This is a question paper for June 2020. Below are model answers to all questions from this paper, and some with additional illustrations of imagery to help give further context to the model answer. If you select a Question from the list below it will shortcut you to a model answer for that question. Each question has been written out at the start of the model answer.

Question 1

1. Polymorph allows for the creation of a grip that can be adjusted to fit a wide range of hand sizes and shapes, making it more comfortable and ergonomic for a larger number of users. Polymorph can be molded to fit the unique contours of an individual's hand, allowing for a more personalized and comfortable grip. Polymorph is a durable material that can withstand repeated use and maintain its shape, making it a suitable option for use in an ergonomic grip design that will be used frequently. Polymorph allows for easy customization of the grip shape to fit the individual user's hand size and shape, ensuring maximum comfort and ease of use. Polymorph is lightweight and durable, making it suitable for use in portable or handheld devices. Polymorph can be easily molded to incorporate additional features such as textured surfaces for improved grip and control.

Question 2

Q. 2 Define the following material properties: malleability; elasticity.

Malleability is the property of a material that allows it to be easily shaped or formed by hammering, bending or compressing without breaking or cracking. It is a measure of a material's ability to be deformed permanently without breaking or cracking.

Elasticity is the property of a material that allows it to return to its original shape after being stretched or compressed. It is a measure of a material's ability to be deformed temporarily and then return to its original shape. Elasticity is closely related to a material's Young's modulus, a measure of a material's resistance to elastic deformation.

Question 3

Using sustainable materials: Manufacturers are increasingly using materials that are renewable, recycled or biodegradable to reduce their environmental impact. This includes using materials such as bamboo, organic cotton, and bioplastics.

Implementing more efficient manufacturing processes: Many manufacturers are implementing more efficient production methods that use less energy and water, and produce less waste. This includes using technologies such as 3D printing, which can reduce material waste and energy consumption.

Manufacturers are also taking steps to increase recycling and reduce waste throughout the product lifecycle. This includes designing products that are easier to recycle, as well as implementing programs to collect and recycle end-of-life products. Additionally, some companies are switching to closed-loop recycling systems where waste from one process is used as the raw material in another process. By using more sustainable materials such as bamboo, recycled plastic and organic cotton. Implementing energy-efficient production processes, such as using renewable energy sources and improving energy efficiency. Incorporating closed-loop manufacturing systems, where waste materials are recycled back into the production process.

Question 4

High speed steel (HSS) is a type of tool steel that is known for its ability to maintain a high level of hardness at high temperatures. This makes it a suitable material for drilling applications where heat is generated during the cutting process. HSS has high wear resistance, which means it can withstand the high stress and abrasion of drilling through hard materials. It has good toughness, which allows it to resist breaking, chipping or cracking while drilling. HSS has high heat resistance, so it can withstand the high temperatures generated during drilling without losing its hardness. HSS is a relatively inexpensive material, making it a cost-effective choice for manufacturers. HSS is widely available and easy to machine, which makes it a readily accessible material for manufacturers to use in drill bit production.

Question 5

Both laser cutting and injection molding are suitable methods for manufacturing plastic corner sections, but they have different strengths and limitations.

Laser cutting is a subtractive manufacturing process that uses a high-powered laser beam to cut and shape materials. It is well-suited for creating complex and intricate designs, and it can be used to cut a wide range of materials, including plastics. Laser cutting can also be used to make small-batch or one-off parts, making it a good choice for prototyping or short-run production.

Injection molding, on the other hand, is an additive manufacturing process that injects molten plastic into a mold to create the desired shape. It is well-suited for mass production and can be used to make large quantities of identical parts very quickly and at low cost. Injection molding is also good for creating parts with consistent dimensions, tight tolerances, and smooth surfaces.

In summary, if you need to create complex or intricate designs, or if you only need a small number of parts, laser cutting may be the better choice. However, if you need to mass produce identical parts quickly and inexpensively, injection molding is likely the way to go.

Both laser cutting and injection molding are suitable methods for fabricating a plastic corner section, but they have different advantages and disadvantages.

