Paper 1 June 2019

Question 1

Q.1 Explain why ‘potatopak’ is a suitable material for the manufacture of disposable cutlery. (3 marks)

This material is suitable for disposable cutlery manufacture because it is biodegradable, compostable and made from a renewable resource. It has similar properties to traditional plastics, such as being durable and able to hold its shape once formed, making it a good substitute for single-use plastic cutlery.

Question 2

Q. 2 Explain how BSI certification impacts on the purchase of a child’s car seat by a consumer. (6 marks)

BSI (British Standards Institution) certification indicates that a child's car seat has undergone rigorous testing and meets strict safety standards set by the UK government. When a consumer purchases a car seat with BSI certification, they can be confident that the seat has been independently verified to provide adequate protection for a child in the event of an accident. This can give peace of mind to the consumer and can influence their purchasing decision.

Safety assurance: BSI certification means that the child's car seat has been tested to meet strict safety standards set by the UK government, providing the consumer with assurance that the seat is safe for their child.
Independent verification: The BSI certification process includes independent testing and verification, giving the consumer confidence in the quality and safety of the seat.
Compliance with regulations: BSI certification ensures that the car seat complies with relevant regulations, giving the consumer peace of mind that they are not purchasing a product that is non-compliant.
Improved product quality: Car seats with BSI certification must meet rigorous standards, meaning that the consumer can be confident that they are purchasing a high-quality product.
Comparison and choice: The availability of BSI certification makes it easier for consumers to compare and choose the best car seat for their child, as they can look for the BSI certification mark to identify products that have met the required safety standards.
Legal protection: If a consumer purchases a BSI certified child's car seat and an accident occurs, they may be protected by the certification, as it can serve as evidence that the seat was compliant with safety regulations at the time of purchase.

Question 3

Q. 3 Give three benefits of using stock forms of material for a manufacturer. (3 marks)

Cost savings: Using stock forms of material, such as standardized sheets, tubes, or rods, can save manufacturers money by reducing the cost of custom fabrication and reducing waste from material that is not used.
Increased efficiency: By using stock forms of material, manufacturers can reduce the lead time for obtaining materials and can more easily schedule production, resulting in increased efficiency and productivity.
Improved quality control: Using stock forms of material allows manufacturers to ensure consistent quality and dimensions, reducing the risk of defects and the need for rework. This leads to improved product quality and increased customer satisfaction.

Question 4

Q. 4 PAR is a stock form of timber. What does PAR stand for? (1 mark)

PAR stands for Planed All Round. In the context of timber, PAR refers to a stock form of wood that has been planed on all sides, resulting in a smooth and uniform surface. This type of timber is commonly used in construction and carpentry, as it is easy to work with and ready for use in a variety of applications.

Question 5

Q. 5 Explain why powder coating is an appropriate finish for the climbing frame shown in Figure 1. (6 marks)

Powder coating is an appropriate finish for an outdoor children's climbing frame for several reasons:

Durability: Powder coating provides a tough, durable finish that can withstand the wear and tear of outdoor use and frequent use by children. It is also resistant to fading, chipping, and peeling, which is important for an outdoor play area.
Safety: Powder coating is a non-toxic and environmentally friendly process, making it a safe choice for use on children's play equipment. It is also smooth and uniform, reducing the risk of sharp edges or rough surfaces that could pose a hazard to children.
Weather resistance: Powder coating provides excellent protection against the elements, including rain, snow, and UV exposure. This is important for an outdoor climbing frame, as exposure to the elements can cause corrosion and degradation of the frame over time.
Aesthetics: Powder coating comes in a wide range of colors and finishes, allowing manufacturers to create an attractive and visually appealing climbing frame that will complement its outdoor surroundings.

Overall, powder coating provides a durable, safe, weather-resistant, and visually appealing finish that makes it an appropriate choice for an outdoor children's climbing frame.

Question 6

Copyright is a form of intellectual property protection that gives the creator of an original work the exclusive right to control the use and distribution of that work. This includes the right to reproduce, display, perform, and distribute the work, as well as to create derivatives or adaptations of the work. Copyright protection applies to a wide range of works, including literary works, musical compositions, artistic works, and software. Copyright law is designed to balance the interests of creators and users of protected works, and it typically lasts for a specified period of time, after which the work enters the public domain and can be used freely by anyone.

