Paper 3 June 2022 32

This is a question paper for June 2022. Below are model answers to all questions from this paper. If you select a Question from the list (below right) it will take you to a model answer for that question.

Question 1

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

Laminating - click on the link to see examples

Steam Bending - click on the link to see examples

Question 2

Q. 2 Fig 2.1 shows two pieces of hardwood prepared to take a countersunk head screw. Sketch onto Fig. 2.1 to show: a countersunk hole; a clearance hole

Question 3

Q. 3 Products such as chisels and screwdrivers, made from high carbon steel, can be ‘hardened’. Hardening makes the metal very brittle. Complete the sentence below by adding the correct term from the list.

normalising tempering annealing alloying

The process of removing the excess ‘hardness’ and improving the toughness of the steel is known as Tempering

Question 4

Q. 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. 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.

Question 5

Q. 5 Complete the sentence below by adding the correct statement from the list.

Planned obsolescence is when a product...

becomes an antique; takes many years to design; lasts for a fixed period of time; is constructed from the best materials

Planned obsolescence is when a product lasts for a fixed period of time. - see iPhone below

Question 6

Q. 6 Fig. 6.1 shows a type of sandwich packaging.

(a) Name a suitable plastic from which the packaging could be made.

Any from the named examples below

PETE, HDPE, PVC, LDPE, PET, Polythene, Polyethylene - link to Plastics section

(b) Give one benefit of using plastic material for food packaging.

Any from the list below

hygienic, keeps food fresh, protects food, can withstand extremes of environment, maintains high quality produce, easily recycled, fast manufacturing process, water resistant, transparent, does not react with food, lightweight

Any drawbacks from the list below:

Plastic is a finite resource; non-biodegradable; wasteful; can cause pollution when thrown away; doesn’t decompose; they fill up landfill; not environmentally friendly; unsustainable

Question 7

Q. 7 Fig. 7.1 shows a knock-down (KD) fitting.

(a) Name the type of knock-down (KD) fitting shown in Fig. 7.1.

This is known as any of these: Corner block / Block fitting / two-piece block / 2 piece connector - see page on KDF's

(b) Use sketches and notes to show how the knock-down (KD) fitting could be used.

Knock Down fitting against 2 pieces of chipboard to join together without glue.

Question 8

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

Any 3 from the list below.

3 advantages could be: Stool B is lightweight or lighter in weight than stool A; Stool B is less bulky to carry as it can fold down; Stool B has a more comfortable canvas seat; Stool B is easier to clean; Stool B is easier to open or close; Stool B packs away smaller; Stool B does not splinter; Stool B has fewer moving parts.

NB: You would not gain a mark if you answered: weatherproof, more stable, durable, attractive

Question 9

Q. 9 Fig. 9.1 shows the end of a length of softwood with a rebate marked out.

(a) Name a power tool that could be used to cut out the rebate.

Router

(b) The rebate could also be cut out using hand tools only. Complete the names of two hand tools that could be used to cut out the rebate.

Question 10

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

Question 11a

Q. 11 (a) (i) State one property of mild steel sheet that makes it suitable for the lantern lid.

Any from the list below

Hardwearing, easily shaped, relatively cheap, takes a variety of finishes, malleable

(ii) The mild steel lantern lid requires a finish. State two suitable finishes that could be applied to the lantern lid.

Paint, dip-coated, electroplated, plastic coated, powder coated, galvanised, chrome plated

Question 11b

(b) A card model of the garden lantern will be made before making it from resistant materials.

(i) State one benefit of making a card model of the garden lantern.

Any from the list below

Allows for checking sizes; appearance; prevent mistakes and waste of material; allows for modifications

(ii) State one benefit of using CAD for on-screen modelling of the garden lantern.

Any from the list below

3D models can be created; editing can be carried out quickly; no materials used; designs can be replicated; designs can be transferred to CAM

Question 11c

(c) Fig. 11.2 shows the development (net) of the lantern lid marked out on mild steel sheet. An additional view shows inside the lantern lid when the flaps have been bent and joined permanently to the sides.

(i) Name two tools or items of equipment that could be used to mark out the development (net) of the lantern lid on the surface of the mild steel sheet.

Any from the list below

scriber, odd-leg calipers, permanent marker, marker pen, engineers square, try square, [steel] rule, engineers blue, sliding bevel - see workshop tools for examples of what these are

(ii) Name the tool shown in Fig. 11.3 that could be used to cut out the mild steel sheet.

Any of the below

Tinsnips, snips, hand shears - see workshop tools for examples of what these are

(iii) Name a permanent method of joining the flaps to the sides that uses heat.

Any from the list below

Brazing, soldering, welding, hard / silver soldering - see joining methods for examples of what these are

(iv) Name an adhesive that could be used to join the flaps to the sides of the lantern lid.

Any from the list below

Epoxy resin, ‘Araldite’ or equivalent trade names, Gorilla Weld - see adhesives for examples of what these are

Question 11d

(d) Fig. 11.4 shows the development (net) of the lantern body made from 5mm thick acrylic.

