TO GIVE YOU BITESIZE CHUNKS OF

INFORMATION RELATED TO THE MAIN CONTEXT OF YOUR YEAR 11 EXAM

YOU WILL NEED TO TAKE NOTES ON EACH SECTION

WRITE DOWN ANY QUESTIONS YOU HAVE FOR THE END OF THE

SESSIONDON’T PANIC - THE EXAM IS NOT TO TRICK YOU!

ONLY TO FIND OUT WHAT YOU ALREADY KNOW

ABOUT THE WORK YOU HAVE DONE IN KEY STAGE 4.

MATERIALS FOR MAKING CONTAINERS

MANUFACTURING PROCESSES

INDUSTRIAL PRACTICES

SCALE OF PRODUCTION

HEALTH AND SAFETY

SORTING OF WASTE MATERIAL

ENVIRONMENTAL ISSUES

ERGONOMICS

AESTHETICS

ICT – CAD/CAM – CNC - CIM

COSTS, PARTS & COMPONENTS

MAINTENANCE

SUITABILITY & DESIGN REQUIREMENTS

SOCIAL CONSIDERATIONS

THIS THE CONTEXT OF SOME QUESTIONS FOR SECTION A.

MAKE A STUDY OF WASTE DISPOSAL AND STORAGE USED AROUND YOUR HOME AND OR

SCHOOL.

YOU MUST TAKE COLOURED PENCILS IN TO THE EXAM.

STUDY THE METHODS IN WHICH WASTE CAN BE SORTED AND STORED

LOOK AT THE EXAMPLES ON THE BACK OF YOUR PREP SHEET

HIGHLIGHT THE MATERIALS

CHECK THE PROPERTIES WITH YOUR TEXT BOOK.

LONG CHAIN MOLECULES !!

GOOD AVAILABILITY !!

VARIETY OF COLOURS !!

QUALITY FINISHES !!

EASY TO WORK WITH !!

HIGH IMPACT STRENGTH !!

EASY TO CLEAN !!

RESISTS CORROSION !!

LOW IN COSTS !!

GOOD STRENGTH TO WEIGHT RATIO !!

BROADLEAF OR DECIDUOUS TREES

GROW IN WARM TEMPERATURES

LOSE THEIR LEAVES IN WINTER

GROW SLOWLY – 100YEARS

MORE EXPENSIVE

BETTER GRAIN STRUCTURE FOR IMPROVED QUALITY FINISH

CONIFEROUS TREES

GROW IN COLDER TEMPERATURES

KEEP THEIR LEAVES ALL YEAR ROUND

GROW QUICKLY - 30 YEARS

LESS EXPENSIVE – READILY AVAILABLE

GOOD CONSTRUCTIONAL TIMBER AND GENERAL WOODWORKING PROJECTS

CONTAINS IRON

VULNERABLE TO CORROSION – RUST

MIXED WITH CARBON TO OBTAIN ALLOY STEELS OF VARYING

STRENGTHS

ONLY MILD STEEL IS EASY TO WORK WITH

CONTAINS NO IRON

LESS VULNERABLE TO CORROSION – RUST

MAINLY PURE METALS

CAN BE MIXED WITH ONE ANOTHER TO OBTAIN REQUIRED CHARACTERISTICS.

ALL ARE GENERALLY EASY TO WORK WITH

COMMON TO BOTH

ELASTICITY

PLASTICITY

MALLEABILITY

DUCTILITY

HARDNESS

TOUGHNESS

COMMON TO BOTH

ELASTICITY

PLASTICITY

MALLEABILITY

DUCTILITY

HARDNESS

TOUGHNESS

ELASTICITY – THE ABILITY TO FLEX AND BEND WHEN FORCED.