Laser cutting is a versatile and precise method for cutting complex shapes out of plastic sheets. It is well-suited for small batch sizes and prototypes, and it can be used to create intricate designs with fine details. However, it is not as efficient as injection molding for producing large quantities of parts, and it can be more expensive for larger parts.

Injection molding, on the other hand, is a highly efficient and cost-effective method for producing large quantities of identical parts. The process involves injecting molten plastic into a mold under high pressure, which creates a part with excellent dimensional accuracy and surface finish. Injection molding is the best option for mass production and the parts will have a consistent quality, but it may be more expensive to set up the mold and it is not as flexible with design as laser cutting.

In summary, laser cutting is a good option for small batch sizes, intricate designs and prototypes while injection molding is better for mass production and consistent quality.

Question 6

The process of soft soldering, also known as tin soldering, involves joining two or more metal surfaces together using a low-melting point alloy, typically made of tin and lead. The main stages in the process of soft soldering are:

The first stage is to prepare the surfaces to be soldered by cleaning them thoroughly to remove any dirt, grease, or oxide. This ensures that the surfaces are clean and smooth, allowing for a good bond to be formed. The next stage is to heat the surfaces to be soldered using a heat source such as a soldering iron or a gas torch. The heat is applied until the surfaces are hot enough to melt the solder alloy. Once the surfaces are heated, the solder is applied to the joint. It should be placed on the area to be joined and not on the heat source. The solder will melt and flow into the joint, forming a strong bond between the two surfaces. After the solder has been applied, the joint should be allowed to cool. This allows the solder to solidify and the bond to be formed. The final stage is to inspect the joint for any defects or issues. This includes checking for any leaks, cracks, or gaps in the joint. The joint should be smooth and have a shiny appearance if it is done correctly. After the inspection, the joint should be cleaned to remove any excess flux. Flux is a chemical used to improve the flow of the solder, but it can leave a residue if not cleaned properly.

Overall, soft soldering process is a relatively simple process that can be used to join a wide range of metal surfaces. It requires proper preparation of the surfaces, heating, soldering, cooling, inspection and cleaning for a strong, leak-free and shiny bond.

Question 7

Electronic Point Of Sale (EPOS) systems are widely used in retail and hospitality businesses to track sales and customer behavior. The data gained from these systems can be used in a variety of ways to improve business operations and increase revenue.

The most basic use of EPOS data is to track sales and analyze performance. Business owners can use this data to identify which products or services are selling well and which are not, allowing them to make informed decisions about inventory management and pricing. EPOS data can also be used to gain insight into customer behavior. This can include information such as the most popular items purchased, the average purchase value, and the frequency of visits. This data can be used to tailor marketing campaigns and improve customer service. EPOS systems can also be integrated with inventory management systems to provide real-time information about stock levels. This allows businesses to quickly identify when items need to be reordered, reducing the risk of stockouts and lost sales. EPOS data can also be used to identify patterns and trends in customer behavior, allowing businesses to target their marketing efforts more effectively. For example, if a business notices that sales of a particular product increase during a certain time of the year, they may choose to run a promotion for that product during that time. EPOS data can also be used to monitor staff performance and identify areas for improvement. This can include information such as the number of sales made by each employee, the average sale value, and the number of customer complaints. Lastly, EPOS data can be used for financial planning and budgeting by providing detailed information about sales, expenses and profit margin. Business owners can use this data to make informed decisions about pricing, inventory, and staffing levels, and better predict the future growth of their business.

In conclusion, the data gained from EPOS systems can provide valuable insights into customer behavior, sales trends, and inventory levels. Businesses can use this data to make informed decisions about inventory management, marketing, staff management, and financial planning, helping them to improve operations and increase revenue.

Electronic Point Of Sale (EPOS) systems are widely used in retail and hospitality businesses to track sales and customer behavior. The data gained from these systems can be used in a variety of ways to improve business operations and increase revenue.

