A-Level Design & Technology Exam Paper 1
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Questions and Answers

What is the primary purpose of a jig in batch production?

  • To expedite the design process
  • To increase the variety of products produced
  • To reduce the need for skilled labor
  • To ensure uniformity and accuracy in production (correct)
  • Which of the following best defines 'vertical in-house production'?

  • Production involving outsourcing tasks to external vendors
  • Production where all processes occur inside a single facility (correct)
  • Production with multiple locations utilizing vertical integration
  • Production where finished products are sold directly to consumers
  • What is a potential disadvantage of using jigs in the manufacture of bird tables?

  • They slow down the production process
  • They eliminate the need for any tool adjustments
  • They complicate the production workflow
  • They require significant initial investment (correct)
  • When calculating the angle needed for the strut cut, what is the main geometric principle used?

    <p>Trigonometric ratios (D)</p> Signup and view all the answers

    Which of the following is NOT a specific benefit of batch production using jigs?

    <p>Flexible production schedules (C)</p> Signup and view all the answers

    Which of the following is a suitable application for bleed proof paper?

    <p>Marker rendering of design ideas (D)</p> Signup and view all the answers

    What characteristic makes corrugated card particularly suited for retail packaging?

    <p>It offers structural strength and insulation (A)</p> Signup and view all the answers

    What is the meaning of 'wastage' in manufacturing?

    <p>Unused material or products that cannot be sold (C)</p> Signup and view all the answers

    Which material would be best to use for model making?

    <p>Mount board (A)</p> Signup and view all the answers

    What aspect of foil backed card makes it suitable for drinks cartons?

    <p>It is resistant to moisture and provides a barrier (C)</p> Signup and view all the answers

    When calculating the percentage of solar PV used in 2015, what is typically needed?

    <p>The total renewable energy generation overall (A)</p> Signup and view all the answers

    Why might markers be preferable on bleed proof paper in design work?

    <p>They provide vibrant and flowing colors (D)</p> Signup and view all the answers

    What is one benefit of using recyclable materials in manufacturing?

    <p>Positive environmental impact (D)</p> Signup and view all the answers

    What is one specific manufactured board that could be used in flat-pack furniture construction?

    <p>MDF (A)</p> Signup and view all the answers

    What are the standard dimensions of a full-size sheet of manufactured board in millimeters?

    <p>1200 mm x 2400 mm (D)</p> Signup and view all the answers

    What is one reason thermoplastic polymers are favored for manufacturing plastic bottles?

    <p>They can be easily reshaped when heated. (C)</p> Signup and view all the answers

    Which of the following is an advantage of manufactured boards regarding user requirements?

    <p>Cost-effective (B)</p> Signup and view all the answers

    Which of the following best defines a thermoset polymer?

    <p>A polymer that does not melt upon reheating (C)</p> Signup and view all the answers

    Which of the following processes is commonly used to manufacture plastic bottles?

    <p>Blow molding (A)</p> Signup and view all the answers

    Which test is primarily used to assess the hardness of metals?

    <p>Rockwell test (C)</p> Signup and view all the answers

    What is one benefit of using computer systems in manufacturing?

    <p>They can optimize production processes. (C)</p> Signup and view all the answers

    What is the best description of toughness in metals?

    <p>The ability to absorb energy before fracturing (D)</p> Signup and view all the answers

    Which biodegradable polymer is known to decompose faster in a suitable environment?

    <p>Polylactic acid (PLA) (C)</p> Signup and view all the answers

    What is an essential property of ash veneer when laminated for furniture?

    <p>Good aesthetics (C)</p> Signup and view all the answers

    Which condition would likely accelerate the degradation of biodegradable polymers?

    <p>High humidity (C)</p> Signup and view all the answers

    What characteristic of manufactured boards makes them suitable for flat-pack furniture?

    <p>Their low cost (C)</p> Signup and view all the answers

    What is one advantage of virtual modeling in product design?

    <p>It allows for real-time adjustments before physical production. (D)</p> Signup and view all the answers

    Which of the following materials is used in the fabrication of the steel car shown?

    <p>Mild steel (A)</p> Signup and view all the answers

    How does the choice of material affect the disposal of products?

    <p>Certain materials can be more easily recycled than others. (A)</p> Signup and view all the answers

    What is the purpose of including an additional 15% of veneer in the cost calculation?

    <p>To account for waste and trimming (C)</p> Signup and view all the answers

    Which property of Kevlar makes it particularly suitable for protective clothing?

    <p>Its lightweight and high strength (A)</p> Signup and view all the answers

    Which of the following is NOT a suggested application for shape memory alloy (SMA)?

    <p>Self-healing materials (B)</p> Signup and view all the answers

    What is the material definition of precious metal clay (PMC)?

    <p>A malleable clay containing real metal particles (D)</p> Signup and view all the answers

    What is the specific thermoplastic commonly used for making the main body of cleaning product bottles?

    <p>Polypropylene (B)</p> Signup and view all the answers

    What is one reason photochromic glass is suited for eyewear applications?

    <p>It changes color in response to UV light (C)</p> Signup and view all the answers

    Which process is specifically used to manufacture the main body of plastic bottles?

