Paper 1

Question 1

How is Potatopak formed and what are some common uses?

Answer 1

Potatopak is formed from waste potato starch, this is mixed with water and cellulose with heat to form a honeycomb formation. It is an alternative to non-biodegradable options (plastic, styrofoam)
Potatopak is used for cups, bowls, trays, packaging, bags etc.

Question 2

What are the positives and negatives of Potatopak?

Answer 2

Positives of Potatopak are:
- Environmentally friendly
- 100% biodegradable
- Reduces waste packaging and waste going to landfill
- Alternative to plastic
Negatives of Potatopak are:
- Cannot be used to hold hot liquid or raw meat as they react with the starch so the starch will break down
- Still requires research to develop a food-safe, biodegradable and chemical-free protective coating to stop the starch breaking down

Question 3

what is BSI (British Standards Institute)?

Answer 3

BSI is an organisation that devises agreed standard procedures for performing a wide range of tasks. They work with industry to product standards (a published document that agreed a way of doing something) to assure reliable and safe products.

Question 4

What is a stock form?

Answer 4

A stock form is when a raw material is machine/processed to look a certain way

Question 5

What are the stock forms of timber?

Answer 5

The different stock forms of timber are:
Rough sawn: The wood has rough surfaces, nominal sizes and cheapest to buy
Planes square edge (PSE): The wood only has one edge that is planed accurately, the rest are rough sawn, Planing removes about 3mm from the original size.
Planed all round (PAR): The wood has sides and edges that are planed square, straight and level, leaving a smooth finish and is ready to use, is it 3mm smaller on each side and is the most expensive to buy.
Natural wood: The wood comes from the trees and is available only at the maximum width of the tree, planks should be joined with the end grain going in opposite directions to minimise distortion.
Manufactured boards: Man-made and produced in large sheets (1220mm x 2440mm)
Mouldings: Pre-made mouldings such as skirting board available in standard length.

Question 6

What are the stock forms of metal?

Answer 6

The different stock forms of metal are:
Sheet: large flat sections of metal in varying thickness from less than 1mm up to 3mm.
Plate: thicker than 3mm and narrower than sheet materials.
Bar: a solid form, flat bar, square bar, round bar or hexagonal bar.
Tube form: hollow cross-section and can be square, rectangular, round or hexagonal.
Structural angular: H beams, L beams, I beams, tee bar and channel.

Question 7

What are the stock form of polymer?

Answer 7

The different stock forms of polymer are:
Granules: small particle of plastic.
Sheet: a large flat section of polymer in varying thickness.
Film: very thin sheet polymer.
Rods/tubes/bars: bar is a solid form, square or round. Tubes are hollow in cross-section and can be rectangular, square or round.
Foam: solid form made by including air or other gases, such as styrofoam from expanding polystyrene.
Powder: very fine granule of polymer.

Question 8

What is powder coating?

Answer 8

Powder coating is when the product is statically charged (negative) and thermoset polymer resin (positive) Is sprayed through an airgun. The opposite charges create a strong attraction between the powder and product. It is baked and the heat from the oven melts the powder over the product to give an even coating. The coating protects from corrosion and is more hardwearing than paint - used on fences, gates, fridges, dishwashers and washing machines.

Question 9

What are IP rights?

Answer 9

Intellectual property (IP) is an idea that is turned into a physical creation. Ideas alone does not count. Some rights are automatically endowed when work is created, others have to be applied.

Question 10

What is copyright?

Answer 10

• Copyright is legal protection for work such as books, photos, drama, music and films.
• It allows management of permission for others to use work.
• The UK Copyright, Design and Patents Act 1988 provides cover for most works for 70 years after the death of creator.

Question 11

What are unregistered design rights?

Answer 11

• Unregistered design rights provide legal protection for designers to stop unauthorised copying for 10 years, they cover appearance (shape, ornamentation etc.), not how products work.
• Ownership is hard to prove because there is no registration. So it is a good idea to keep early drafts, sketches, recordings and modifications.

Question 12

What is a patent?

