec. points must not interfere with operation of machine, must be secure on pillar of machine, hold different types of drill, allow for easy access, easy to adjust [2  1] 11(b)(i) Number of separate plies shown (minimum 3) [1] 2 Grain shown in opposite directions on plies [1] 11(b)(ii) Explanation: grain structure cancels out movement making 2 board stable [0 – 2] 11(c)(i) Hole saw, hole cutter, tank cutter, Forstner bit, saw tooth bit 1 11(c)(ii) Mortising machine, router 1 11(c)(iii) Saw off waste [1] 4 Coping, Hegner, scroll, band saws. jig saw Edges filed smooth [1] Hand, flat, half round files ‘Sand’ edges [1] Glasspaper, sandpaper, bobbin sander, disk sander Accuracy of named tools and equipment [1] 11(d) Depth stop can be set to 12 mm on portable, bench or 2 Accept references to milling machine setting pedestal drills Use of tape or equivalent wrapped around drill Collars can be fitted to twist drill bits set to 12 mm 11(e)(i) Allen key, hex key, hexagonal head screwdriver 1 11(e)(ii) Screw shown through collar and rack 4 [2  1] Barrel nut shown in side or top of rack [1] Quality of sketches and notes [1] 11(f) Suitable materials named [1] 6 Fixing to wall: Constructions used to make the container 2 screw holes inside box = 1, slot screws = 2 [0 – 2] 2 screw holes in ‘backboard’ (extends beyond box) = 2 Some sort of ‘lid’ to keep glasses clean [1] Do not accept use of magnets Method of fixing to wall [0 – 2]

This question in 0445/33 May/June 2025

Q462 · A child’s xylophone that could be made in a school workshop 0445/33 May/June 2025

12 Fig. 12.1 shows a child’s xylophone that could be made in a school workshop. bar 50 peg support stand 400 110 Fig. 12.1 (a) The stand is made by laminating beech veneers. Describe what is meant by the term ‘veneer’. … … [2] (b) Use sketches and notes to show how veneers could be laminated to make the shape of the stand. Give details of all the tools, materials and equipment used. [4] (c) Fig. 12.2 shows one of the bars marked out on part of a length of mild steel strip. A C B Fig. 12.2 (i) Name a tool that could be used to mark out line A. … [1] (ii) Name a tool that could be used to mark out line B. … [1] (iii) Name a tool that could be used to make an indentation in the metal at point C. … [1] (iv) Name an appropriate saw that could be used to saw off the bar to the required length along line A. … [1] (v) Name a specific file that could be used to make the sawn edge flat and square. … [1] (d) Each of the mild steel bars will be spray painted a different colour. (i) Give the names of two abrasives that could be used to prepare the bars for painting. 1 … 2 … [2] (ii) Give two advantages of spraying the paint onto the bars rather than by using a brush. 1 … 2 … [2] (iii) State two safety precautions that must be taken when spray painting. 1 … 2 … [2] (e) There are 16 pegs made of Ø9 beech dowel that need to be cut to length. Use sketches and notes to show a design for a jig that could be used when sawing 16 pegs, each 25 mm long, from a length of Ø9 beech dowel. [3] (f) Fig. 12.3 shows the beater that will be used to strike the bars of the xylophone. Ø25 Ø6 250 long Fig. 12.3 Use sketches and notes to show a modification to the xylophone so that the beater could be stored safely and securely. Give details of sizes, materials and constructions used. [3] (g) The main materials used to make the xylophone are mild steel and beech. Compare both materials and decide which of the two could be considered more sustainable. … … … [2]

