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Questions and Answers
What is likely the reason for rounding up the overall length of material required to make one strut to the nearest whole millimetre?
What is likely the reason for rounding up the overall length of material required to make one strut to the nearest whole millimetre?
In calculating angle 𝒙 for the strut, what factor must be considered to ensure a precise fit?
In calculating angle 𝒙 for the strut, what factor must be considered to ensure a precise fit?
Which of the following is a likely disadvantage of using jigs for batch production of the bird table?
Which of the following is a likely disadvantage of using jigs for batch production of the bird table?
What does ‘vertical in-house production’ refer to in manufacturing?
What does ‘vertical in-house production’ refer to in manufacturing?
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Which is an advantage of vertical in-house production?
Which is an advantage of vertical in-house production?
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What is one advantage of using manufactured boards in furniture construction regarding aesthetics?
What is one advantage of using manufactured boards in furniture construction regarding aesthetics?
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What are the standard dimensions in millimeters for a full-size sheet of manufactured board?
What are the standard dimensions in millimeters for a full-size sheet of manufactured board?
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What is the primary information needed to calculate the length of the external curve A?
What is the primary information needed to calculate the length of the external curve A?
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What is the primary application of bleed proof paper?
What is the primary application of bleed proof paper?
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What does the term 'thermoset polymer' refer to?
What does the term 'thermoset polymer' refer to?
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Which test would best determine the hardness of a metal sample?
Which test would best determine the hardness of a metal sample?
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How is the cost of the veneer calculated for manufacturing the side frames?
How is the cost of the veneer calculated for manufacturing the side frames?
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Which paper or board is most suitable for retail packaging for a TV?
Which paper or board is most suitable for retail packaging for a TV?
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In the context of furniture manufacturing, what is one potential drawback of using manufactured boards regarding user requirements?
In the context of furniture manufacturing, what is one potential drawback of using manufactured boards regarding user requirements?
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What characteristic is essential for foil backed card in its application?
What characteristic is essential for foil backed card in its application?
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Which property of Kevlar makes it suitable for protective clothing?
Which property of Kevlar makes it suitable for protective clothing?
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What is precious metal clay (PMC) mainly used for?
What is precious metal clay (PMC) mainly used for?
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What is the primary reason for using mount board in model making?
What is the primary reason for using mount board in model making?
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Which type of manufactured board is often used for cabinetry and furniture due to its surface finish?
Which type of manufactured board is often used for cabinetry and furniture due to its surface finish?
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What does the term 'wastage' refer to in manufacturing?
What does the term 'wastage' refer to in manufacturing?
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Laminating layers of veneer to form a chair frame aims to enhance which property of the final product?
Laminating layers of veneer to form a chair frame aims to enhance which property of the final product?
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Why must manufacturers account for shrinkage when using PMC?
Why must manufacturers account for shrinkage when using PMC?
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Which of the following instruments is NOT required for the AQA Product Design exam?
Which of the following instruments is NOT required for the AQA Product Design exam?
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What is a specific example of a thermoset polymer?
What is a specific example of a thermoset polymer?
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Which type of smart material is best suited for applications requiring flexibility and shape retention?
Which type of smart material is best suited for applications requiring flexibility and shape retention?
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What is one property of Kevlar that contributes to its protective capabilities?
What is one property of Kevlar that contributes to its protective capabilities?
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When is it necessary to cross through work in the AQA Product Design exam?
When is it necessary to cross through work in the AQA Product Design exam?
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How long is the allotted time for the AQA Product Design exam?
How long is the allotted time for the AQA Product Design exam?
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Which process is commonly used to manufacture bottle bodies made from polymers?
Which process is commonly used to manufacture bottle bodies made from polymers?
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What is a key reason thermoplastic polymers are favored for making plastic bottles?
What is a key reason thermoplastic polymers are favored for making plastic bottles?
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Which method would most likely be used to manufacture a series of plastic bottles?
Which method would most likely be used to manufacture a series of plastic bottles?
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How do computer systems contribute to the reduction of waste in manufacturing?
How do computer systems contribute to the reduction of waste in manufacturing?
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What is one condition that can accelerate the degradation of biodegradable polymers?
What is one condition that can accelerate the degradation of biodegradable polymers?
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Which of the following is a benefit of virtual modeling and testing before product manufacture?
Which of the following is a benefit of virtual modeling and testing before product manufacture?
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What material property of polypropylene influences its use in children’s cars?
What material property of polypropylene influences its use in children’s cars?
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Which finishing process is typically applied to mild steel children's cars?