Answer 12

• A patent protects a working part of a product. It is granted from the Intellectual Property Office (IPO).
• They provide up to 20 years legal protection.
• Detailed, labelled diagrams and clear description are essential and it is essential that the design is completely new.

Question 13

What is a registered design?

Answer 13

• A registered design offers protection for product appearance and decoration, not working rights.
• Designs are registered for up to 25 years by illustrations and a fee to the IPO.

Question 14

What is a trademark?

Answer 14

• A trademark gives legal protection for brand identity and facilitates marketing. It is a recognisable combination of logos, colours, sounds and words.

Question 15

What is a compliant material? Give examples of 2 compliant materials.

Answer 15

• Papers and boards are compliant materials meaning they can be scored, folded and cut with basic cutting tools to form nets for packaging.
• The original source of paper is wood pulp. During manufacture, bleaches are added to make paper whiter..
• Corrugated card is with carton board outer layers and a corrugated middle layer.
• Foil-backed and laminated card with polymer film of foil applied to provide a water resistant/heat-insulating layer.

Question 16

What should employers ensure for safe working practices? [8]

Answer 16

Employers should ensure:

• The workplace is safe and free from risks to health.
• Welfare facilities such as first aid is provided.
• Dangerous items and substances are used and stored safely and removed if necessary.
• Training, info and adequate supervision is provided as necessary.
• PPE is provided.
• Machinery has guards, is safe to use, maintained and in good working order.
• Appropriate safety signage is provided.
• Accident report systems are in place, RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations, 2013)

Question 17

What should employees ensure for safe working practices? [4]

Answer 17

Employees should ensure:

• Take reasonable care for own H&S, as well as those in their vicinity.
• Use the PPE provided.
• Use machinery in accordance with training provided.
• Report any accidents, near miss or dangerous events.

Question 18

What is neoprene? [7]

Answer 18

Neoprene is an elastomer with:

• Good thermal resistance
• Toughness
• Good oil and thermal resistance
• Excellent weather resistance
• Good abrasion resistance
• Electrical insulator
• Some examples are swimming suits, laptop cases, hose covers.

Question 19

What is inclusive design and empathetic design?

Answer 19

Inclusive design aims to meet the need of the widest possible range of people who might interact with the product in question. This include groups such as the elderly, children, people with disabilities.
Empathetic design involves the designer analysing tasks while emulating user restrictions such as a third age suit.

Question 20

How is tensile strength tested?

Answer 20

Tensile strength is tested with a tensometer machine where is the test piece is clamped on each side and pulled apart.

Question 21

How is toughness tested?

Answer 21

Toughness is tested with an Izod impact test. A notched test piece is held vertically in a vice, a pendulum is released from a set position and swings to strike the test piece.

Question 22

What is the Rockwell test?

Answer 22

The Rockwell test is a hardness test where a preload is applied to a material sample using a diamond indenter, which breaks through the surface of the material. The load is increased and held for a certain time. The load is released and the distance between the preload and the applied load is measured.

Question 23

What is the Brinell test?

Answer 23

The Brinell test is when a hardened steel ball is forced into the materials surface using a set preload, the diameter is measured.

Question 24

What is the Vickers pyramid test?

Answer 24

The Vickers pyramid test is used for very hard materials and it uses a diamond square-based pyramid to indent the surface of the material, a microscope is used to measure the size of the indent.

Question 25

What are the 2 types of Non-destructive testing (NDTs)?

Answer 25

NDT is carried out on products rather than materials. THe 2 types are:
Ultrasonic - sound waves are passed through the product and faults are detected
X-Ray - an x-ray beam is passed through the product and an image is projected onto a display screen allowing observations of hairline fractures etc.

Question 26

How is malleability tested?

Answer 26

Malleability is tested using a bend test. The material is placed in a bending machine and held, a mandrel loads the test piece at the centre and bends it to a predetermined angle or until the test piece fractures. The material is inspected, if the cracks are on the outer edge it is more ductile, if the cracks are on the inside of the bend, the material is more malleable.

Question 27

How is corrosion tested?

Answer 27

Corrosion is tested by placing materials in a stimulated weather environment and leaving them for a set time. The materials are inspected for surface corrosion.