25 marks

Mark scheme: 12(a) Thin layer of solid wood, cut from logs, used to cover 2 Accept references to uses for veneer manufactured boards to make attractive [2  1] 12(b) Veneers glued together [1] 4 Accept references to ‘vacuum bag’ Use of male and female formers [2  1] Veneers clamped around former [1] 12(c)(i) Scriber, felt tip pen 1 12(c)(ii) Odd-leg calipers 1 12(c)(iii) Centre or dot punch 1 12(c)(iv) Hacksaw, junior hacksaw 1 12(c)(v) Hand, flat or half round file 1 12(d)(i) 2 abrasives: emery cloth, wet and dry (silicon carbide 2 paper), aluminium oxide paper, steel/wire wool [2  1] 12(d)(ii) 2 advantages: more even finish, no brush strokes, quicker 2 [2  1] 12(d)(iii) 2 safety precautions: well-ventilated area, no naked flames, 2 Accept mask and goggles as 2 different answers goggles, mask to prevent inhalation of fumes, face mask, gloves [2  1] 12(e) Length of 25 mm marked or cut on jig [1] 3 Dowel held securely while sawn [1] Quality of sketches and notes [1] 12(f) Modification example: 3 Hole in one end of stand with support underneath, some sort of hook or bracket attached to stand Safe and secure storage of ‘beater’ [1] Sizes, materials and constructions used [reward any 2 from 3] [0 – 2] 12(g) Beech is more sustainable than mild steel [1] 2 Beech trees can be replaced when felled OR Mild steel comes from a finite source [1]

This question in 0445/33 May/June 2025

Q463 · A basic design for a headphone stand made from 5 mm thick acrylic 0445/33 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 0445/33 May/June 2025

Q464 · Two methods of seasoning wood 0445/31 Oct/Nov 2025

1 Fig. 1.1 shows two methods of seasoning wood. Method A is kiln seasoning. Method B is open-air seasoning. outlet valve inlet valve steam pipes roof to protect from sun and rain heating pipes timber boards battens brick piers timber stacked on trolley A B Fig. 1.1 (a) Give one advantage of kiln seasoning compared to open-air seasoning. … [1] (b) Give one advantage of open-air seasoning compared to kiln seasoning. … [1]

2 marks

Mark scheme: Question Answer Marks Guidance 1(a) Quicker, meet customer demands, less prone to warping, 1 Do not accept more environmentally friendly temperature controlled 1(b) More evenly dried, better quality timber, cheaper, cost 1 effective, low maintenance, uses less electricity, larger scale

This question in 0445/31 Oct/Nov 2025

Question 465 0445/31 Oct/Nov 2025

2 Complete Fig. 2.1 to show the construction of blockboard. 18 mm thick Fig. 2.1 [2]

2 marks

Mark scheme: 2 Strips shown on one end [1] 2 Award 1 mark for ‘strips’ shown on one side Strip shown along the length of one side [1]

This question in 0445/31 Oct/Nov 2025

Q466 · A tool used to mark a circle on metal surfaces 0445/31 Oct/Nov 2025

3 Fig. 3.1 shows a tool used to mark a circle on metal surfaces. tip Fig. 3.1 (a) Name the tool shown in Fig. 3.1. … [1] (b) Describe how the tip of the tool could be prevented from slipping when marking a circle. … … [2]

3 marks

Mark scheme: 3(a) Dividers 1 3(b) Make indentation [1] 2 Use of centre or dot punch [1]

This question in 0445/31 Oct/Nov 2025

Q467 · A spray bottle with parts made from two different plastics 0445/31 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 0445/31 Oct/Nov 2025

Q468 · A hardwood block with line A marked across the grain and lines B marked along the grain 0445/31 Oct/Nov 2025

5 Fig. 5.1 shows a hardwood block with line A marked across the grain and lines B marked along the grain. B A Fig. 5.1 (a) Name the type of gauge that would be used to mark out line A. … [1] (b) Name the type of gauge that would be used to mark out lines B. … [1]

2 marks

Mark scheme: 5(a) Cutting gauge 1 5(b) Mortise gauge 1

This question in 0445/31 Oct/Nov 2025

Question 469 0445/31 Oct/Nov 2025

6 Fig. 6.1 shows an office chair. Fig. 6.1 Give three ways in which anthropometric data has been used in the design of the office chair. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 6 Sitting height, shoulder height, lower leg length, hips width, 3 Reference to parts of the chair must be accompanied with elbow height, buttock seat depth], buttock-knee length reference to human body [3  1]