Which finishing process is typically applied to mild steel children's cars?
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What is a common consideration for disposing of polypropylene products?
What is a common consideration for disposing of polypropylene products?
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Study Notes
A-Level Product Design Exam Paper 1
- Materials Required: Normal writing and drawing instruments, scientific calculator, protractor
- Instructions: Use black ink or black pen for answers. Use pencil for drawing. Answer all questions in the spaces provided. Do all rough work in the paper. Cross out any work you do not want marked.
- Time Allowed: 2 hours and 30 minutes
- Maximum Marks: 120
- Exam Information: The marks for each question are shown in brackets
- Candidate Information: Candidates must write clearly and in block capitals, include centre and candidate numbers, candidate's signature and forenames/surname.
Question 1 - Paper/Board Applications
- Specific Paper/Board: Includes bleed proof paper, corrugated card, foil backed card, and mount board
- Suitable Applications: Marker rendering of ideas, retail packaging (TV), drinks cartons, model making
- Performance Characteristics: Candidates must describe the characteristics that make each paper/board suitable for its application. For example, bleed proof paper is good for rendering ideas because it allows ink to bleed.
Question 2 - Waste in Manufacturing
- Wastage: The meaning of 'wastage' in manufacturing is about the materials or resources lost during the production process.
Question 3 - Renewable Energy Use
- Installed Capacity Data: Information is provided in a bar chart showing renewable energy use over time from 2010 to 2015, including solar PV, offshore wind, onshore wind, other bioenergy, landfill gas, hydro..
- Solar PV 2015 Calculation: Candidates need to find the percentage of solar PV installed capacity in 2015.
Question 4 - Flat-pack Furniture
- Manufactured Board: Examples of manufactured board in the furniture include melamine and chipboard.
- Standard Sheet Dimensions:: Specific width and length of a standard sheet of manufactured board (in millimetres) are required.
Question 5 - Thermoset Polymers
- Definition: A thermoset polymer is one that is formed from a liquid and then undergoes a chemical change (curing) to form a fixed shape and lose its plasticity.
- Example: Epoxy resin
Question 6 - Metal Properties Testing
- Metal Properties: Methods for testing hardness and toughness of metal samples in a school workshop are required.
Question 7 - Laminated Chair Frame
- Curve A: Description and measurement of the curve
- Material Length Calculation: Calculation of the total length of material required to make one strut is needed.
- Veneer Cost: Calculation of the cost of veneer needed to manufacture two side frames for the chair, including an additional 15% for waste/trimming.
Question 8 - Smart Materials Applications
- Applications: One application, including explanation, for each of the following materials: piezo electric materials, shape memory alloys (SMA), photochromic glass
Question 9 - Protective Clothing Materials
- Kevlar Properties: Candidates need to state three properties of Kevlar and explain how each property makes it suitable for protective clothing.
Question 10 - Plastic Bottle Manufacturing
- Manufacturing Process: Identification of the process used to make the plastic bottle bodies.
- Thermoplastic Polymer: Identification of a thermoplastic polymer used for the bottle bodies
- Use of Thermoplastics in Bottles: Provide two reasons why thermoplastic polymers are used in plastic bottle production.
Question 11 - Computer Systems in Manufacturing
- Plan and Control Manufacturing: Explain how computer systems are used for planning and controlling manufacturing, reducing waste, and responding to consumer demand.
Question 12 - Biodegradable Polymers
- Biodegradable Polymer: Name one biodegradable polymer
- Environmental Conditions: State two environmental conditions that would enable a biodegradable polymer to degrade faster
Question 13 - Virtual Modelling and Testing
- Virtual Modelling and Testing: Explain two ways in which virtual modelling and testing are used in industry prior to product manufacture.
Question 14 - Child's Car Manufacturing
- Polypropylene Car: Comparing and evaluating the suitability of the main fabrication and finishing processes used to manufacture a car made of polypropylene.
- Mild Steel Car: Comparing and evaluating the suitability of the main fabrication and finishing processes used to manufacture a car made of mild steel.
Question 15 - Bird Table Strut
- Strut Material Length Calculation: Calculate the overall length of material required to make one strut.
Question 16 - Vertical In-House Production
- Definition: Define 'vertical in-house production'.
- Advantage/Disadvantage: Explain one advantage and disadvantage of this production system.
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Description
Prepare for your A-Level Product Design Exam Paper 1 with this comprehensive quiz. Focus on material applications, performance characteristics, and design processes to excel in your exam. Make sure to familiarize yourself with specific paper and board types used in various applications.