A trademark is a form of intellectual property protection that identifies a specific brand or product and distinguishes it from those of other companies. A trademark can be a word, phrase, symbol, design, or combination of these elements, and it is used to indicate the origin of goods or services. The purpose of a trademark is to protect the reputation and goodwill of the brand, and to prevent confusion among consumers about the source of goods or services. Trademarks are registered with the appropriate government agency and are legally protected, allowing the owner to take legal action against anyone who infringes on their trademark rights. Once a trademark is registered, it can be used in commerce to promote and sell the brand or product, and it can also be licensed or sold to others.

A patent is a form of intellectual property protection that gives the inventor the exclusive right to control the use, manufacture, and sale of an invention for a specified period of time, usually 20 years from the date of filing. A patent is granted by a government agency, and it provides the inventor with legal protection against others who may try to use or sell their invention without permission. To be eligible for a patent, an invention must be novel, non-obvious, and useful. This means that it must be something new and innovative, not obvious to someone skilled in the field, and have practical applications. Patents are typically used to protect new products, processes, and technologies, and they can provide the inventor with a competitive advantage by giving them the exclusive right to exploit their invention. In exchange for this exclusive right, the inventor must publicly disclose the details of the invention, allowing others to learn from it and build upon it.

Question 7

Q. 7 Figures 2 and 3 show rolls of adhesive tape. Compare the environmental impact of the materials used to manufacture the cores of the adhesive tapes shown. (6 marks)

The environmental impact of manufacturing a roll of adhesive tape with an ABS (Acrylonitrile Butadiene Styrene) core and a roll of adhesive tape with a cardboard core can vary.

ABS is a plastic material that is derived from petrochemicals, which are non-renewable resources. The production of ABS contributes to greenhouse gas emissions and the release of toxic chemicals into the environment.

Cardboard, on the other hand, is made from renewable resources such as wood pulp and can be easily recycled. The production of cardboard results in lower greenhouse gas emissions compared to the production of ABS.

In conclusion, a roll of adhesive tape with a cardboard core is likely to have a lower environmental impact compared to a roll of adhesive tape with an ABS core.

The production of adhesive tape with an ABS (Acrylonitrile Butadiene Styrene) core and a cardboard core has different environmental impacts. ABS is a synthetic plastic material that is derived from non-renewable petrochemicals, leading to high levels of greenhouse gas emissions during production. Furthermore, the production process releases toxic chemicals into the environment, contributing to pollution and environmental degradation.

On the other hand, adhesive tape with a cardboard core is made from renewable resources such as wood pulp, which are more sustainable. The production process of cardboard results in lower greenhouse gas emissions, making it a more environmentally friendly option. Additionally, cardboard can be easily recycled, reducing waste and helping to conserve natural resources.

In terms of energy consumption, the production of ABS requires more energy compared to the production of cardboard. This further contributes to high levels of greenhouse gas emissions and the depletion of non-renewable energy resources.

In conclusion, adhesive tape with a cardboard core has a lower environmental impact compared to tape with an ABS core. The production of ABS contributes to pollution, environmental degradation, and the depletion of non-renewable resources, while the production of cardboard is more sustainable, leading to lower greenhouse gas emissions and the conservation of natural resources.

Question 8

Question 9

Name a specific application for each of the following compliant materials:

• bleed proof paper

duplex card

• moulded paper pulp.

One specific application for bleed proof paper is in the field of calligraphy, where the paper is used to prevent ink from spreading and ruining the written work.

Bleed proof paper is commonly used in the printing industry, specifically for creating color separations in offset printing. The paper prevents the ink from bleeding through to the other side, ensuring that each color is printed precisely where it should be.

One specific application for bleed proof paper is in the printing of high-quality color documents, such as photographs or graphic design work, where bleeding of inks through the paper is not desired.

A specific application for duplex card is in the manufacturing of ID cards, where a double-sided printing capability is required for personal information and photos to be printed on both sides of the card.

A duplex card, also known as double-sided card, is often used as a business card or membership card. The front and back of the card can be printed with different information, such as a person's name, company name, title, contact information, and more.