PLASTICITY – ABILITY TO BE CHANGED PERMANENTLY THROUGH EXTERNAL BLOWS

MALLEABILITY – THE EXTENT TO WHICH A MATERIAL CAN PERMANENTLY DEFORM IN ALL DIRECTIONS WITHOUT CRACKING

DUCTILITY – THE ABILITY TO UNDERGO COLD PLASTIC DEFORMATION

HARDNESS – THE ABILITY TO RESIST WEAR AND ABRASION – USUALLY BRITTLE

TOUGHNESS – THE ABILITY TO WITHSTAND SUDDEN SHOCKS OR IMPACT. RESISTS CRACKING WHEN BENDING

LONG CHAIN MOLECULES THAT ARE CHEMICALLY BONDED TOGETHER

RIGID AND NON FLEXIBLE

HIGH RESISTANCE TO HEAT

GOOD ELECTRICAL INSULATORS

LONG CHAIN MOLECULES THAT ARE ENTANGLED BUT FLEXIBLE

CAN BE RE-SHAPED WITH LITTLE HEAT

VARIETY OF COLOURS

PLASTIC MEMORY THAT ALLOWS THEM TO RETURN TO ORIGINAL

SHAPE

FRAME JOINTS

BOX JOINTS

EDGE JOINING

NAILS & SCREWS

KNOCK DOWN

SOLDERING

WELDING

RIVETTING

NUTS & BOLTS

TENSOL CEMENT

INJECTION MOULDING

VACUUM FORMING

STRIP / LINE HEATING

ULTRA-SONIC WELDING

FRAME JOINTS

BOX JOINTS

EDGE JOINING

NAILS & SCREWS

KNOCK DOWN

MORTISE AND TENON –

REQUIRES A TENON SAW AND ACCURATE MARKING OUTTENON

MORTISE

DOWELLED JOINT –

BUTT JOINTS REINFORCED WITH DOWELS FOR STRENGTH

DOWEL

COMB JOINT – ATTRACTIVE JOINT WITH STRENGTH FROM LARGE GLUEING AREA

FINGER

HOUSING JOINT – USED FOR SHELVES AND PARTITIONS.

POSITIVE SUPPORT

HOUSING

POSITIVE SUPPORT

NAILS & SCREWS – USED TO HOLD ITEMS TOGETHER

WHILST GLUE SETS

TEMPORARY FIXING

SOLDERING

WELDING

RIVETTING

NUTS & BOLTS

SOLDERING – INCLUDES :-

SOFT SOLDERING

SILVER SOLDERING

BRAZING

SOFT SOLDERING – QUICK AND EASY METHOD OF JOINING COPPER, BRASS AND TIN PLATE

SILVER SOLDERING – JOINTS ARE BUILT UP IN DECREASING TEMPERATURES

BRAZING – ALLOY OF COPPER AND ZINC. VERY HIGH TEMPERATURE

ALL REQUIRE FLUX TO HELP KEEP JOINT CLEAN AND STRONG.

WELDING

INCLUDES FOLLOWING

OXYGEN – ACETYLENE – VERY HOT FLAME USING BURNING GASES TO MELT BOTH PARENT METAL AND FILLER ROD – MAINLY THIN PLATE WORK.

ELECTRIC ARC – USES ELECTRICAL CURRENT (ARC) TO CREATE HEAT ENOUGH TO FUSE TOGETHER PARENT METALS – CAN BE USED FOR LIGHT AND HEAVY PLATE WORK.

RIVETTING – NUTS & BOLTS :-

ROUND HEAD – REQUIRES AN ENGINEERS (BALL PEEN HAMMER) AND RIVET SET (DOLLY) TO ROUND OVER THE HEAD OF THE RIVET

POP RIVET – QUICK AND EASY METHOD OF JOINING THIN PLATE. WEAKER THAN A SOLID ROUND HEAD RIVET.

NUTS & BOLTS – A TEMPORARY FIXING THAT RELIES ON FRICTION TO HOLD PARTS TOGETHER. HOLDING THROUGH MECHANICAL ADVANTAGE OF SCREW THREADS.