This question in 0445/31 Oct/Nov 2025

Q470 · A table number made from 1.5 mm thick aluminium sheet, for use in a local café 0445/31 Oct/Nov 2025

7 Fig. 7.1 shows a table number made from 1.5 mm thick aluminium sheet, for use in a local café. bend line 60 12 12 30 25 Fig. 7.1 Use sketches and notes to show how the aluminium sheet could be cut out and bent into shape. Name one of the tools or items of equipment used. [4]

4 marks

Mark scheme: 7 Saw/cut made: hacksaws, tin snips, piercing saw [1] 4 Secure sheet vice, cramps, folding bars [1] Method of force: hammer, mallet, pliers [1] 3 Correctly named tools/equipment [1]

This question in 0445/31 Oct/Nov 2025

Q471 · Two wooden boards that are to be joined together by means of a biscuit joint 0445/31 Oct/Nov 2025

9 Fig. 9.1 shows two wooden boards that are to be joined together by means of a biscuit joint. Fig. 9.1 Complete Fig. 9.1 to show how two biscuits could be used to make a biscuit joint. [3]

3 marks

Mark scheme: 9 2 ‘slots’ in right hand piece [1] 3 Biscuit should ‘match’ size of slot 2 ‘slots’ in left hand piece [1] Reward biscuit shown in slot 1 biscuit shown [1]

This question in 0445/31 Oct/Nov 2025

Q472 · An item of equipment that can be used to join pieces of metal permanently 0445/31 Oct/Nov 2025

10 Fig. 10.1 shows an item of equipment that can be used to join pieces of metal permanently. Fig. 10.1 (a) Name the item of equipment shown in Fig. 10.1. … [1] (b) Name a method of joining metal permanently that uses heat. … [1]

2 marks

Mark scheme: 10(a) Pop rivet gun, rivet gun, pop rivet 1 Do not accept ‘rivet’ 10(b) Soldering, brazing, welding 1

This question in 0445/31 Oct/Nov 2025

Q473 · A child’s toy bus made mainly from 12 mm thick plywood 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

Q474 · A stand used to display a model yacht 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]

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Q475 · A menu stand that has been produced by a D&T student for use in a local café 0445/31 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]

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Q476 · A solid wood board A, and the same board B, after it has warped 0445/32 Oct/Nov 2025

1 Fig. 1.1 shows a solid wood board A, and the same board B, after it has warped. A B Fig. 1.1 Give two reasons why the solid wood board could have become warped. 1 … 2 … [2]

2 marks

Mark scheme: Question Answer Marks Guidance 1 2 reasons: board not stacked level, uneven seasoning, 2 Accept any valid reason referencing removal of moisture excess moisture removed too quickly, exposed to sun/heat, Do not accept references to ‘weight placed on board’, or change in temperature, improper storage during seasoning added moisture [2  1]

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Question 477 0445/32 Oct/Nov 2025

2 Fig. 2.1 shows a saucepan. The body is made from ferrous metal. The handle is made from thermosetting plastic. handle body Fig. 2.1 (a) Name a suitable ferrous metal for the body. … [1] (b) Name a suitable thermosetting plastic for the handle. … [1]

2 marks

Mark scheme: 2(a) Stainless steel, cast iron 1 Do not accept iron, steel, mild steel 2(b) Phenol formaldehyde (PF) phenolic resin, Bakelite, 1 melamine formaldehyde (MF)

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Q478 · Name the process that uses all the following materials 0445/32 Oct/Nov 2025

3 Name the process that uses all the following materials. gel coat release agent polyester resin … [1]

1 marks

Mark scheme: 3 (Laying up) glass fibre 1

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Q479 · Two wooden boards that will be joined together by means of a half-lap joint 0445/32 Oct/Nov 2025

4 Fig. 4.1 shows two wooden boards that will be joined together by means of a half-lap joint. Fig. 4.1 Complete Fig. 4.1 to show a half-lap joint. [3]

3 marks

Mark scheme: 4 1 board shown with ½ lap [1] 3 Award 1 mark for ‘double lapped joint 1 board shown ‘unchanged’ [1] Technical accuracy, proportion [1]