Packaging: Moulded paper pulp is used to make packaging for food and consumer goods, as it is biodegradable and compostable.
Tableware: Moulded paper pulp is used to make disposable plates, bowls, and cups, as it is strong, lightweight, and can be molded into various shapes and sizes.
Gardening: Moulded paper pulp is used in the horticulture industry to make seed trays and pots, as it provides good protection and aeration for seedlings and young plants.
Art & Craft: Moulded paper pulp can be used as a sculpting material in art and craft projects, as it can be molded, carved, and painted.

Question 10

Q. 10 Evaluate the following techniques for rendering a design:

• using computer aided design (CAD)

• hand generated.

Using computer aided design (CAD) for rendering a design has several advantages:

Precision: CAD software allows designers to create accurate and detailed designs with precise measurements and dimensions, reducing the risk of errors and mistakes.
Speed: With CAD, designs can be created, edited, and modified much faster than traditional manual methods, saving time and increasing productivity.
Collaboration: CAD allows multiple people to work on the same design at the same time, making it easier for teams to collaborate and share ideas.
Flexibility: CAD software provides a wide range of tools and features that allow designers to make changes to their designs quickly and easily, providing greater flexibility and versatility.
Documentation: CAD designs can be easily documented and stored for future reference, making it easier for designers to keep track of their work and maintain a record of their design process.

Overall, CAD is a powerful tool for rendering designs that offers numerous benefits over traditional manual methods, making it an essential tool for many designers and engineers.

Hand rendering is a traditional and personal approach to rendering designs, allowing the designer to express their creativity and demonstrate their skills in a unique and custom manner. Hand rendering techniques, such as sketching, watercolor, or pastel, can be used to create a wide range of effects, such as shading, texture, and color.

Hand rendering can be beneficial for creating conceptual designs, exploring different ideas, and presenting designs in a more personal and engaging way. It also helps to develop an understanding of materials and construction techniques, and can be useful for communicating ideas to clients and other stakeholders.

However, hand rendering can be time-consuming, and the final results may not be as precise or accurate as digital rendering techniques. Additionally, hand rendering can be limited in terms of reproducibility and scalability, making it challenging to create multiple copies of the same design or to accurately resize the design.

In conclusion, hand rendering is a valuable tool for designers, but it is important to carefully consider the intended use of the rendering and the desired outcome before deciding whether hand rendering or digital rendering is the best approach.

Question 11

Question 12

Q. 12 Explain the safe work practices necessary to protect workers when using solvent adhesives.

To ensure worker safety when using solvent adhesives, the following safe work practices should be implemented:

Proper ventilation: Workers should be provided with adequate ventilation to reduce the risk of exposure to fumes from solvent adhesives. This can be achieved by using exhaust fans or by opening windows and doors to allow for natural ventilation.
Personal Protective Equipment (PPE): Workers should be provided with appropriate PPE such as gloves, goggles, and respirators to protect their skin and respiratory system from the effects of solvent adhesives.
Proper storage: Solvent adhesives should be stored in a well-ventilated area away from sources of ignition and in containers that are properly labeled and securely sealed to prevent spills or leaks.
Labeling: All solvent adhesives should be properly labeled with information about their composition, hazards, and first aid measures in case of an emergency.
Training: Workers should receive training on the safe handling and use of solvent adhesives, including information about the potential health effects and first aid measures in case of an emergency.
Emergency response plan: Employers should have an emergency response plan in place to deal with spills or other accidents that may occur when using solvent adhesives. This plan should include procedures for evacuation, first aid, and spill cleanup.

Question 13

Explain why neoprene is a suitable material to manufacture a case to carry a laptop.

Neoprene is a suitable material to manufacture a laptop case due to the following reasons:

Durability: Neoprene is a synthetic rubber that is known for its durability and resistance to wear and tear. This makes it an ideal material for protecting delicate electronic devices like laptops.
Water resistance: Neoprene is also resistant to water and moisture, which is important for protecting a laptop from accidental spills or splashes.
Shock absorption: The material has a high level of elasticity and can absorb shocks and impacts, which helps to protect the laptop from damage if dropped or bumped.
Flexibility: Neoprene is a flexible material that can easily be molded into different shapes and sizes to accommodate different laptop models.
Lightweight: Neoprene is a lightweight material, which makes it easy to carry around and reduces the overall weight of the laptop case.
Chemical resistance: Neoprene is also resistant to many chemicals, oils, and solvents, which helps to protect the laptop from accidental spills or exposure to harsh chemicals.