The most basic use of EPOS data is to track sales and analyze performance. Business owners can use this data to identify which products or services are selling well, which are not, and which need to be discontinued, allowing them to make informed decisions about inventory management and pricing. EPOS data can also be used to gain insight into customer behavior. This can include information such as the most popular items purchased, the average purchase value, and the frequency of visits. This data can be used to tailor marketing campaigns, improve customer service and increase customer loyalty. EPOS systems can also be integrated with inventory management systems to provide real-time information about stock levels. This allows businesses to quickly identify when items need to be reordered, reducing the risk of stockouts and lost sales, and also helps in forecasting future demands. EPOS data can also be used to identify patterns and trends in customer behavior, allowing businesses to target their marketing efforts more effectively. For example, if a business notices that sales of a particular product increase during a certain time of the year, they may choose to run a promotion for that product during that time. EPOS data can also be used to monitor staff performance and identify areas for improvement. This can include information such as the number of sales made by each employee, the average sale value, and the number of customer complaints. Lastly, EPOS data can be used for financial planning and budgeting by providing detailed information about sales, expenses and profit margin. Business owners can use this data to make informed decisions about pricing, inventory, and staffing levels, and better predict the future growth of their business.

In conclusion, the data gained from EPOS systems can provide valuable insights into customer behavior, sales trends, and inventory levels. Businesses can use this data to make informed decisions about inventory management, marketing, staff management, and financial planning, helping them to improve operations, increase revenue and customer satisfaction.

Question 8 

Silicone is an appropriate material for the manufacture of an oven mitt because it has a number of properties that make it well-suited for this application.

Silicone has a high temperature resistance and can withstand temperatures up to 500°F (260°C) without melting or degrading, making it suitable for use around hot ovens and cooking surfaces. Silicone is an excellent insulator and can provide good protection against heat transfer, which helps to prevent burns and scalds. Silicone is a flexible material and can be easily molded into different shapes and sizes, which makes it an ideal choice for oven mitts. It can also withstand repetitive bending and stretching, which is important for a product that will be frequently used. Silicone is a non-stick material and does not absorb liquids or odors which makes it easy to clean and maintain, and also prevents contamination of food. Silicone is a durable material that is resistant to wear and tear, which means that oven mitts made from silicone will last a long time. Silicone is a safe material and is considered to be a food-grade material, it is also non-toxic, and non-allergenic which makes it safe to use in contact with food.

Overall, silicone is an appropriate material for the manufacture of an oven mitt because of its high temperature resistance, insulation, flexibility, non-stick, durability, and safety properties.

Question 9

Phosphorescent pigment is a type of pigment that is able to store energy from an external light source and then release it as visible light in the dark. This makes it a suitable option for use in indoor emergency signage, as it can provide visibility during power outages or other emergency situations.

Phosphorescent pigments provide high visibility in low light conditions, making it easy for people to see the emergency signage even when the lights are off. This is particularly important in emergency situations where visibility is limited and quick identification of emergency exits is crucial. Phosphorescent pigments are energy efficient, as they can store energy from natural or artificial light sources for extended periods of time and emit light for hours after the lights go out. This means that emergency signage does not require a constant power supply and can remain visible even during power outages. Phosphorescent pigments are also durable, as they are resistant to fading, cracking, and peeling. This means that the emergency signage will remain visible and readable even after extended periods of time. Phosphorescent pigments are cost-effective, as they do not require a constant power supply, which reduces the cost of energy consumption and maintenance. Phosphorescent pigments are considered as environmentally friendly, as they don't emit UV radiation, which can be harmful to humans and animals.

However, phosphorescent pigments have some limitations that need to be considered when evaluating their suitability for use in indoor emergency signage.

Phosphorescent pigments require an initial charging time before they can emit light. This means that if the emergency signage is not exposed to light for a long period of time, it may not be visible during the first minutes of an emergency. Phosphorescent pigments have a luminance decay over time, meaning that the emitted light will gradually decrease over time. This means that the emergency signage may not be as visible after a prolonged period of time. Phosphorescent pigments are typically available in a limited range of colors, and may not be suitable for all applications.

Overall, phosphorescent pigments are a suitable option for use in indoor emergency signage because of their high visibility, energy efficiency, durability, and cost-effectiveness. However, it is important to consider the initial charging time, luminance decay, and color limitations when evaluating their suitability for a specific application.