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Q480 · A toy fire engine 0445/32 Oct/Nov 2025

5 Fig. 5.1 shows a toy fire engine. Fig. 5.1 Name a process that could be used to manufacture the toy fire engine when made from: (a) zinc based alloy … [1] (b) ABS. … [1]

2 marks

Mark scheme: 5(a) Diecasting 1 5(b) Injection moulding, 3D printing 1

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Q481 · The casing of a television remote control made from moulded plastic 0445/32 Oct/Nov 2025

7 Fig. 7.1 shows the casing of a television remote control made from moulded plastic. Fig. 7.1 Give two quality control checks that could be carried out after the casing has been manufactured. 1 … 2 … [2]

2 marks

Mark scheme: 7 2 checks: surface check for marks/blemishes, rough 2 Accept references to 2 dimensional checks surfaces/edges, ‘bubbles’, dimensional checks, do the two Accept any valid checks parts fit and separate, do the buttons line up with the holes [2  1] Question Answer Marks Guidance

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Q482 · Views of a bracket made from 1.6 mm thick mild steel sheet 0445/32 Oct/Nov 2025

8 Fig. 8.1 shows views of a bracket made from 1.6 mm thick mild steel sheet. 60 30 bend lines 20 60 20 Fig. 8.1 Use sketches and notes to show how the mild steel sheet could be bent to shape. [3]

3 marks

Mark scheme: 8 Sheet steel shown secured in vice or clamped [1] 3 Do not accept use of heat, or references to marking out Use of former for steel to be bent around [1] Method of force: use of hammer and scrap wood or mallet [1]

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Q483 · A length of hardwood that needs to be planed 0445/32 Oct/Nov 2025

10 Fig. 10.1 shows a length of hardwood that needs to be planed. The hardwood is only 6 mm thick and could not be held securely in a woodworker’s vice. 30 side to be planed 6 mm thick 200 Fig. 10.1 Use sketches and notes to show how the hardwood could be held securely while it is planed. [3]

3 marks

Mark scheme: 10 Use of bench stop or clamped wood equivalent shown 3 Accept double-sided tape: clearly [0 – 2] Award 1 mark if stated only Award 2 marks if tape is shown on base of wood OR Use of pins/nails to secure wood to bench [0 – 2] Added explanatory notes [1]

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Q484 · An incomplete design for scales and weights that could be used by children 0445/32 Oct/Nov 2025

11 Fig. 11.1 shows an incomplete design for scales and weights that could be used by children. A parts list gives details of the materials used and their sizes. arm pivot A arrow upright weights base block Fig. 11.1 Parts List Part length x width x thickness Material base 400 × 150 × 15 beech upright 400 × 150 × 15 beech arm 420 × 60 × 15 beech arrow 210 × 50 × 5 MDF block 195 × 60 × 20 beech weights Ø25 aluminium (a) Give two reasons why beech is often used to make school equipment used by children. 1 … 2 … [2] (b) Sketch and name a suitable joint that could be used to join the upright to the base. Name of joint … [4] (c) Fig. 11.2 shows the shape of the arrow marked out on MDF. waste A waste B 210 5 mm thick 50 Fig. 11.2 (i) Name a machine saw that could be used to remove the waste. … [1] (ii) After the waste has been removed at A the sawn edge will be made flat and smooth by using a disk sander. State one safety precaution that must be taken when using a disk sander. … [1] (iii) Fig. 11.3 shows a woodworker’s vice. After the waste has been removed at B the sawn edge will be made flat and smooth by using a bench plane. Fig. 11.3 Add a sketch to Fig. 11.3 to show how the MDF arrow could be held in the vice so that the sawn edges could be planed flat and smooth. [1] (iv) Name a suitable bench plane that could be used to make the sawn edge flat and smooth. … [1] (d) (i) A contact adhesive could be used to join the arrow to the arm of the scales. Give one advantage of using a contact adhesive rather than PVA. … [1] (ii) State one safety precaution that must be taken when using a contact adhesive. … [1] (iii) Use sketches and notes to show how the arm, with the arrow attached, could be joined to the upright at pivot A and allowed to move as shown in Fig. 11.1. [3] (e) Fig. 11.4 shows the block, made of beech, that is used to store the four weights. Ø30 holes 15 mm deep 20 mm thick Fig. 11.4 (i) Name a specific type of drill bit that could be used to drill holes to a depth of 15 mm. … [1] (ii) Describe a method that would ensure the holes are drilled to a depth of exactly 15 mm. … … … [2] (f) Fig. 11.5 shows the scales with two pans that will be attached to the arm. arm string pan Fig. 11.5 Fig. 11.6 shows details of one of the pans that will be used to hold the metal weights and the mould that will be used to vacuum form the pans. inside Ø150 60 draft angle outside Ø120 pan mould Fig. 11.6 (i) Explain the purpose of the draft angle on the mould. … … … [2] (ii) Fig. 11.7 shows a sectional view through part of a vacuum forming machine. Add sketches to Fig. 11.7 to show the mould, the heater and the plastic sheet in position ready to vacuum form one pan. clamp platen vacuum pump Fig. 11.7 [3] (g) Fig. 11.8 shows one of the pans ready to be attached to the arm of the scales. string Fig. 11.8 Use sketches and notes to show how one pan could be attached to the arm of the scales. The method of attachment must allow the pan to be removed. [2]