TENSOL CEMENT

DRILLED AND JOINED WITH MACHINE

SCREWS

TENSOL CEMENT 12

TENSOL CMENT 70

A SOLVENT BASED ADHESIVE. NOT VERY STRONG. WORKS BY ATTACKING THE SURFACE OF THE ACRYLIC TO BOND THEM TOGETHER.

SUPPLIED READY TO USE AND SETS QUICKLY

A POLYMERISING ADHESIVE LIKE ‘LIQUID’ ACRYLIC THAT LINKS WITH THE MATERIAL RESULTING IN A JOINT THAT IS NEARLY AS STRONG AS THE ACRYLIC ITSELF. NEEDS CAREFUL MIXING AND A LONGER SETTING TIME.

MAKE SURE YOU SUPPORT THE

UNDERNEATH OF THE PLASTIC BEFORE

DRILLING

DO NOT OVER TIGHTEN TO AVOID CRACKING

THE MATERIAL.

COMMON TO ALL

MARKING OUT

CUTTING TO SIZE

SHAPING/FORMING

JOINING

FINISHING

PENCIL, RULER, TRY SQUARE, MARKING GAUGE, MARKING KNIFE.

TENON SAW, COPING SAW, FRET SAW, BENCH HOOK, MITRE BLOCK

SANDING MACHINE, JACK PLANE, CHISEL, MALLET, SPOKESHAVE, TURNING, DRILLING.

GLASS PAPER, VARNISH, PAINTS, POLISH, WAX.

SCRIBER, ENGINEERS SQUARE, STEEL RULER, CALIPERS,

DOT PUNCH, DIVIDERS.

HACKSAW, TIN SNIPS, COLD CHISELS, ABRAFILE

FORGING, PRESSING, BENDING, TURNING, MILLING, DRILLING

EMERY CLOTH, WIRE WOOL, PAINT, POLISH, DIP COATING.

MARKING OUT

CUTTING TO SIZE

SHAPING/FORMING

JOINING

FINISHING

MUST HAVE PAPER BACKING LEFT ON. - PENCIL, CHINAGRAPH OR SPIRIT PEN, SCRIBER, RULER, TRY OR SET SQUARE, MOST METAL WORK MARKING OUT TOOLS.

HACKSAW, COPING SAW, BAND SAW, HAND FILES,

STRIP BENDER/HEATER, VACUUM FORMER, INJECTION MOULDING, CASTING.

GO TO TECHNOLOGYSTUDENT.COM TO SEE VIDEOS OF THESE PROCESSES.

DRAW FILING, EMERY CLOTH, WET AND DRY, POLISH,

COMMON TO ALL MATERIALS

JIGS AND FORMERS

USED TO MAINTAIN ACCURACY FOR MARKING OUT, CUTTING AND

SHAPING.

ESSENTIAL TO REPEAT ACCURACY OF PARTS THAT GO TOGETHER TO

MAKE COMPLETE UNIT.

ITEMS THAT ARE PRODUCED (MADE) SINGLY. POSSIBLY DUE TO THE NATURE OF THE PRODUCT, E.G. BRIDGES, SATELLITES, JEWELLERY, WEDDING DRESSES, MACMILLAN COLLEGE AND OF COURSE YOU - SAFETY AND RELIABILITY ARE OFTEN OF HIGH PRIORITY THAN COSTS, ALSO HIGH AESTHETIC CONSIDERATIONS.A SYSTEM OF PRODUCING IDENTICAL ITEMS IN

FIXED NUMBERS FOR A SPECIFIC CLIENT. E.G. SCHOOL TIES, FURNITURE, DESIGNER CLOTHING, ITEMS WITH CLIENT LOGO RATHER THAN MAKERS LOGO. WHEN THE BATCH IS COMPLETE, THE TOOLS USED CAN BE USED TO PRODUCE A BATCH OF DIFFERENT PRODUCTS.