Question 10

Risk assessment is the process of identifying, evaluating and controlling hazards in a manufacturing environment. The purpose of risk assessment is to identify potential hazards that could cause harm to employees, customers, or the environment, and to implement appropriate controls to eliminate or reduce the risk of harm.

The first step in risk assessment is to identify potential hazards in the manufacturing environment. This includes identifying potential sources of harm, such as machinery, chemicals, and hazardous processes. Once hazards have been identified, they need to be evaluated in terms of the likelihood and severity of harm they could cause. This allows the manufacturer to prioritize hazards and focus on those that pose the greatest risk. After hazards have been identified and evaluated, appropriate controls need to be put in place to eliminate or reduce the risk of harm. This could include installing guards on machinery, implementing safe work procedures, providing personal protective equipment, or substituting hazardous materials with safer alternatives. Risk assessments are not a one-time process, they need to be reviewed and updated regularly to ensure that controls are still effective and that new hazards have not emerged. Risk assessment is also a legal requirement that helps companies to comply with regulations and standards such as OSHA and ISO.

In summary, the purpose of risk assessment in a manufacturing environment is to identify and evaluate potential hazards, and to implement appropriate controls to eliminate or reduce the risk of harm to employees, customers, and the environment. This process helps to ensure a safe and healthy working environment, reduce the risk of accidents and incidents, and comply with legal and regulatory requirements.

Question 11

Concrete is a suitable material for the manufacture of an outdoor table tennis table because it has a number of properties that make it well-suited for this application.

Concrete is a highly durable material and can withstand extreme weather conditions (think of all of the construction in Thailand that uses concrete (BTS, roads, buildings) and temperature changes without showing signs of wear and tear. This makes it suitable for outdoor use, where tables may be exposed to rain, sun, and other elements. Concrete is highly resistant to water, frost and high temperatures, which means that it will not warp or crack due to exposure to the elements. Concrete is a low-maintenance material, and does not require any special treatment or coating to maintain its strength and durability. This makes it a cost-effective option for outdoor table tennis tables. Concrete is a heavy material, which makes it stable and sturdy. This is important for table tennis tables as they need to be stable to ensure a good playing experience. Concrete can be cast in any shape, size and color and can be customized to fit any design, which means that it can be used to create tables that are visually appealing and match the aesthetics of the surroundings. Concrete is a cost-effective option for outdoor table tennis tables, as it is relatively inexpensive and long-lasting, which will help to reduce costs over time.

In summary, concrete is a suitable material for the manufacture of an outdoor table tennis table due to its durability, weather resistance, low maintenance, weight, customization and cost-effectiveness properties. The material is sturdy, stable, and weather-resistant which makes it an ideal choice for an outdoor table tennis table that will be exposed to the elements.

Question 12

Question 13

Bio-batch is a type of additive that is added to polymers in order to make them biodegradable. This means that they can break down naturally in the environment, rather than remaining as plastic waste. Bio-batch is added to polymers used in the manufacture of single-use carrier bags to help reduce the environmental impact of these bags.

Bio-batch makes the polymer biodegradable, meaning that it will break down naturally in the environment over time, rather than remaining as plastic waste. This reduces the amount of plastic waste that ends up in landfills, and the potential of plastic pollution. Bio-batch also makes the polymer compostable, which means that it can be broken down by microorganisms into natural materials such as water, carbon dioxide, and biomass. This helps to further reduce the environmental impact of single-use carrier bags and also helps to improve soil health. Bio-batch also helps to improve the sustainability of the polymer by reducing the dependency on fossil-based resources and promoting the use of natural, renewable resources. Bio-batch is a cost-effective solution for improving the environmental impact of single-use carrier bags, as it does not require significant changes to the manufacturing process and can be added to the polymer in small quantities. Many countries have implemented laws and regulations to reduce the environmental impact of single-use carrier bags, and bio-batch can help manufacturers comply with these regulations.

In summary, bio-batch may be added to a polymer used in the manufacture of single-use carrier bags to make the bags biodegradable and compostable, which helps to reduce their environmental impact. Bio-batch also helps to promote sustainability, reduce dependency on fossil-based resources and comply with legal regulations.