Overall, the combination of durability, water resistance, shock absorption, flexibility, lightweight, and chemical resistance make neoprene an ideal material for manufacturing a laptop case.

Question 14

Lift interfaces have been designed with varying levels of inclusiveness for different users. Some of the design elements that contribute to the inclusiveness of lift interfaces include:

Universal Design: Universal design principles aim to create products and spaces that are accessible and usable by the widest possible range of users, regardless of their abilities or disabilities. Lift interfaces that follow universal design principles are generally more inclusive and usable by a wider range of users.
Clear Labeling: Clear labeling and signage on lift interfaces, such as button labels, floor numbers, and braille, can help users who have visual impairments to navigate and use the lift independently.
Braille and Audio Announcements: Braille buttons and audio announcements in the lift help users who are visually impaired to identify the buttons they need to press and the floor they are on.
Accessibility Features: Accessibility features such as low buttons, large buttons, audio cues, and wheelchair ramps can help users with disabilities to use the lift more easily.
Ease of Use: Lift interfaces that are user-friendly, intuitive, and easy to use can help users of all abilities to navigate the lift and reach their destination with confidence.

However, despite these design elements, there is still room for improvement in the inclusiveness of lift interfaces. Some older lift interfaces may not have been updated to meet the latest accessibility standards, and new lift interfaces may not always be designed with accessibility in mind. As such, it is important to continually evaluate and improve the design of lift interfaces to ensure that they are inclusive to all users.

Question 15

Question 16

Explain why industrial tests are more accurate than workshop tests when testing material properties. (2 marks)

Industrial tests are typically considered more accurate than workshop tests for testing material properties due to several factors:

Equipment: Industrial tests use advanced and calibrated equipment that is specifically designed for testing material properties, ensuring more accurate and consistent results.
Environment: Industrial tests are performed in controlled environments that minimize the impact of external factors, such as temperature, humidity, and atmospheric pressure, on the results.
Expertise: Industrial tests are often carried out by trained technicians or engineers with specialized knowledge and experience in testing procedures, ensuring that tests are performed correctly and consistently.
Repeatability: Industrial tests often have strict protocols in place to ensure that results are repeatable and that the same results are obtained in the same conditions.
Standardization: Many industrial tests follow established standards, such as ASTM or ISO standards, which ensure consistency in test methods and results across different labs and industries.

All these factors make industrial tests more reliable and accurate in determining material properties compared to workshop tests, which may not have the same level of equipment, environment, expertise, repeatability, and standardization.

Question 17

Q. 17 Describe how a specific industrial test is undertaken to measure material hardness. (4 marks)

One common industrial test used to measure material hardness is the Rockwell hardness test. The Rockwell hardness test is a widely used method for measuring the hardness of metals and alloys. The test is performed by applying a minor load to the material, followed by a major load. The depth of penetration of the indenter into the material is then measured and converted to a hardness value.

The procedure for a Rockwell hardness test is as follows:

Preparation: The surface of the material is cleaned and prepared for testing. The specimen must be flat and free from defects that could affect the test result.
Selection of indenter and load: The Rockwell hardness test uses a diamond cone or a ball indenter and a specific load, depending on the material being tested and the desired hardness scale.
Minor load: A minor load is applied to the material using the selected indenter. This load serves to pre-load the material and reduce measurement errors.
Major load: The major load is then applied to the material using the same indenter. The major load is typically several times greater than the minor load.
Measurement: The depth of penetration of the indenter into the material is measured after the major load has been removed. This measurement is converted to a hardness value using a Rockwell hardness scale.
Repeatability: The Rockwell hardness test is usually performed several times on the same material to ensure repeatability and to obtain an average hardness value.

The Rockwell hardness test is a quick and straightforward method for measuring material hardness, and it is widely used in industries such as aerospace, automotive, and manufacturing to ensure that materials meet specified hardness requirements.

Question 18

Q. 18 Aluminium TIG welded bicycle frame CFRP lay-up bicycle frame

Evaluate the suitability of the materials and manufacturing methods used for each of the bicycle frames shown.