25 marks

Mark scheme: 11(a) 2 reasons include: hard, tough, durable, resists splits and 2 Do not accept easy to work, lightweight, strong, cheap splintering, close-grained, finishes well, attractive [2  1] 11(b) Name of suitable joint: mortise and tenon, dowel, biscuit [1] 4 Accept ‘mortise’ Tenon shown with ‘shoulders’ [2] Complete width of ‘support’ shown in mortise 1 Quality of communication [1] Do not accept nails or screws through base into ‘support’ Dowels: min. 2 – max. 4 Biscuits: min. 2 – max. 3 11(c)(i) Circular saw, table saw, band saw, scroll saw, Hegner saw, 1 jig saw 11(c)(ii) Fingers behind surfaces being sanded, face mask, safety 1 Do not accept gloves, apron glasses, goggles, glasses, respirator, hair tied back, no loose clothing, no spectators, hold the workpiece securely 11(c)(iii) Hardwood shown angled so that sawn edge B could be 1 horizontal when planed 11(c)(iv) Smoothing plane, jack plane, block plane 1 11(d)(i) Contact adhesive bonds immediately, no need for clamping, 1 Do not accept stronger PVA takes 2–3 hours to set 11(d)(ii) Well-ventilated area, no naked flames, mask to prevent 1 Do not accept goggles fume inhalation, wear gloves 11(d)(iii) Sketch showing fitting through arrow, arm and upright [1] 3 Dowel, ‘pin’, rod, screw thread must pass through arm and support [1] Must be retained at front and back [1] 11(e)(i) Forstner, saw tooth bit 1 11(e)(ii) Depth stop can be set to 15 mm on portable, bench or 2 Award 1 mark for: pedestal drills Adhesive tape can be fitted to drill bits set to 15 mm OR OR mark made on drill bit Lower bench drill table to allow 15 mm depth 11(f)(i) Draft angle enables the plastic pan to be released more 2 Award 1 mark for reference to removal from mould without easily from the mould more easily stated 11(f)(ii) Correct positions: mould, heater and plastic sheet 3 [3  1] 11(g) Variety of methods include: use of hook and eye, ‘notches’ 2 Accept any valid method cut out of arm [0 – 2] Award 0 – 2 dependent on technical accuracy of practical idea