Question 14

Question 15

Q.15 Describe how physical and virtual prototypes can be used during the development of a product. Include the benefits of each kind of prototype to the designer in your answer.

Model answer

During the development of a product, physical and virtual prototypes are commonly used to test and refine the design before final production.

Physical prototypes are physical models of the final product that can be held and tested. They allow designers to test the product's form, fit and function in real-world conditions. Physical prototypes are created using various materials such as plastic, metal, or wood. Physical prototypes can be held, touched, and tested for durability, which can help designers identify potential issues with the design and make necessary adjustments. They are also beneficial for testing the product's usability and ergonomics, and for getting feedback from potential users. Benefits of physical prototypes include the ability to test the product's ergonomics and user-interaction, as well as the ability to identify and fix any manufacturing or assembly issues. Physical prototypes can also be used to evaluate the product's reliability, and to get feedback from potential customers.

Virtual prototypes are computer-generated models of the final product, which can be viewed on a computer screen or virtual reality headset or AR. They allow designers to explore and test the product's design without the need for physical models. Benefits of virtual prototypes include the ability to test the product's design in a virtual environment, which can save time and money on physical prototyping. Additionally, virtual prototypes can be easily modified and iterated, allowing for more design options to be explored. Virtual prototypes can also be used to simulate the product's performance, such as its strength and stability, which can be useful for engineers.

In conclusion, physical and virtual prototypes are both important tools that can be used during the development of a product. Physical prototypes provide the ability to test the product's form, fit and function in real-world conditions, and identify and fix any manufacturing or assembly issues. Virtual prototypes, on the other hand, provide the ability to test the product's design in a virtual environment, and simulate its performance. Physical prototypes provide tangible feedback and testing opportunities while virtual prototypes are great for design iterations and testing performance. Both types of prototypes provide benefits to the designer, allowing them to improve the product's design and functionality before final production.

Question 16

The first thing that I did when looking at this question was to create a right angled triangle because the question gives you two dimensions and then asks you to find an angle. This is then Trigonometry and so you can use what you know / are presented with. That is: They give you the height of the Adjacent (b2 = 30) and the Opposite (a2 = 10). Use SOHCAHTOA to remember.

Question 17

Q.17 Figure 8 and Figure 9 show children’s toys. Analyse and evaluate the suitability of the materials and manufacturing methods used for each of the children’s toys.

Model answer

Beech and ABS are two different materials that can be used to make a children's toy train model, each with its own advantages and disadvantages.

Beech is a hardwood that is known for its durability, strength, and resistance to wear and tear. It is also a natural and renewable resource that can be sustainably sourced. Hand-making a toy train model from beech allows for a high level of craftsmanship and customization, making it a unique and personalised toy. However, hand-making the train model from beech can be more time-consuming and labour-intensive compared to using injection moulding. ABS is a type of plastic that is known for its strength, durability and resistance to impact and temperature changes. Injection moulding is a manufacturing method that allows for the mass production of plastic parts at high speeds and low costs. It also allows for a high level of precision and consistency in the final product. However, ABS is a synthetic material, and it can be less environmentally friendly than natural materials like beech wood.

Beech is a durable material that can withstand the wear and tear of playtime, making it a suitable material for a children's toy train model. ABS, being a plastic, is also durable and can withstand impacts and temperature changes making it a suitable material. Beech is a natural and renewable resource that can be sustainably sourced, making it a more environmentally friendly option than ABS. However, ABS can be recycled and used to make new products, whereas beech can not. Hand-making a toy train model from beech allows for a high level of craftsmanship and customization, making it a unique and personalised toy. Injection moulding is a method that allows for mass production and high precision but less customisation. Hand-making a toy train model from beech can be more time-consuming and labour-intensive compared to using injection moulding, making it more expensive. Injection moulding allows for mass production at high speeds and low costs.

