Questions as text
Q1 · 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
Q2 · 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
Q3 · 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.
This question in 0445/32 May/June 2017
Q4 · 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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Q5 · 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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Q6 · 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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Q7 · Views of a cabinet and a 6 mm thick sliding glass door to be fitted inside the cabinet 0445/32 May/June 2018
8 Fig. 7 shows views of a cabinet and a 6 mm thick sliding glass door to be fitted inside the cabinet. Add sketches and notes to Fig. 7 to show how two sliding glass doors could be fitted inside the cabinet. top of cabinet 15 thick glass door 6 thick bottom of cabinet 15 thick Fig. 7 [3]
3 marks
Mark scheme: 8 Grooves or applied beads in bottom = 1 Depth of grooves/beads in top twice as deep = 1
This question in 0445/32 May/June 2018
Q8 · 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
This question in 0445/32 May/June 2018
Q9 · 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
This question in 0445/33 May/June 2018
Question 10 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
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Q11 · A three jaw and a four jaw chuck that are used with a centre lathe 0445/32 Oct/Nov 2018
6 Fig. 5 shows a three jaw and a four jaw chuck that are used with a centre lathe. Fig. 5 (a) Describe a specific use for a three jaw chuck. … … [1] (b) Describe a specific use for a four jaw chuck. … … [1]
2 marks
Mark scheme: 6(a) References to turning: e.g. to hold round or hexagonal shaped metal 1 6(b) References to turning: e.g. to hold round, square or irregular shaped metal 1
This question in 0445/32 Oct/Nov 2018
Q12 · 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
This question in 0445/32 Oct/Nov 2018
Question 13 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
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Q14 · 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
This question in 0445/31 May/June 2019
Q15 · The table shows two different centre lathe processes used when turning round metal bar 0445/32 May/June 2019
7 The table shows two different centre lathe processes used when turning round metal bar. Complete the table by naming each process. Process Description of process Name of process Cutting across the end of the round bar Cutting off a length of round bar [2]
2 marks
Mark scheme: 7 Facing off 1 Parting off 1 2
This question in 0445/32 May/June 2019
Q16 · 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
This question in 0445/32 May/June 2019
Q17 · 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
Q18 · Name the centre lathe operation shown below 0445/31 Oct/Nov 2019
9 (a) Name the centre lathe operation shown below. work piece textured surface … [1] (b) State the purpose of the textured surface produced by the operation shown in part (a). … [1]
2 marks
Mark scheme: 9(a) Knurling 1 9(b) To provide additional grip 1
This question in 0445/31 Oct/Nov 2019
Q19 · 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
Q20 · 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
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Q21 · Name the centre lathe operation shown below 0445/32 Oct/Nov 2019
9 (a) Name the centre lathe operation shown below. work piece textured surface … [1] (b) State the purpose of the textured surface produced by the operation shown in part (a). … [1]
2 marks
Mark scheme: 9(a) Knurling 1 9(b) To provide additional grip 1
This question in 0445/32 Oct/Nov 2019
Q22 · 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
Q23 · 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
Q24 · A length of wood set up on a woodturning lathe 0445/33 Oct/Nov 2019
9 Fig. 9 shows a length of wood set up on a woodturning lathe. Fig. 9 (a) Name the method of woodturning shown in Fig. 9. … [1] (b) Fig. 10 shows a length of wood ready to be set up on the woodturning lathe. Fig. 10 Give one reason why the corners of the wood have been removed. … [1]
2 marks
Mark scheme: 9(a) Between-centres turning 1 9(b) To make the start of turning easier, to prevent splitting 1
This question in 0445/33 Oct/Nov 2019
Q25 · 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.