This question in 0445/32 Oct/Nov 2025

Q485 · A holder to store a gaming controller and a headset 0445/32 Oct/Nov 2025

12 Fig. 12.1 shows a holder to store a gaming controller and a headset. The holder is made from MDF. neck upright 6 mm thick support 6 mm thick 260 base 12 mm thick 260 190 Fig. 12.1 (a) Give two items of research a designer would need to consider when designing the holder for the gaming controller and headset. 1 … 2 … [2] (b) The holder could be made from MDF or plywood. Give two advantages of using MDF to make the holder rather than plywood. 1 … 2 … [2] (c) Fig. 12.2 shows a template that could be used to mark out the shape of the base and the positions for joining the upright and supports to the base. template positions for joints 12 mm thick base Fig. 12.2 (i) Give one benefit of using a template to mark out the base and positions for the joints. … [1] (ii) State one advantage of making a template from thin sheet metal rather than card when making a batch of holders. … [1] (iii) Give the names of two different saws that could be used to cut out the shape of the base. 1 … 2 … [2] (d) The upright and supports will be joined to the base in the positions shown in Fig. 12.2. Use sketches and notes to show how the upright could be joined to the base. [3] (e) Fig. 12.3 shows an exploded view of three pieces of MDF that will be glued together to make the neck of the holder. 35 140 20 6 Fig. 12.3 Use sketches and notes to show how the three pieces of MDF could be glued and clamped together accurately and securely to make the neck of the holder. Include the following details: • the name of a suitable adhesive • the method of clamping used • two checks that would be carried out after the pieces have been glued and clamped. [6] (f) The parts of the holder will be painted before they are assembled. (i) The surfaces of the MDF will be sanded using a fine grade glasspaper wrapped around a cork sanding block. Give one benefit of using a cork sanding block with the glasspaper. … [1] (ii) A primer coat of paint will be applied to the MDF. Describe the purpose of a primer coat. … … [2] (iii) The final coat of paint will be sprayed onto the surfaces. Give one advantage of spraying the paint rather than by using a brush. … [1] (iv) State one safety precaution that must be taken when spray painting. … [1] (g) Explain how an evaluation of the final product could be carried out. … … … … [3]

25 marks

Mark scheme: 12(a) 2 items: dimensions of controller, headset, weight of 2 Accept any valid items of research controller, headset, size of controller, headset, best areas to be supported, method of secure support, location, research existing products [2  1] 12(b) 2 advantages: smoother surfaces, ‘consistent’ structure, no 2 Accept any valid advantages grain, easier to work, cheaper Do not accept lightweight, stronger [2  1] 12(c)(i) Benefit: speed, [repetitive] accuracy 1 Accept any valid benefits 12(c)(ii) Thin metal sheet will withstand ‘wear and tear’ better than 1 Accept any valid advantage card, durable 12(c)(iii) 2 saws: coping, jig, Hegner, scroll, band saws, tenon, 2 Accept combination of any two saws dovetail [2  1] 12(d) Upright and supports joined to base with shoulders [2] 3 No name of joint required OR Upright and supports joined to base without shoulders [1] Technical accuracy of sketches/Quality of communication [1] 12(e) Suitable adhesive: PVA [accept wide range available] [1] 6 Internet search for uncommon names Clamping: G cramps or vice [1], use of scrap wood [1] Clamping: accept ‘F’ cramp and ‘sash’ cramps accurately drawn [1] Checks: wipe off surplus glue, check tightness of cramps, check alignment [2  1] 12(f)(i) More even pressure, more effective use of glasspaper, 1 Do not accept better grip, easier to sand quicker, smoother 12(f)(ii) Descriptions include: primer coat seals the surface of the 2 Accept ONE detailed description of one point or two wood, provides better adhesion for subsequent coats of separate descriptions paint, prevents wood from absorbing the final paint, prepares the surface/to take the final coat 12(f)(iii) Advantages: more even finish, no brush strokes, quicker, 1 better appearance 12(f)(iv) Safety precaution: face mask, mask, ventilation 1 Accept any valid precaution Do not accept goggles, safety glasses, gloves 12(g) Checking the product: check position of controller on 3 Award 0–3 dependent on quality of response holder, is it stable and secure in position, does the headset fit? check against original specification Use of questionnaire/survey with potential users, collate results data [0 – 3]

This question in 0445/32 Oct/Nov 2025

Q486 · An incomplete design for a wall-mounted adjustable shelving unit 0445/32 Oct/Nov 2025