PRODUCING ITEMS IN VERY HIGH QUANTITIES THAY CAN RECOVER THE COSTS OF TOOLING UP. COST OF MANUFACTURE IS AS LOW AS POSSIBLE. E.G. CARS, BIRO’S, CHOCOLATE BARS, SCHOOL SHIRTS, CD’S. NO FIXED NUMBER AND NO SPECIFIC CLIENT.

THE EXAM WILL BE LOOKING FOR MORE THAN JUST THE BASIC UNDERSTANDING OF – WEAR GOGGLES, TIE YOUR

HAIR BACK, WEAR AN APRON.

IT WILL BE CONCERNED WITH RESPONSIBILITY FOR HEALTH AND SAFETY

I.E.

AWARNESS OF SAFETY SIGNS AND THEIR MEANINGS

LEGISLATION REGARDING ROOM LAYOUT

POSITIONING OF SAFETY EQUIPMENT

SAFETY GUARDS AND USAGE

SPEEDS OF MACHINERY

TRAINING PROGRAMMES

ADEQUATE SPACE FOR WALKWAYS BETWEEN TABLES

WHERE THE EMERGENCY STOP BUTTONS AND FIRE EXTINGUISHERS ARE LOCATED.

THAT THEY ARE IN TACT AND MOVE FREELY. SIGNS IN PLACE INFORMING THEIR USAGE

THAT REVOLVING CUTTERS CAN BE ADJUSTED MANUALLY ACCORDING TO THE SIZE OF MATERIAL OR HOLE TO BE CUT

MAKING USE OF TRAINING TO ENABLE SAFE USE OF

MACHINERY AND EQUIPMENT – GET SUPERVISION.

DISABLED ACCESS REQUIRED

USING COMPUTERS IN DESIGNINGINTERNET

RESEARCH - VISITING THE CLIENT .

LETTERS TO CLIENTS – FINDING OUT THEIR NEEDS .

QUESTIONNAIRES TO CUSTOMERS.

FINDING OUT WHAT THEY WANT – COSTS, MATERIALS, SIZES, APPEARANCE, COLOUR ETC.

WORKING DRAWINGS.

INFORMATION TO HELP MAKE YOUR

IDEAS.

GRAPHICAL RESULTS OF YOUR QUESTIONNAIRE –

INFORMATION FOR YOUR SPECIFICATION

LIST.

FEEDBACK TO LET YOU KNOW THAT YOUR IDEAS ARE ACCEPTABLE BY THE

CLIENT/CUSTOMER

VALUABLE INFORMATION BEFORE YOU GO TO

MANUFACTURING STAGE.

C O L O U R C H O IC E S

0

1

2

3

4

5

6

7

8

9

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0

1

2

3

4

5

6

7

8

9

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R E D B L U E G R E E N B L A C K Y E L L O W

S e rie s 1

THE PRODUCT IN RELATION TO ITS ENVIRONMENT (E & E) AND ITS USER.

1. HUMAN PHYSIQUE – HEIGHT, WEIGHT, RANGE OF REACH AND MOVEMENT.

2. HUMAN ABILITIES – STRENGTH, POSTURE, RANGE OF MOTION.

3. HOW THE PRODUCT FITS IN WITH ITS SURROUNDINGS – LOOKS, SIZE, FEEL, COMFORT ETC.

THE SCIENCE CONCERNED WITH MEASURING PEOPLE AND HOW THEY WILL FIT THE PRODUCT.

1. STATIC DIMENSIONS – TAKEN WHEN A PERSONS BODY IS IN A FIXED POSITION. STANDING, HOLDING TOOLS ETC.

2. DYNAMIC DIMENSIONS – TAKEN DURING MOVEMENT. CONCERNED WITH THE AREA OF REACH FOR ARMS AND LEGS.

ERGONOMICS USES ANTHROPOMENTRICS

YOU CANNOT DESIGN A PRODUCT WITHOUT FIRST MEASURING THE USER

THIS WILL BE IMPORTANT WHEN THINKING ABOUT THE HAND ACCESS TO ALLOW RETRIEVAL OF THE CD

BOXES

IT IS NOT JUST HOW THE PRODUCT LOOKS.