This question in 0445/33 Oct/Nov 2019
Q26 · Two items of equipment used with a centre lathe 0445/31 May/June 2020
6 Table 6.1 shows two items of equipment used with a centre lathe. Complete Table 6.1 by stating the name of each item of equipment. Table 6.1 Item of equipment Name [2]
2 marks
Mark scheme: 6 Chuck 1 2 Knurling tool 1
This question in 0445/31 May/June 2020
Q27 · 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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Q28 · 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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Q29 · Two items of equipment used with a centre lathe 0445/33 May/June 2020
6 Table 6.1 shows two items of equipment used with a centre lathe. Complete Table 6.1 by stating the name of each item of equipment. Table 6.1 Item of equipment Name [2]
2 marks
Mark scheme: 6 Chuck 1 2 Knurling tool 1
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Q30 · 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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Q31 · Parts of a fastening device 0445/32 Oct/Nov 2020
1 Fig. 1.1 shows parts of a fastening device. A B C Fig. 1.1 Give the correct name to parts A, B and C. A … B … C … [3]
3 marks
Mark scheme: 1 A bolt, screw [thread] 1 B washer 1 C wing nut, 1 3
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Q32 · 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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Q33 · 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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Q34 · 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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Q35 · 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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Question 36 0445/33 Oct/Nov 2020
7 Fig. 7.1 shows a hardwood box. lid 300 12 mm thick hardwood Fig. 7.1 Sketch a suitable type of hinge that could be used to join the lid to the sides of the box. [3]
3 marks
Mark scheme: 7 Suitable hinge: butt, piano. 2 equal ‘flaps’ [1] Appropriate number/spacing of screw holes [1] Centre ‘pin’ [1] 3
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Q37 · 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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Q38 · 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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Q39 · 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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Q40 · 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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Q41 · An incomplete drawing of a flush hinge 0445/31 Oct/Nov 2021
3 Fig. 3.1 shows an incomplete drawing of a flush hinge. Fig. 3.1 Add to Fig. 3.1 to complete the drawing of the flush hinge. [2]
2 marks
Mark scheme: 3 Completed drawing shows left hand flap 1 Two holes shown in flap 1 2 Do accept max. 3 holes in added flap Do accept reverse shape on right with 2 holes shown
This question in 0445/31 Oct/Nov 2021
Q42 · 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
This question in 0445/31 Oct/Nov 2021
Q43 · Two tools, A and B, that are used to remove nails from wood 0445/32 Oct/Nov 2021
4 Fig. 4.1 shows two tools, A and B, that are used to remove nails from wood. A B Fig. 4.1 (a) Name each tool: A … B … [2] (b) Fig. 4.2 shows tool A removing a nail from wood. scrap wood Fig. 4.2 State the purpose of the scrap wood shown in Fig. 4.2. … [1]
3 marks
Mark scheme: 4(a) A claw hammer 1 B pincers 1 2 Do accept ‘pinchers’ 4(b) Purpose of scrap wood to prevent damage caused by leverage of hammer 1 1
This question in 0445/32 Oct/Nov 2021
Q44 · 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
This question in 0445/32 Oct/Nov 2021
Q45 · An incomplete design for a bending jig used when bending acrylic sheet 0445/32 Oct/Nov 2021
7 Fig. 7.1 shows an incomplete design for a bending jig used when bending acrylic sheet. X adjustable board Y hinge fixed board Fig. 7.1 Add to Fig. 7.1 to show how the adjustable board could be held securely in any position between X and Y so that acrylic sheet could be bent to the required shape. [3]
3 marks
Mark scheme: 7 Some form of ‘stay’ that joins the adjustable board to the fixed board 1 Locked in any position 1 Method of tightening/loosening 1 3
This question in 0445/32 Oct/Nov 2021
Q46 · 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
This question in 0445/32 Oct/Nov 2021
Q47 · 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
This question in 0445/32 Oct/Nov 2021
Q48 · An incomplete drawing of a flush hinge 0445/33 Oct/Nov 2021
3 Fig. 3.1 shows an incomplete drawing of a flush hinge. Fig. 3.1 Add to Fig. 3.1 to complete the drawing of the flush hinge. [2]
2 marks
Mark scheme: 3 Completed drawing shows left hand flap 1 Two holes shown in flap 1 2 Do accept max. 3 holes in added flap Do accept reverse shape on right with 2 holes shown
This question in 0445/33 Oct/Nov 2021
Q49 · 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
Q50 · A cabinet with a hinged door and parts A and B of a magnetic door catch 0445/31 May/June 2022
10 Fig. 10.1 shows a cabinet with a hinged door and parts A and B of a magnetic door catch. hinge hinge cabinet 15 mm thick wood A B Fig. 10.1 (a) Show clearly on Fig. 10.1 where each part of the magnetic door catch, A and B, would be attached to the cabinet. [2] (b) Name a suitable type of hinge that could be used in the positions shown in Fig. 10.1. … [1]
3 marks
Mark scheme: 10(a) A fastened inside edge of door 1 B fastened inside right side of cabinet 1 2 10(b) Suitable hinge: butt 1 Accept piano hinge
This question in 0445/31 May/June 2022
Q51 · 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
Q52 · 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
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Q53 · A screw thread being cut on a length of mild steel rod using a circular split die held in… 0445/32 May/June 2022
4 Fig. 4.1 shows a screw thread being cut on a length of mild steel rod using a circular split die held in a die stock. Fig. 4.1 Use sketches and notes to show how the end of the rod shown below could be prepared before the circular split die is used to cut the screw thread. [2]
2 marks
Mark scheme: 4 Sketch showing end of rod chamfered 1 Produced by filing, centre lathe 1 2
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Q54 · 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
This question in 0445/32 May/June 2022
Q55 · Two measuring tools, A and B, that can be used with round section materials 0445/33 May/June 2022
4 Fig. 4.1 shows two measuring tools, A and B, that can be used with round section materials. A B Fig. 4.1 Add sketches and notes to Fig. 4.1 to show how the tools, A and B, could be used. [4]