13 Fig. 13.1 shows an incomplete design for a wall-mounted adjustable shelving unit. end frame shelf rod 500 700 180 Fig. 13.1 Parts List Number Part Material and sizes required end frames 2 mild steel square tube 20 × 20 rods 14 mild steel round tube Ø10 shelves 3 veneered chipboard 18 thick (a) Give two benefits of using veneered chipboard for the shelves. 1 … 2 … [2] (b) There are 14 lengths of Ø10 mild steel tube used to make the end frames. Use sketches and notes to show a design for a jig that could be used when sawing each of the Ø10 mild steel tubes to a length of 170 mm. Name the material from which the jig is made and state the name of an appropriate saw that could be used. [4] (c) Fig. 13.2 shows two lengths of mild steel tube that will be joined at the corner of one end frame. square tube 20 × 20 Fig. 13.2 (i) The mild steel tube will be joined by brazing. Name two abrasives that could be used to clean the joint before the mild steel tube is brazed. 1 … 2 … [2] (ii) Flux will be applied to the joint before the mild steel tube is heated. Explain the purpose of the flux. … … … [2] (iii) The ‘open’ ends of the mild steel tube are unattractive. Use sketches and notes to show how the appearance of the open end of the tube could be improved. Name any materials used. [3] (d) Fig. 13.3 shows details of one of the brackets that will allow the adjustable shelf unit to be fixed to a wall. The brackets, made from mild steel sheet, fit around the mild steel tube when the parts of the end frames are assembled. Ø10 Ø5 30 20 30 70 Fig. 13.3 (i) Name two marking out tools that could be used to mark out the centres for the Ø10 and Ø5 holes. 1 … 2 … [2]

15 marks

Mark scheme: 13(a) 2 benefits: cheap, cheaper than solid wood, more stable, 2 Do not accept durable, lightweight, aesthetically pleasing more readily available [2  1] 13(b) Mild steel tube held securely [1] 4 Jig allows tube to be cut without measuring/marking out [1] Suitable material for jig named [1] Saw used: hacksaw, junior hacksaw [1] 13(c)(i) 2 abrasives: emery cloth, wet and dry [silicon carbide] paper, 2 steel wool [2  1] 13(c)(ii) Flux prevents oxidisation [keeps the metal clean] [1] 2 Allows the brazing rod to flow [1] 13(c)(iii) Recognisable ‘plug’, ‘cap’ or ‘cover’ [1] 3 Named material [1] Technical accuracy & quality of communication [1] 13(d)(i) Scriber, steel rule, [engineer’s] try square, centre punch, dot 2 punch [2  1] 13(d)(ii) Mild steel secure in vice, folding bar, clamped to bench [1] 4 Do not accept use of heat Some sort of former/shape to bend around [1] Method of force: hammer and scrap wood or mallet Award 1 mark for at least 2 tools or equipment are named Accuracy of named tools and equipment [1] correctly 13(d)(iii) Annealing 1 13(e) Method: some sort of ‘hook’ joined to the shelf and onto or 5 Accept any practical design idea that shows connection around the Ø10 tube. between shelf and Ø10 tube Method: rod or dowel fitted into end of shelf and resting on Ø10 tube Size not already given Practical method [0 – 2] Suitable named material [1] Constructions [1] One important size [1]

This question in 0445/32 Oct/Nov 2025

Q487 · Two methods of seasoning wood 0445/33 Oct/Nov 2025

1 Fig. 1.1 shows two methods of seasoning wood. Method A is kiln seasoning. Method B is open-air seasoning. outlet valve inlet valve steam pipes roof to protect from sun and rain heating pipes timber boards battens brick piers timber stacked on trolley A B Fig. 1.1 (a) Give one advantage of kiln seasoning compared to open-air seasoning. … [1] (b) Give one advantage of open-air seasoning compared to kiln seasoning. … [1]

2 marks

Mark scheme: Question Answer Marks Guidance 1(a) Quicker, meet customer demands, less prone to warping, 1 Do not accept more environmentally friendly temperature controlled 1(b) More evenly dried, better quality timber, cheaper, cost 1 effective, low maintenance, uses less electricity, larger scale