HOW IT LOOKS IN RELATION TO OTHER ITEMS IN THE ROOM – E.G. COOKER, FRIDGE, WASHING MACHINE COMPUTER, STERIO, IPOD ETC.

WHAT DOES IT FEEL LIKE – TEXTURE, SMOOTH, CLEAN, HYGIENIC ETC.

ARE THE SIZES CORRECT AND IN RELATION TO ONE ANOTHER – HEIGHT, WIDTH, THICKNESS.

DO BOTTLES, CANS, PAPER ETC HAVE SEPARATE STORAGE

APPEARANCE – COLOURS, SHADES, STYLE, CULTURE, THEME, VALUE FOR MONEY.

AN OPINION OF THE WHOLE PRODUCT

I.E. IS IT SUITABLE FOR THE PURPOSE???

MATERIALS

RAW MATERIAL COSTS, TREATING COSTS, HOW MANY COMPONENT PARTS CAN BE MADE?

MANUFACTURING

CUTTING TO SIZE, CLEANING, SHAPING,

ASSEMBLY, FINISHING,

RUNNING COSTS.

SALES

RECOVERING MAKING COSTS,

MAKING A PROFIT,

REPLACING PARTS ETC.HOW MANY CONTAINERS CAN BE MADE FROM ONE SHEET OF MATERIAL??

THE LIFE EXPECTANCY OF A PRODUCT OR MATERIAL

THE ABILITY TO WITHSTAND WEAR AND TEAR, WEATHERING AND DETERIORATION

THROUGH CORROSION

PREVENTING CHANGES IN APPEARANCE AND STRENGTH.

CAN THE MATERIALS BE REPLACED? REUSED, RECYCLED. WHAT IS THE ‘TURNAROUND’ TIME?????

WHAT EFFECT ON THE ENVIRONMENT – FEWER TREES, FEWER NATURAL RESOURCES. DAMAGE TO OZONE LAYER THROUGH SPRAY FINISHES ?????

CAN EVERYONE AFFORD THE LUXURY – IS THERE AN ALTERNATIVE. ARE STANDARDS OF LIVING MORE IMPORTANT THAN LIFE ITSELF?????????

WHICH ONE ??????

A more durable material Increases life

expectancy.

Improved accuracy.

Batch producing facility

Quality control check

LOCATING TABS

ALL SECTIONS ARE IDENTICAL IN SHAPE, SIZE AND HOLE POSITIONS.

A MILD STEEL JIG WILL HELP KEEP ALL PARTS IDENTICAL. SIZE, SHAPE AND HOLES POSITION

BUT HOW CAN IT BE IMPROVED ???HOLDING SECURELY!!

GRIPPED SECURELY USING MECHANICAL SCREW THREAD

A DEVICE THAT ENSURES REPEAT ACCURACY OF COMPONENT PARTS.

IT IS AS UNIQUE AS THE PRODUCT OR PART ITSELF.

JIG OR FORMER

TUBULAR MILD STEEL FRAME SHAPED AROUND JIG TO MAINTAIN REPEAT ACCURACY

ALTHOUGH DESIGNED TO DIFFERENT JOBS, ALL MECHANISMS HAVE 5 THINGS IN COMMON.