4 marks
Mark scheme: 4 A rod/bar shown inside tips of calipers 1 4 Names of tools not required How it is used: measuring external diameters 1 B tube shown inside tips of calipers 1 How it is used: measuring internal diameters 1
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Q56 · Two pieces of hardwood, A and B, set up, ready to be ‘turned’ on a woodturning lathe 0445/33 May/June 2022
7 Fig. 7.1 shows two pieces of hardwood, A and B, set up, ready to be ‘turned’ on a woodturning lathe. wood to be ‘turned’ B A Fig. 7.1 Name the woodturning processes to be carried out on the hardwoods A and B. Process for A … Process for B … [2]
2 marks
Mark scheme: 7 A faceplate turning 1 2 B between-centres turning 1
This question in 0445/33 May/June 2022
Q57 · 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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Q58 · 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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Q59 · 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
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Question 60 0445/33 Oct/Nov 2022
5 Fig. 5.1 shows a centre lathe. Fig. 5.1 Two items of centre lathe equipment are shown below. A B Add the labels A and B to Fig. 5.1 to indicate where each part would be fitted. [2]
2 marks
Mark scheme: 5 A shown in headstock 1 2 Accept answers where the parts of the B shown in tailstock 1 lathe are drawn on the centre lathe
This question in 0445/33 Oct/Nov 2022
Q61 · Two tools, A and B, that can be used to cut sheet metal 0445/31 May/June 2023
3 Fig. 3.1 shows two tools, A and B, that can be used to cut sheet metal. A B Fig. 3.1 Give the name of the tools labelled A and B in Fig. 3.1. A … B … [2]
2 marks
Mark scheme: 3 A tin snips / snips OR metal shears / shears [1] B cold chisel /chisel [1] 2
This question in 0445/31 May/June 2023
Q62 · 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
This question in 0445/32 May/June 2023
Q63 · 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
Q64 · 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
Q65 · 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]
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Q66 · 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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Q67 · 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
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Q68 · Three types of drill bit 0445/31 May/June 2024
2 Table 2.1 shows three types of drill bit. Table 2.1 Chosen Types of drill bit number 20 Complete Table 2.1 by adding the number from the list below to show the correct use for each drill bit. 1 used to drill smooth sided, flat bottomed holes 2 used in a centre lathe to start off a hole in metal 3 used for countersinking holes in wood and metal 4 used for fast drilling in wood 5 used to drill 20–75 mm diameter holes [3]
3 marks
Mark scheme: 2 Top – bottom: numbers 4 1 3 [31] 3
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Q69 · 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 [41] 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 [02] 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 [31] 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
This question in 0445/31 May/June 2024
Q70 · 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 [31] Tools/equipment: vice/clamping method, mallet or hammer + scrap wood [21] 5 12(c)(ii) Anodising gives a protective layer, greater corrosion resistance, attractive [coloured] appearance [21] 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 [41] OR Details of router: width + length of groove, spacing, set up of router [41] 5 Question Answer Marks Guidance 12(e) Any two properties: attractive colours to match environment, corrosion resistance in wet areas, easily cleaned [21] 2 Accept any other valid properties
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Q71 · 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 [21] 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 [21] 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 02 dependent on technical accuracy, proportion [02] 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 [02] Locking method: added strips, use of nuts and screws [1] Locks at 4 different angles [1] Named materials [1] 5
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Q72 · Two different types of caliper, A and B, measuring the diameters of round bars 0445/32 May/June 2024
4 Fig. 4.1 shows two different types of caliper, A and B, measuring the diameters of round bars. A B Fig. 4.1 (a) Name the type of caliper labelled B. … [1] (b) Explain why the measurement taken by caliper A will be less accurate than the measurement taken by caliper B. … … … [2]
3 marks
Mark scheme: 4(a) Digital or vernier caliper [1] 1 4(b) Explanation: the measurement taken has to be set against a rule [1] Likelihood of moving caliper legs/human error taking reading [1] 2
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Q73 · A hardwood box with a hinged lid 0445/32 May/June 2024
8 Fig. 8.1 shows a hardwood box with a hinged lid. lid opens too far sides 15 mm thick lid must open to 60° maximum Fig. 8.1 Use sketches and notes to show a fitting that could be attached to the lid and box to prevent the lid from opening more than 60° as shown in Fig. 8.1. [3]
3 marks
Mark scheme: 8 Some form of ‘stay’, chain, ribbon, string, spring [1] Attached to lid and attached to side [21]
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Q74 · Part of an incomplete design for a towel rack 0445/32 May/June 2024
10 Fig. 10.1 shows part of an incomplete design for a towel rack. The backboard is made of hardwood and the arm is made from ∅8 aluminium rod. 80 20 50 backboard arm Fig. 10.1 Use sketches and notes to show how the arm could be attached to the backboard and allowed to ‘swing’ as shown in Fig. 10.1. Name the materials used. [3]
3 marks
Mark scheme: 10 Some form of wooden ‘block’, metal ‘bracket’ [1] Construction [1] Suitable material named [1] 3
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Q75 · 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 [21] 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 [21] 2
This question in 0445/32 May/June 2024
Q76 · 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 [21] 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 [31] 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 [21] 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. [61] 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. [61] 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. [61] 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. [51] 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.