This question in 0445/33 Oct/Nov 2025

Question 488 0445/33 Oct/Nov 2025

2 Complete Fig. 2.1 to show the construction of blockboard. 18 mm thick Fig. 2.1 [2]

2 marks

Mark scheme: 2 Strips shown on one end [1] 2 Award 1 mark for ‘strips’ shown on one side Strip shown along the length of one side [1]

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Q489 · A tool used to mark a circle on metal surfaces 0445/33 Oct/Nov 2025

3 Fig. 3.1 shows a tool used to mark a circle on metal surfaces. tip Fig. 3.1 (a) Name the tool shown in Fig. 3.1. … [1] (b) Describe how the tip of the tool could be prevented from slipping when marking a circle. … … [2]

3 marks

Mark scheme: 3(a) Dividers 1 3(b) Make indentation [1] 2 Use of centre or dot punch [1]

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Q490 · A hardwood block with line A marked across the grain and lines B marked along the grain 0445/33 Oct/Nov 2025

5 Fig. 5.1 shows a hardwood block with line A marked across the grain and lines B marked along the grain. B A Fig. 5.1 (a) Name the type of gauge that would be used to mark out line A. … [1] (b) Name the type of gauge that would be used to mark out lines B. … [1]

2 marks

Mark scheme: 5(a) Cutting gauge 1 5(b) Mortise gauge 1

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Question 491 0445/33 Oct/Nov 2025

6 Fig. 6.1 shows an office chair. Fig. 6.1 Give three ways in which anthropometric data has been used in the design of the office chair. 1 … 2 … 3 … [3]

3 marks

Mark scheme: 6 Sitting height, shoulder height, lower leg length, hips width, 3 Reference to parts of the chair must be accompanied with elbow height, buttock seat depth], buttock-knee length reference to human body [3  1]

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Q492 · A table number made from 1.5 mm thick aluminium sheet, for use in a local café 0445/33 Oct/Nov 2025

7 Fig. 7.1 shows a table number made from 1.5 mm thick aluminium sheet, for use in a local café. bend line 60 12 12 30 25 Fig. 7.1 Use sketches and notes to show how the aluminium sheet could be cut out and bent into shape. Name one of the tools or items of equipment used. [4]

4 marks

Mark scheme: 7 Saw/cut made: hacksaws, tin snips, piercing saw [1] 4 Secure sheet vice, cramps, folding bars [1] Method of force: hammer, mallet, pliers [1] 3 Correctly named tools/equipment [1]

This question in 0445/33 Oct/Nov 2025

Q493 · Two wooden boards that are to be joined together by means of a biscuit joint 0445/33 Oct/Nov 2025

9 Fig. 9.1 shows two wooden boards that are to be joined together by means of a biscuit joint. Fig. 9.1 Complete Fig. 9.1 to show how two biscuits could be used to make a biscuit joint. [3]

3 marks

Mark scheme: 9 2 ‘slots’ in right hand piece [1] 3 Biscuit should ‘match’ size of slot 2 ‘slots’ in left hand piece [1] Reward biscuit shown in slot 1 biscuit shown [1]

This question in 0445/33 Oct/Nov 2025

Q494 · An item of equipment that can be used to join pieces of metal permanently 0445/33 Oct/Nov 2025

10 Fig. 10.1 shows an item of equipment that can be used to join pieces of metal permanently. Fig. 10.1 (a) Name the item of equipment shown in Fig. 10.1. … [1] (b) Name a method of joining metal permanently that uses heat. … [1]

2 marks

Mark scheme: 10(a) Pop rivet gun, rivet gun, pop rivet 1 Do not accept ‘rivet’ 10(b) Soldering, brazing, welding 1

This question in 0445/33 Oct/Nov 2025

Q495 · A child’s toy bus made mainly from 12 mm thick plywood 0445/33 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 0445/33 Oct/Nov 2025

Q496 · A stand used to display a model yacht 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

Q497 · A menu stand that has been produced by a D&T student for use in a local café 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