WorksheetsWorksheet Questions Extracted
Total questions: 18
Worksheet time: 9mins
Identify the polymer stock form used for Injection Moulding
Polymer granules
Polymer powder
Thermoplastic sheet
Liquid resin
Identify the polymer stock form used for Vacuum Forming
Thermoplastic sheet
Polymer granules
Polymer powder
Pre‑impregnated fibre mat
Identify the polymer stock form used for Rotational Moulding. This question is part of a 3‑mark prompt.
Polymer powder
Thermoplastic sheet
Polymer pellets
Liquid resin
Explain why thermochromatic pigment has been used in the child’s forehead thermometer shown in Figure 2.
It changes colour at specific temperatures to provide an immediate visual reading without electronics
It ensures the thermometer can only be used once before disposal
It enables non‑invasive monitoring by reading from the forehead and is safe for children
It prevents heat transfer by insulating the skin
It provides a low‑cost, durable temperature indication suitable for mass manufacture
Which reasons explain why pewter is often used for casting in a school workshop? Select all that apply.
It has a low melting point suitable for simple heating equipment
It flows well and captures fine detail in moulds
It is relatively safe to handle compared with many other casting alloys
It can be filed and polished easily after casting
It requires high‑temperature industrial kilns to melt
Which properties make Plastazote foam appropriate for manufacturing a mat
It is lightweight and provides cushioning for impact absorption
Its closed‑cell structure resists water ingress and is easy to clean
It offers thermal insulation and comfort when used on cold floors
It has a rigid, brittle structure that prevents flexibility
It provides a durable, non‑slip surface suitable for repeated use
Compare the following joining methods for attaching two thin sheets of aluminium: pop rivets; nuts and bolts. [6 marks]
Pop rivets are quick to install from one side and create a permanent joint; nuts and bolts allow disassembly but need access to both sides.
Pop rivets and nuts and bolts both allow repeated disassembly without damaging the sheets.
Nuts and bolts typically add more weight and protruding hardware compared to pop rivets.
Pop rivets require threaded holes; nuts and bolts do not require holes.
Pop rivets are less likely to loosen under vibration than un-lockered nuts and bolts, but cannot be tightened later.
Explain the benefits of a manufacturing simulation when making a component on a Computer Numerically Controlled (CNC) router. [6 marks]
Identifies collisions, gouges, and toolpath mistakes before running the machine.
Optimizes machining sequence and feeds to reduce cycle time and material waste.
Confirms fixture placement and work offsets so the program aligns with the stock.
Removes the need for any post-processing or setup on the physical machine.
Allows operator training and risk-free testing without occupying the router.
Using the information provided, select the statements that correctly analyse and evaluate how the textured handle surfaces are created on the two dishwashing accessories. Figure 7: injection moulded handle with TPE over moulded texture. Figure 8: blow moulded handle with texture integrated during moulding.
Over moulding a TPE onto an injection moulded handle enables a soft, high friction grip but adds a secondary operation and dual material tooling cost.
Integrating texture during blow moulding relies on the mould cavity pattern and parison inflation, giving consistent texture without extra parts but limited control near weld lines and varying wall thickness.
Over moulded TPE textures cannot be colour matched to the substrate, making them unsuitable for consumer products.
Blow moulded integrated texture typically requires adhesive bonding of a separate elastomer layer after forming.
The TPE over moulded texture can be selectively placed on ergonomic contact areas, whereas blow moulded integrated texture is applied more uniformly around the hollow handle.
Select the techniques a company may use throughout design and manufacture to reduce material waste.
Design for manufacture and assembly to minimise part count and simplify processes.
Nesting and layout optimisation for sheet or blank cutting to maximise material utilisation.
Using statistical process control to intentionally increase tolerances so more parts are rejected.
Standardising component sizes and materials across products to enable reuse and reduce scrap.
Implementing closed loop recycling and regrind protocols to capture and reuse process scrap.
State four measures that an employer may consider to ensure that they are meeting the Health and Safety at Work Act 1974. [4 marks]
Carry out regular risk assessments and act on the findings
Provide appropriate training and supervision for employees
Maintain safe equipment and workplaces, including guarding and scheduled maintenance
Supply and enforce the use of suitable personal protective equipment
Ignore minor incidents to reduce paperwork
Figure 10 and Figure 11 show cookbook stands. Figure 10 is made from cast iron using sand casting. Figure 11 is made from Medium Density Fibreboard (MDF) and beech using a CNC router and hand fabrication. Which statements best analyse and evaluate the materials and manufacturing methods of these two stands? Select all that apply.
Cast iron in Figure 10 provides high strength and stability but increases weight; sand casting suits lower-cost batch production and may leave a rough surface that needs finishing.
Cast iron in Figure 10 is best produced by injection moulding, giving thin walls and minimal finishing.
MDF and beech in Figure 11 make the stand lighter and warmer in appearance; CNC routing enables precise repeatable components, while hand fabrication allows fitting and finishing.
MDF in Figure 11 is naturally moisture-proof and requires no coating for kitchen use; CNC routing typically yields inconsistent accuracy.
Compared with Figure 10, Figure 11 is likely less durable under heavy impact but easier to manufacture with accessible workshop processes.
Discuss the implications to a company of rebranding. Select all implications that typically arise for a company undertaking rebranding. [9 marks]
Changes to brand recognition and customer perceptions
Increased marketing and communication costs
Legal and packaging updates across products and channels
Guaranteed immediate sales growth without risk
Potential confusion or loss of existing customers during transition
Figures 12, 13 and 14 show graphical representations of material testing processes. In Figure 12, a standardized test specimen is pulled in the direction of force as shown. Identify the material property being tested. [1 mark]
Tensile strength
Hardness
Impact toughness
Compressive strength
Figures 12, 13 and 14 show graphical representations of material testing processes. In Figure 13, an indenter is pressed into the test specimen in the direction of force as shown. Identify the material property being tested. [1 mark]
Hardness
Ductility
Elastic modulus
Fatigue resistance
Figure 14. Material property being tested
Toughness
Hardness
Tensile strength
Ductility
Explain why the screen printing process is suitable for a low volume production run. [6 marks]
Low setup costs and simple screens make short runs economical.
Requires complex, expensive plates, making short runs costly.
Designs or colours can be changed easily between runs with minimal retooling.
Only feasible at very high speeds and very large quantities.
Can be used on a wide range of substrates and product forms, supporting small-batch jobs.
Which factors should be considered before forming a curved piece of timber by steam bending? (6 marks) Select all that apply.
Timber species and grain orientation suitability for bending
Moisture content and conditioning prior to steaming
Section thickness and desired bend radius to prevent failure
Presence of knots, defects, and grain run-out in the blank
Paint color selection and final surface finish before bending