This question in 0445/32 May/June 2024
Q77 · 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
Q78 · Two tools, A and B, being used on the end of a round metal rod 0445/31 May/June 2025
4 Fig. 4.1 shows two tools, A and B, being used on the end of a round metal rod. A B metal rod Fig. 4.1 Name tools A and B. A … B … [2]
2 marks
Mark scheme: 4 A scriber 2 B centre square, centre finder [2 1]
This question in 0445/31 May/June 2025
Q79 · A box with a hinged lid 0445/31 May/June 2025
8 Fig. 8.1 shows a box with a hinged lid. lid 12 mm thick hardwood A 300 Fig. 8.1 Sketch and name a suitable hinge that could be used to join the lid to the box at A shown in Fig. 8.1. [3]
3 marks
Mark scheme: 8 Suitable hinge: piano [1] 3 Accuracy: award any two from: 2 leaves, drilled holes, length [2 1]
This question in 0445/31 May/June 2025
Q80 · Details of a jig used when bending a brass strip to shape 0445/31 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]
This question in 0445/31 May/June 2025
Q81 · Three tools, A, B and C, that can be used to cut sheet metal 0445/32 May/June 2025
1 Fig. 1.1 shows three tools, A, B and C, that can be used to cut sheet metal. B A C Fig. 1.1 Name each of the tools. A … B … C … [3]
3 marks
Mark scheme: Question Answer Marks Guidance 1 A tinsnips 3 A Accept snips, straight/curved snips, tin snippers, metal B cold chisel shears C guillotine, bench shears [3 1]
This question in 0445/32 May/June 2025
Q82 · A handle made from aluminium 0445/32 May/June 2025
3 Fig. 3.1 shows a handle made from aluminium. A Fig. 3.1 (a) Name a machine that could be used to make the handle. … [1] (b) Give the correct term to describe the surface produced at A in Fig. 3.1. … [1]
2 marks
Mark scheme: 3(a) Centre lathe, lathe, metal lathe, engineers lathe, 1 Do not accept CNC 3(b) Knurling 1
This question in 0445/32 May/June 2025
Q83 · A box with a hinged lid 0445/33 May/June 2025
8 Fig. 8.1 shows a box with a hinged lid. lid 12 mm thick hardwood A 300 Fig. 8.1 Sketch and name a suitable hinge that could be used to join the lid to the box at A shown in Fig. 8.1. [3]
3 marks
Mark scheme: 8 Suitable hinge: piano [1] 3 Accuracy: award any two from: 2 leaves, drilled holes, length [2 1]
This question in 0445/33 May/June 2025
Q84 · 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
Q85 · 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
Q86 · 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
Q87 · 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]
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![Question 41: Fig. 3.1 shows an incomplete drawing of a flush hinge. Fig. 3.1 Add to Fig. 3.1 to complete the drawing of the flush hinge. [2]](https://img.pastlit.com/crops/79c6435b-e18e-4207-9c4f-158ff8a1b445/q3.webp)
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![Question 48: Fig. 3.1 shows an incomplete drawing of a flush hinge. Fig. 3.1 Add to Fig. 3.1 to complete the drawing of the flush hinge. [2]](https://img.pastlit.com/crops/aa3424dc-30cd-46c2-80d6-9deed5725a50/q3.webp)
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