    <p>Blow molding (A)</p> Signup and view all the answers

    What additional factor must manufacturers consider when working with precious metal clay (PMC)?

    <p>Shrinkage during the firing process (D)</p> Signup and view all the answers

    Flashcards

    Wastage

    Refers to the material leftover or discarded during the manufacturing process. It can include excess materials, off-cuts, or rejected pieces, contributing to waste and inefficiency.

    Bleed proof paper

    The ability to resist tearing or ripping, often associated with fabrics or papers. This property makes it ideal for marker rendering, ensuring a smooth and clean drawing surface.

    Corrugated Card

    Strong, durable, and lightweight, this paper is commonly used for packaging because it offers excellent protection and structural support.

    Foil backed card

    A type of card with a layer of foil on one side providing a barrier against moisture and light making it suitable for packaging drinks.

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    Mount Board

    Thick, rigid material used for making models, displays, or mounting artwork. It offers durability and a smooth surface for precise work.

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    Solar PV Percentage

    The proportion of energy generated from solar panels in a specific year, calculated based on the total renewable energy used.

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    Harnessing Renewable Energy

    The utilization of renewable energy sources, such as solar, wind, and hydro power, to meet energy demands.

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    Rising Demand for Renewable Energy

    The rate at which the use of renewable energy sources increases over time, indicating a shift towards sustainability.

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    What is a Piezoelectric Material?

    A material that produces an electric charge when pressure is applied to it.

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    What is a Shape Memory Alloy (SMA)?

    An alloy with the ability to return to its original shape after being deformed by heat.

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    What is Photochromic Glass?

    A type of glass that darkens in response to ultraviolet (UV) light.

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    What are three properties of Kevlar that make it suitable for protective clothing?

    Kevlar is a strong and lightweight synthetic fiber known for its high tensile strength and resistance to heat and chemicals. These make it ideal for protective clothing.

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    Explain Precious Metal Clay (PMC) and its shrinkage properties.

    Precious Metal Clay (PMC) is a clay made from precious metals like silver or gold. It shrinks during the firing process.

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    What is the specific process for manufacturing plastic bottles?

    The process used for manufacturing plastic bottles is called blow molding.

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    Name a thermoplastic used for making bottles for cleaning products.

    Polyethylene terephthalate (PET) is a common thermoplastic used for manufacturing cleaning product bottles.

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    Determine the length of curve A and the total veneer length used for the chair.

    The length of the external curve A is approximately 150mm. The total length of veneer used is approximately 300mm.

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    What is a common type of manufactured board used in furniture?

    A type of manufactured board used for furniture construction.

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    What are the standard dimensions of a manufactured board sheet?

    A standard full-size sheet of manufactured board measures 2440mm in width and 1220mm in length.

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    What aesthetic advantage of ash veneer is used in the lounge chair?

    Ash veneer provides a smooth, aesthetically pleasing finish to the lounge chair.

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    What user requirement does ash veneer satisfy in the lounge chair?

    Ash veneer is strong and durable, making it suitable for the load-bearing structure of the chair.

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    What is a thermoset polymer and give an example?

    A thermoset polymer is a type of plastic that permanently hardens when heat is applied. An example of a thermoset polymer is epoxy resin, often used for bonding.

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    How do you test the hardness of a metal?

    A hardness test measures a material's resistance to indentation. A test can be done by pressing a standardized object into the metal surface and observing the resulting indentation.

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    How do you test the toughness of a metal?

    A toughness test measures a material's resistance to fracture. A test can be done by bending or hitting the metal sample, observing how much force it takes to break or permanently deform the sample.

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    What is laminating?

    Laminating involves bonding multiple layers of a material together, typically with an adhesive. This is used to create stronger, thicker, or more aesthetically pleasing structures.

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    Overall strut length

    The total distance of the material needed to construct a single strut, considering all the individual segments and joints.

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    Angle 𝒙

    The angle formed between the strut and the underside of the bird table, ensuring a precise fit. This is essential for structural stability.

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    Jigs

    Specialized tools or templates designed to guide the manufacturing process, ensuring consistent and accurate results for identical parts.

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    Vertical in-house production

    A production system where all stages of creating a product, from design to assembly, occur within the same company or facility.

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    Vertical Integration

    When the company making a product also owns and controls the supply chain, including materials, manufacturing plants, and distribution channels.

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    Why are thermoplastics used for bottles?

    Thermoplastic polymers can be repeatedly heated and reshaped without degrading. This makes them ideal for manufacturing bottles, as they can be easily molded into the desired shape and can be recycled multiple times.

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    What properties make thermoplastics suitable for bottles?

    Thermoplastic polymers are lightweight and durable, making them suitable for packaging liquids. The lightweight nature reduces transportation costs, while their strength prevents breakage and leaks.

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    How are bottles made using injection molding?

    The process involves heating thermoplastic granules and then injecting the molten material into a mold with the desired bottle shape. The plastic cools and solidifies, forming the bottle.

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    How do computer systems help plan bottle production?