TIG welding and CFRP lay-up are two different methods of manufacturing bicycle frames, each with its own advantages and disadvantages.

TIG welding is a method of welding aluminum, which involves heating the material with a tungsten electrode to create a strong, permanent bond between two pieces of metal. Advantages of TIG welding aluminum include its ability to produce a strong, lightweight, and durable frame. However, TIG welding requires specialized equipment and skilled personnel, which can make the process more time-consuming and expensive.

CFRP lay-up, on the other hand, is a method of creating composite structures by layering carbon fiber reinforced polymer (CFRP) material over a mold and curing it with a resin. This method can produce a highly customized and lightweight frame, but is more complex and requires specialized equipment and personnel. CFRP lay-up is also more expensive than TIG welding.

In terms of suitability, the choice between TIG welding and CFRP lay-up will depend on the specific requirements and constraints of the project. If weight is a key concern and a high degree of customization is desired, then a CFRP lay-up frame may be more suitable. If cost and time constraints are a concern, then TIG welding may be the better choice.

The suitability of aluminum TIG welded and carbon fiber reinforced polymer (CFRP) lay-up bicycle frames depends on several factors, including:

Aluminum TIG Welded:

Strength: TIG welding provides strong and durable welds, making aluminum TIG welded frames suitable for demanding riding conditions.
Cost: Aluminum is a relatively cheap material, and TIG welding is a relatively simple manufacturing process, making aluminum TIG welded frames more cost-effective than other materials.
Weight: Aluminum is a lightweight material, making TIG welded frames suitable for lightweight and performance-oriented bikes.
Weldability: Aluminum is highly weldable and can be easily joined using TIG welding, making it suitable for creating complex frame shapes.

CFRP Lay-up:

Strength: CFRP is a very strong and stiff material, making lay-up frames suitable for demanding riding conditions and providing an excellent strength-to-weight ratio.
Cost: CFRP is a relatively expensive material, and lay-up is a more complex manufacturing process compared to TIG welding, making CFRP lay-up frames more expensive than aluminum TIG welded frames.
Weight: CFRP is a very lightweight material, making lay-up frames suitable for lightweight and performance-oriented bikes.
Complexity: The lay-up process is more complex and requires specialized knowledge and equipment, making CFRP lay-up frames more challenging to manufacture compared to aluminum TIG welded frames.

In conclusion, both aluminum TIG welded and CFRP lay-up bicycle frames have their advantages and disadvantages, and the suitability of each will depend on factors such as cost, weight, and complexity of manufacture.

Question 19

Question 20

Q. 20 Explain why the knock down fittings named above are appropriate for each of the specific applications. [3 × 2 marks]

Barrel nut and bolt; Cam Lock; Dowel

A barrel nut and bolt can be suitable for a baby cot frame as it can provide a strong and secure connection between the various parts of the baby cot frame, ensuring the stability and safety of the cot. It allows allows for adjustability, allowing the height of the cot to be easily changed to suit the needs of the child as they grow. It is a simple and straightforward fastening mechanism that can be easily assembled, making the construction of the baby cot frame easier. It is a robust and durable fastening mechanism that can withstand the repeated use and weight of a baby, making it suitable for use in a baby cot frame.

In summary, the barrel nut and bolt is a suitable fastening mechanism for a baby cot frame due to its strength, adjustability, ease of assembly, and durability.

A cam lock can be suitable for a shelf unit frame as a Cam lock provides a strong and secure connection between the various parts of the shelf unit frame, ensuring the stability and safety of the unit. They are a simple and straightforward fastening mechanism that can be easily assembled, making the construction of the shelf unit frame easier and faster. They can often be tightened or loosened without the use of tools, making it easy to adjust or disassemble the shelf unit frame if necessary. Cam locks are available in a variety of sizes and styles, making them suitable for use in a wide range of shelf unit frames, regardless of the size or shape of the frame components.

In summary, cam locks are a suitable fastening mechanism for a shelf unit frame due to their strength, ease of assembly, no-tool requirement, and versatility.