1. THEY MAKE A JOB EASIER TO DO.

2. THEY INVOLVE SOME KIND OF MOVEMENT.

3. THEY INVOLVE SOME KIND OF FORCE.

4. THEY NEED SOME KIND OF INPUT.

5. THEY PRODUCE SOME KIND OF OUTPUT.

1. EASY GRIP

2. MOVING JAWS

3. TURNING FORCE

4. TWISTING HANDLE

5. ROTARY TO LINEAR

THE CAM - TAKES IT NAME FROM IT’S SHAPE E.G. PEAR CAM

FOLLOWS THE MOVEMENT OF THE CAM – CHANGES ROTARY MOTION TO LINEAR OR RECIPROCATING MOTION

CRANK ROTATES – ANY DIRECTION – TURNED USING A HANDLE

TABLE MOVES UP AND DOWN – WITH A RECIPROCATING MOTION

THE DESIGN WHEEL

PROBLEMANALYSIS

BRIEF

RESEARCH

SPECIFICATION

DESIGN IDEAS

CHOSEN IDEA

DEVELOPMENT

MAKING

MODIFYING

EVALUATING

PROBLEM = THE TASK IN HAND

ANALYSIS = INVESTIGATE

WHAT NEEDS TO BE DONE

BRIEF = WHAT YOU

WILL DO

RESEARCH = YOUR

FINDINGS

SPECIFICATION = WHAT THE

PRODUCT MUST BE AND WHAT IT

MUST DO. SKETCHES OF

POSSIBLE SOLUTIONS TO THE PROBLEM

THE BEST IDEA TO DEVELOP

FURTHER

ALL THE STEPS NEEDED TO MAKE YOUR CHOSEN IDEA

TOOLS AND EQUIPMENT ETC.

PROTOTYPE OF THE IDEA

RECORD ANY CHANGES YOU MAKE

WHAT WOULD YOU DO DIFFERENTLY – WHAT ARE THE NEW PROBLEMS?

GET PLENTY OF SLEEP THE NIGHT BEFORE

YOU’LL FEEL ON TOP OF THE WORLD

HAVE SOMETHING TO EAT KEEP BODY AND SOUL TOGETHER TO ALLOW THE

MIND TO FUNCTION CORRECTLY

MAKE SURE YOU GO TO THE TOILET BEFORE THE EXAM

YOU CAN’T ANSWER CALLS OF NATURE ONCE THE EXAM

HAS STARTED

IMPORTANT

REMEMBER THE EXAM IS 2 HOURS LONG

Practice drawing using Isometric grids.

1. Start with a basic regular shape

2. Make the shape softer or rounder

3. Expand the product to include boxes in different positions

4. Label 5 points of Annotation and 5 points of evaluation.

Sizes, colour, processes, materials, properties, functions etc.

5. Try producing an Orthographic drawing of your final solution

Consider – Dimensions, hidden detail, construction lines, view points.

1. SCAN READ THE WHOLE PAPER BEFORE YOU ANSWER ANY QUESTIONS – THIS WILL GIVE YOU THE CONTEXT OF THE PAPER.2. USE A HIGHLIGHTER PEN TO IDENTIFY KEY POINTS OF THE QUESTION.3. READ 2 QUESTIONS AHEAD BEFORE ANSWERING – THIS WILL HELP AVOID REPEATING PREVIOUS ANSWERS AND SAVE TIME.4. LOOK OUT FOR QUESTIONS WITHIN QUESTIONS – I.E. WHERE MORE THAN ONE ANSWER IS ASKED FOR5. NEVER LEAVE BLANK SPACES – MARKS ARE ALWAYS AWARDED FOR ATTEMPTED QUESTIONS – YOU MIGHT GUESS CORRECTLY!!6. TAKE TIME BEFORE THE END TO PROOF READ YOUR ANSWERS – IF IT DOES NOT MAKE SENSE TO YOU – IT WON’T TO THE MARKER7. ABOVE ALL - DON’T PANIC. IF YOU’RE STUCK, MOVE ON TO THE NEXT QUESTION – YOU CAN ALWAYS GO BACK LATER.

REVISION WEBSITES

• http://www.btinternet.com/~hognosesam/elpinands/mainmenu.htm

• Google images of CD, DVD etc holders.• BBC-GCSE BITESIZE.• LEARN.CO.UK• REVISION-NOTES.CO.UK• TOPMARKS• SAM LEARNING• www.the-warren.org