1. GCSE Resistant Materials Super Learning Lesson
Summer Examination 2015

2. 1 paper worth 40% of your final grade The paper is 2 hours long
1 paper worth 40% of your final grade The paper is 2 hours long. (120 mins) There are 120 marks available for the paper (1 mark a minute) You should try to answer all the questions in all sections to the best of you’re ability, including the long questions worth up to 10 marks. You will needs, a pen (black/ballpoint), pencil, pencil crayons, a ruler, an eraser, a sharpener. Use only pencils and pencil crayons on any design work. Check all your answers carefully. Answer your questions/designs in the appropriate space. Read the question carefully before answering – what is it really asking you???
What you need to know

3. Design Question Specification:
Make sure you answer the specification appropriately, think about:
Health and safety – safe for the user
Ergonomics – appropriate size and dimensions for the user
Materials – appropriate materials, not overly expensive
Function – what does it need to do?
Form – appropriate shape for the product.
Design Question

4. Sketch a range of ideas, if it asks for 5, draw 5
Sketch a range of ideas, if it asks for 5, draw 5. Try to be as creative and original as possible, and don’t repeat a design.
Design Question

5. Design Question

7. Developing your idea: Make sure you show development in design, make 2 – 3 changes that are clear to see. Check what the examiner is asking for, quality sketches, dimensions, notes? Be detailed with your notes, explain why you have changed or developed the idea, mention materials, and the target market, explain how the design works. If you need to add (3) dimensions then include them clearly, what is the proposed height, width, and length? Quality of sketches: Draw a neat, 3D image, add colour and detail, and use the space provided, if you have to enlarge a section to show features – do so!
Design Question

9. Evaluation: You will be asked to evaluate the ideas and development you have come up with. Link the evaluation back to the design brief and design specification (like you did in your coursework) Explain how you have accomplished the task.
Design Question

10. Materials you should know
Wood
Hardwood:
Oak – Strong and durable with an attractive grain. Can be more expensive but good for making furniture. Will need a finish.
Softwood:
Pine/Redwood – Lighter in colour and weight, can contain knots, cost effective compared to hardwood. Used for furniture or outdoor structures.
Man Made Board:
Plywood – Laminated sheets of material that are glued together at right angles to form boards. Can be more expensive than other man made boards.
MDF – Made from compressed sawdust, to create large boards which are lightweight and easy to cut.
Plastic
Thermoplastic – Acrylic, HIPS or Polypropylene (PP) – Can be reformed when heated, available in a variety of colours and thicknesses. Have a high quality finish applied.
Materials you should know

11. Materials you should know
Metal
Mild steel: Contains Iron, can rust unless galvanized, strong and tough material.
Stainless Steel: Contains iron, wont rust, strong and tough material, shiny surface, so is aesthetically pleasing.
Smart Material
GRP – Glass reinforced plastic, strands of glass fibers that have been coated in polyester resin. Can be moulded into shape, improves strength and toughness of the material.
Carbon fiber reinforced plastic, similar to GRP, carbon strands that have been coated in polyester resin. Stronger, tougher and lighter than GRP.
Polymorph – plastic granules. When heated can change from a solid to a moldable state. Its shape can be changed when reheated. Good for ergonomic handles on children’s cutlery for example.
Materials you should know

12. Answering the questions
Look at the number of marks available! If the questions is worth one mark, it should be a suitable small answer, for example naming a material (be specific) If the questions are worth a number of marks, (8 -10) the exam board are testing your subject knowledge, so a lengthy answer is required. Marks will be available for spelling, punctuation and grammar. Try to back up you point with examples if you are asked to! If you are given an example answer, you can assume that the questions need a similar response. If there is a table to fill in, fill all areas – these are easy marks! Check your answers carefully. Read the question twice to be sure you know what is being asked!
Answering the questions

13. Information you should know
Anthropometrics : Anthropometrics is the measurements of the human body, Anthropometric data provides us with the average sizes of body.
Ergonomics: Ergonomics is the study of people in relation to their working environment. It means that products need to be adapted to suit the needs of the user
Sustainability: the ability to keep making or using a product without excessive damage to the environment.
The 6 R’s: Reduce, Recycle, Reuse, Refuse, Rethink, Repair.
Market Pull: Market pull is the influence society has on the development of a new product.
Technology Push: Where engineers and designers work to improve products, materials and manufacturing technologies.
Information you should know

14. Information you should know
BSI: British standards Institute – The company that carries out testing on product against safety regulations.
CE Mark: Products that meet European guidelines and can therefore be sold in the European Union.
COSHH: Control of substances hazardous to health.
PPE: Personal protective equipment.
Quality Control: a check made to ensure that a component meets the specification, for example correct size, shape and colour.
Quality Assurance: a system of quality control checks and procedures throughout the manufacturing process.
CAD: Computer Aided Design (2D Design)
CAM: Computer Aided Manufacture (Laser Cutter)
Information you should know

15. Vacuum Forming

16. Injection Moulding

17. Line Bending

18. Finally