Question 28

How is electrical conductivity tested?

Answer 28

Electrical conductivity is tested by placing a multimeter probe on a material and measure the resistance. If the resistance is high, the conductivity is low.

Question 29

How is thermal conductivity tested?

Answer 29

Thermal conductivity is tested using a heat flow meter, a square shaped material test piece is placed between 2 temperature controlled plates. The temperature is increased at a controlled rate and the heat flow through the material. As the material is heated to a specific temperature, the sensors measure and record the rate of thermal conductivity

Question 30

What is TIG welding?

Answer 30

TIG welding is an addition process where a filler rod is used with heat generated with an electric arc to produce a join in the metal. An inert gas is used to protect the weld pool and the tungsten electrode.

Question 31

What is carbon reinforced polymer (CFRP)? [6]

Answer 31

Carbon fibres mixed with polyester resin. It is:

• Lightweight
• Corrosion resistant
• Tough
• Hard
• Good compressive strength
• Low thermal expansion

Question 32

What is a knockdown fitting and what are the 5 types of KD fittings?

Answer 32

A knockdown fitting is used to manufacture flat-pack furniture. The types are:

• Modesty blocks are small rigid, polymer blocks, they are moulded holes and take screws that are used to join the block and panel.
• Barrel nuts and bolts use a cross-dowel that is fitted into one of the pieces to be joined.
• Cam-lock connectors consist of a metal dowel that is screwed into one of the pieces, the disk is inserted and when it is turned it pulls both pieces tightly together.
• Wood screws screw 2 pieces of wood together where.
• Coach bolts are used to join wood pieces together with a bolt, they are used for fitting street furniture.

Question 33

What is JIT?

Answer 33

• Organising the manufacture of the products to order rather than for stockpiling in the hope of future sales
• It is ideal for products such as computers and vehicles
• Stockpiling is an increasingly risky strategy as electronic products become outdated quickly

Question 34

What are JIT implementation strategies?

Answer 34

JIT implementation strategies:

• Increased management and worker cooperation
• Regular feedback
• Careful selection of suppliers
• Reduction of waste and stock
• Optimised layout of machinery
• Use of visual or electrical stock control systems

Question 35

What are some advantages and disadvantages of JIT?

Answer 35

Advantages of JIT:
- Less material costs
- Less storage requirements
- Less damage to stock
- Allows flexibility to customer requirements
- Higher quality
Disadvantages of JIT:
- JIT production can be very sensitive to any kind of error. Since bare minimum inventory levels are maintained, there is no room for any kind of error.
- JIT production will not be able to adapt well to sudden increase in volume of demand from the market, since the inventory levels are maintained at much lower level.
- Just in time manufacturing is a philosophy which is achieved only when all the parties involved in the whole supply chain will work in great tandem and coordination. JIT may fail sometime if any of the suppliers will fail to fulfil their obligations and respond to the requirements in a timely manner.
- JIT focuses on lean inventory; hence there is not much buffer in stock levels. For any reason, if there is any kind of failure that happens in the supply chain, that can lead to sudden down time in production leading to huge losses for the organisation.

Question 36

What are the properties and uses of urea formaldehyde?

Answer 36

The properties of urea formaldehyde are:

• Hard
• Heat resistant
• Good electrical insulator
• Brittle
• Safe working temperature: 80ºC
• Uses: electrical fitting, adhesives

Question 37

What are the properties and uses of melamine formaldehyde?

Answer 37

The properties of melamine formaldehyde are:

• Hard
• Opaque
• Heat resistant
• Tough
• Food safe
• Safe working temperature: 130ºC
• Uses: decorative laminations, picnic ware, buttons

Question 38

What is lamination for wood and polymer? What are some uses?

Answer 38

Wood lamination is when a veneer such as a natural wood are laminated on the board surface to enhance aesthetics.
Polymer lamination is when fibre-based composite sheets are moulded around using a polyester resin as the polymer. A top gelcoat is applied which may have a pigment.
Uses are: boat hulls, kayaks, train carriages, theatre props.