In conclusion, Beech and ABS are both suitable materials for a children's toy train model, but each has its own advantages and disadvantages. Beech is a natural and renewable resource that can be sustainably sourced and allows for high levels of craftsmanship and customisation, whereas ABS is a synthetic material that is strong, durable, and allows for mass production at low costs. The choice between the two materials and methods will depend on the specific needs and priorities of the manufacturer and customer.

Question 18

Q.18 Explain why polypropylene (PP) is an appropriate material for the manufacture of an ice cream container.

Model answer

Polypropylene (PP) is an appropriate material for the manufacture of an ice cream container because it has a number of properties that make it well-suited for this application.

PP has a low-temperature resistance, it can withstand temperatures as low as -20°C ( -4°F) which makes it suitable for use in storing frozen products like ice cream. PP is a tough and impact-resistant plastic, making it able to withstand the stresses of being transported and stored in a freeze environment without cracking or breaking. PP is resistant to many chemicals, including oils and fats, which makes it ideal for storing food products such as ice cream. PP can be made in a transparent form which allows for easy identification of the contents without opening the container. PP is a recyclable material, which makes it a more environmentally friendly option for packaging products. PP is a cost-effective material for the manufacture of ice cream containers as it is relatively inexpensive and can be easily moulded into different shapes and sizes.

Overall, polypropylene (PP) is an appropriate material for the manufacture of an ice cream container because it has low-temperature resistance, impact resistance, chemical resistance, transparency, recyclability, and cost-effectiveness properties. These properties make it an ideal choice for packaging frozen products like ice cream.

Question 19

Q.19 Figure 10 shows the internal view of an injection moulded component. State the function of each of the labelled features.

Model answer

A moulded boss is a raised feature on an injection moulded component that serves as a location for attaching another component or for providing a location for a fastener, such as a screw or bolt, to be inserted.

A rib in an injection moulded component is a raised feature that adds strength and stiffness to the part by spanning the direction of the applied loads. The rib allows the part to resist bending and deflection and can also be used to increase the overall structural rigidity of the part. Additionally, they can be used to control the flow of plastic during the injection moulding process and improve the cosmetic appearance of the finished part. Ribs can also be used to make a part wall thickness to be thinner and so save on plastic material.

A snap fitting in an injection moulded component is a mechanism that allows two parts to be securely and quickly connected together without the use of fasteners such as screws or bolts. A snap fit typically works by having one part with a protrusion that snaps into a corresponding recess in the other part. This creates a mechanical interference that holds the two parts together. Snap fittings are commonly used in consumer goods and other products where ease of assembly and disassembly is desired.

Question 20

Question 21

Q. 21 Compare and contrast the suitability of producing vehicle signage using either a digital printed image or plotter cut vinyl.

Model answer

Both digital printing and plotter cut vinyl are suitable for producing vehicle signage, but they have some key differences that make them more suitable for different types of applications.

Digital printing is a process that uses inkjet or other digital printing technology to produce an image on a surface. This method is ideal for producing high-quality, full-colour images with fine detail and gradations. Digital printing is also a good option for producing large-scale graphics, such as those used on the sides of a delivery truck.

Plotter cut vinyl, on the other hand, is a process that uses a computer-controlled cutting machine to cut vinyl into specific shapes. This method is ideal for producing simple, single-colour graphics, such as text or logos, that can be applied to a vehicle's surface. Plotter cut vinyl is also a good option for producing graphics that are intended to be temporary, as it can be easily removed without leaving any residue or damaging the underlying surface.

Overall, digital printing is more suitable for producing high-quality, full-colour images with fine detail and gradations. Plotter cut vinyl is more suitable for producing simple, single-colour graphics, such as text or logos, that can be applied to a vehicle's surface and are intended to be temporary.

Question 22

Q. 22 Explain why foam board is a suitable material for the manufacture of an architectural model.

Model answer

Foam board is a suitable material for the manufacture of an architectural model because it is lightweight, easy to cut and shape, and has a smooth surface that is suitable for painting or adding details. Additionally, foam board is inexpensive and readily available, making it a cost-effective option for creating models. The foam board can also be easily glued together to create multi-story models or large structures. Overall, foam board is a versatile and durable material that is well-suited for creating architectural models.