Use sketches and notes to show how the development (net) could be formed to produce the shape of the lantern body.

Question 11e

(e) Fig. 11.5 shows the garden lantern and part of a support from which it will be suspended. Use sketches and notes to show a method of joining the lantern lid to the lantern body so that it could be easily removed to allow access to the plastic candle. Include details of the fittings and constructions used.

Question 11f

(f) Use sketches and notes to show modifications to the lantern lid and the end of the support shown in Fig. 11.5 so that the garden lantern could be suspended safely. The modifications must allow the garden lantern to be detached from the support. Include details of the materials, fittings and constructions used.

Question 12a

Q.12 Fig. 12.1 shows an incomplete design for a pinball game. (a) The sides of the pinball game are made from beech.

Give two properties of beech that make it suitable for the pinball game.

Any two from the list below:

hardwearing; close-grained; finishes well; high impact resistant; attractive; tough

Question 12b

(b) State two ways in which the designer would need to consider safety when designing the pinball game.

Any two from the list below:

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.

Question 12c

(c) Fig. 12.2 shows part of two sides that will be joined at each corner of the pinball game. Sketch and name a suitable corner joint that could be used to join the sides of the pinball game together.

Variety of acceptable corner constructions including: butt joint, rebate, lap joint, mitre, dovetail joint, finger (comb) joint, dowel

Question 12d

(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.

(i) Name the type of drill bit shown in Fig. 12.3.

Saw tooth bit or Forstner bit

(ii) Give two reasons why scrap wood would be clamped underneath the base of the pinball game when drilling the holes.

It can prevent damage to the work surface; prevents splitting of wood as drill cuts through; cleaner cut hole; protects drill table

Question 12e

(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. Give two advantages of using method B rather than method A.

Any two from the list below:

Less likely to be pulled off sides (stronger); edges not visible (more attractive); gluing not required; more secure; lasts longer.

Question 12f

(f) Fig. 12.5 shows the MDF sheet from which the curved shape will be produced.

(i) Name two different machine tools that could be used to cut out the curved shape.

Any two from the list below:

Router; scroll saw; band saw; jig saw; laser cutter; CNC milling machine

(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.

Any from the lists below:

Benefit of PVA: stronger joint; more time to clamp parts; no toxic fumes; does not cause skin irritation

Benefit of contact adhesive: immediate bond; no clamping required; quicker to dry / set

Question 12g

(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. 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.

Question 12 h

(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.

Model answer

some sort of ‘leg’ support that remains upright support can fold flat

Question 13a

Q. 13 Fig. 13.1 shows an incomplete design for a child’s toy lorry that could be made in a school workshop. The sides are made from acrylic. The tipper is made from ABS. The base, cab and wheels are made from beech.

(a) (i) State one benefit of using plastics such as acrylic and ABS for parts of the toy lorry.

Any from the list below:

Tough; durable; inherent colour; easily moulded; lightweight; attractive; range of colours; impact resistant; weather resistant

(ii) State one benefit of using beech for the base, cab and wheels of the toy lorry.

Any from the list below:

Hardwearing; close grained; finishes well; attractive; smooth surfaces; tough

Question 13b

(b) The sides of the toy lorry have been designed using CAD. Fig. 13.2 shows one side of the toy lorry made from 5mm thick acrylic.

(i) Complete Table 13.1 by stating three processes to be carried out when making the side using CAM.

Place acrylic sheet on bed of machine, set tool parameters, on the computer choose ‘print’, ‘run’, transfer data to CNC machine, extractor unit on

(ii) The acrylic sides could be glued to the beech base using a contact adhesive. Describe how a contact adhesive would be applied to make a strong joint.

Contact adhesive applied to both surfaces; Allow to dry then stick together on contact (impact)

Question 13C

(i) Give two advantages of making the vacuum forming mould from MDF rather than a solid wood.

Any two from the list below:

No grain texture to mark plastic; easier to work; cheaper; does not shrink or warp; smoother surfaces; more stable

(ii) State two features of the vacuum forming mould that are necessary to ensure a successfully formed product.

Any two from the list below:

Smooth surfaces; rounded corners / edges; draft angle (tapered sides); no undercuts

(iii) Complete Table 13.2 by stating four processes to be carried out when vacuum forming the tipper.

Process: Clamp plastic to machine, turn on heater, check pliability of plastic, raise platen, turn on pump to remove air, leave to cool

Question 13d

(d) Fig. 13.4 shows the tipper that will be attached to the base. The tipper will pivot at point A as shown. Use sketches and notes to show how the tipper could be made to tip while attached to the base. Include details of all the constructions, materials and fittings used.

Model answer

Question 13e

(e) Fig. 13.6 shows details of one of the wheels that will be fixed to the toy lorry. Use sketches and notes to show a method of attaching the wheels to the base that allows them to rotate freely. Include details of all the constructions, materials and fittings used and state one important dimension.

Model answer

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