Question 21

Q. 21 Explain the importance of the efficient supply of materials and components in a Just In Time (JIT) manufacturing process. (9 marks)

The efficient supply of materials and components is of utmost importance in a Just In Time (JIT) manufacturing process. JIT is a production strategy that is designed to minimise waste and increase efficiency by only producing what is needed, when it is needed, and in the amount that is needed. An efficient supply chain is essential in ensuring that the right materials and components are delivered just in time for use, reducing the risk of overproduction and associated costs. With JIT, there is no need to maintain large inventories, reducing the costs associated with storage, handling, and insurance. A constant and reliable supply of materials and components is necessary to maintain the flow of production. Any disruption in the supply chain can result in production downtime, bottlenecks, and a decrease in overall efficiency. Efficient supply management ensures that the right materials and components are available when they are needed, maximizing production efficiency. An efficient supply chain helps ensure that the right materials and components are delivered just in time for production, reducing the risk of delays and improving delivery times. This leads to improved customer satisfaction and helps build a positive reputation for the manufacturer. An efficient supply chain requires close collaboration between suppliers and manufacturers. This helps to ensure that materials and components are delivered on time and to the required specifications. In this type of system, the supply of materials and components must be carefully managed to ensure that the production process runs smoothly and without interruption. JIT manufacturing is designed to increase the quality of the final product. An efficient supply chain is essential in ensuring that high-quality materials and components are used in production, reducing the risk of defects and increasing customer satisfaction. JIT allows for a flexible response to changing customer demand, as materials and components can be sourced and delivered quickly as needed. This enhances the manufacturer's ability to respond to changes in the market and adapt to new customer requirements. A well-designed and efficiently managed JIT system can provide a significant competitive advantage. The benefits of reduced waste, increased efficiency, improved quality, and reduced costs can help manufacturers to remain competitive in a highly dynamic marketplace.

In conclusion, the efficient supply of materials and components is a critical factor in the success of a Just In Time (JIT) manufacturing process. It helps to minimize waste, increase efficiency, improve quality, reduce costs, enhance flexibility, and improve customer satisfaction, all of which are essential to remain competitive in today's fast-paced and dynamic marketplace.

Question 22

Q. 22 Give three reasons why a kitchen work surface may have a melamine formaldehyde layer applied.

Durability: Melamine formaldehyde is a hard, durable material that can withstand wear and tear and resist damage from moisture, heat and most household chemicals, making it an ideal choice for kitchen work surfaces.
Ease of maintenance: Melamine formaldehyde is easy to clean and maintain, as it is resistant to staining, fading, and discoloration, meaning that it will look good for many years.
Cost-effectiveness: Melamine formaldehyde is an economical choice for kitchen work surfaces, as it is less expensive than other materials such as solid wood or granite, yet provides a similar appearance and durability.

Question 23

Q. 23 Describe the process of forming a timber product using lamination. (6 marks)

Laminating is a process in which thin layers of timber are glued together to form a thicker, stronger and more stable product. Here is a detailed description of the process:

Selection of Timber: The first step in the lamination process is to select the right type of timber for the desired product. Different types of timber have different characteristics, such as density, grain pattern, and color, which can affect the final appearance and performance of the product.
Preparation of Layers: The individual layers of timber are then prepared by cutting them to the required size and shape. Any knots or other imperfections in the wood are removed to ensure that the final product will be strong and stable.
Drying the Layers: The individual layers are then dried to remove any moisture content. This helps to prevent warping and ensure that the final product will remain stable over time.
Glue Application: The next step is to apply a thin layer of glue to the individual layers. The type of glue used will depend on the desired end product, but common options include PVA, resin, and epoxy. The layers are then placed together and clamped to ensure a tight bond.
Pressing: The glued layers are then placed into a press, where pressure is applied to ensure that the glue has fully penetrated the layers and that the bond is as strong as possible. The pressure and time for which the layers are clamped will depend on the type of glue and the desired end product.
Finishing: Finally, the laminated product is removed from the press and the excess glue is trimmed away. The surface may then be sanded and finished to a high standard, ready for use in a wide range of applications, including flooring, furniture, and cabinetry.

In conclusion, laminating is an effective way to produce strong, stable, and attractive timber products from a variety of different materials. The process involves the selection of the right type of timber, preparation of the individual layers, drying, glue application, pressing, and finishing to produce a final product that is both functional and aesthetically pleasing.

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