    Computer systems are used to design bottle shapes and sizes, plan production schedules, and control the injection molding process. This ensures accurate bottle production and minimizes material waste.

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    How do computer systems help reduce waste in bottle production?

    Computer systems can track production data, such as bottle output and material usage, allowing manufacturers to identify and eliminate waste. This helps reduce environmental impact and maximize efficiency.

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    How do computer systems help respond to changing consumer demand?

    Computer systems can monitor and manage processes like injection molding, allowing for quick adjustments to production lines based on changing consumer demand. This allows manufacturers to respond quickly to market changes.

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    What is a biodegradable polymer?

    Biodegradable polymers break down naturally in the environment, decomposing into less harmful components. They are often produced from plant-based materials, making them a more sustainable alternative to traditional plastics.

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    How do some environmental conditions affect biodegradation?

    A biodegradable polymer degrades faster in environments with optimal conditions for microbial activity, such as warmth, moisture, and the presence of oxygen. These conditions encourage the breakdown of the polymer by microorganisms.

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    Study Notes

    A-Level Design & Technology (Product Design) Exam Paper 1

    • Exam Duration: 2 hours 30 minutes
    • Materials Required: Normal writing and drawing instruments, scientific calculator, protractor
    • Instructions: Use black ink or pen. Answer all questions in the provided spaces.
    • Information: Marks for questions are shown in brackets. Maximum mark is 120.

    Paper 1, Question 1

    • Specific Papers/Boards and Applications: Bleed proof paper used for design ideas; corrugated card for retail packaging; foil backed card for drinks cartons; mount board for model making.
    • Performance Characteristics: Describe the features of each paper/board type that make them suitable for their application.

    Paper 1, Question 2

    • Wastage in Manufacturing: Define manufacturing wastage, explain its implications.

    Paper 1, Question 3

    • Renewable Energy Use (Bar Chart): Analyze the bar chart of installed UK renewable energy capacity (MW) showing trends over time. Data includes solar PV, offshore wind, onshore wind, other bioenergy, landfill gas, and hydro.
    • Solar PV Percentage (2015): Calculate the percentage of solar PV use in 2015, rounded to the nearest whole number.

    Paper 1, Question 3 (continued)

    • Pie Chart Completion: Complete the pie chart provided for renewable energy use (2015) by adding data for PV solar and offshore wind.

    Paper 1, Question 4

    • Manufactured Board: Identify a specific manufactured board used in the flat-pack furniture, shown in the image.
    • Standard Sheet Size: Specify the width and length of a standard full-size sheet of the identified manufactured board in millimetres.

    Paper 1, Question 5

    • Thermoset Polymers: Explain the meaning of the term “thermoset polymer” and give a relevant example.

    Paper 1, Question 6

    • Metal Testing (Hardness): Outline the procedure for testing metal samples' hardness in a school workshop.
    • Metal Testing (Toughness): Describe how toughness in metal samples is assessed in a workshop setting.

    Paper 1, Question 7

    • Curve A (Length): Calculate the external length of Curve A in Figure 1 (round up to the nearest whole number).
    • Veneer Length: Determine the total length of veneer needed for the two side frames of the chair. Add 15% for waste/ trimming. Give the answer in pounds and pence (using the retail price given).

    Paper 1, Question 8

    • Smart Material Applications: Provide an application for each smart material (piezoelectric, shape memory alloy, photochromic glass); explain why it suits that application.

    Paper 1, Question 9

    • Protective Clothing Material (Kevlar): State 3 properties of Kevlar and describe how each makes it a suitable material for protective clothing, with examples.

    Paper 1, Question 10

    • Manufacturing Process (Plastic Bottles): Identify the manufacturing process used for the bottles shown in Figure 10.
    • Thermoplastic Polymer (Bottles): Give one suitable thermoplastic used to manufacture the cleaning product bottles.
    • Thermoplastic Use (Plastic Bottles): Provide two reasons for using thermoplastic polymers in plastic bottle manufacturing.

    Paper 1, Question 11

    • Computer Systems in Manufacturing: Explain how computer systems are used to plan, control, and optimize manufacturing, reducing waste, and responding to customer demand.

    Paper 1, Question 12

    • Biodegradable Polymer: Give one example of a biodegradable polymer and two environmental conditions to enable it to degrade faster.

    Paper 1, Question 13

    • Virtual Modelling and Testing: Explain two ways virtual modelling/testing is used in industry prior to product manufacture.

    Paper 1, Question 14

    • Child's Car Manufacturing: Compare the suitability of manufacturing processes (rotational moulding and press forming) for two child's car designs (Figure 2 & 3), including material properties, use, care and disposal.

    Paper 1, Question 15

    • Bird Table Strut Length: Calculate the required material length for one strut in a bird table, round up to the nearest whole millimeter.

    Paper 1, Question 16

    • 'Vertical In-House Production': Define, listing one advantage and disadvantage.

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    Description

    This exam paper covers various aspects of A-Level Design & Technology with a focus on Product Design. Students are required to demonstrate their understanding of materials, manufacturing processes, and renewable energy applications. Prepare to answer questions that analyze design choices and sustainability practices within the industry.

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