section two

Question 1

Describe a range of techniques the designer could have used to ensure the
comfort, safety and ease of use of the Initial Eazy Changer.
(refer to image one)

6 marks

Answer 1

 Testing prototypes
 Test rigs
 User trips
 User trials
 Use of outside agencies
 Focus groups

Question 2

Identify techniques and explain why they are suitable for communication of
information between the following people:
• Market Researcher and Designer
• Designer and Production Engineer
• Designer and Client.

6 marks

Answer 2

Market Researcher and Designer
 Market research data through face to face meeting
 Spreadsheets or statistical data to support findings
 Written or graphical evidence from focus groups
etc.

Designer and Production Engineer
 Detailed CAD models
 Exploded views to show assembly details and help
to communicate assembly processes
 Detailed scale drawings/CAD models of component
parts to help with tooling and manufacture planning
and costing for materials
 Regular meetings with engineers and manufacturing
specialists throughout the design process.

Designer and Client
 Refined presentation visuals including photo
realistic CAD renderings
 Advertising images showing the intended use,
accentuating the positive aspects and features of
the product. Needed to convince the customer
(parent/carer) of the benefits for the child
 More refined preliminary renderings to show the
progress and track changes for client
 Rapid prototype models, traditionally crafted
models.

Question 3

Explain why the selected materials are suitable for the different components of
the Sleek Dive Light.
(refer to image two)

3 marks

Answer 3

ABS Casing
Demonstrates and understanding of environmental
requirements, the need for the material to be
waterproof, to withstand the pressures and
temperature changes in diving. The need for strength
to withstand bumps and knocks in normal use while
diving. The need for dimensional stability to prevent
leaks which could lead to failure.
Need to be able to be injection moulded into the
complex shape with integrated internal features.

Silicon rubber
Has ability to be a tight fit between the 2 halves of the
product and the light housing to give a secure seal to
prevent leaks. It is flexible enough to fill the gap
between the casing completely.
Toughened glass
Is very transparent and performs well. Is tough enough
to withstand knocks against the diver’s equipment and
any other hard or sharp edges on the boat or diving
area.

Anodised Aluminium
Anodising aluminium allows colour to be added without
adding paint or other coatings.
Anodising thickens the oxidised layer to better protect
against further oxidisation.

Question 4

With reference to products with which you are familiar, describe features that
have been incorporated into the product to ensure ease of assembly. Use
sketches to illustrate your answer.

5 marks

Answer 4

Answers likely to include:
 Location pins
 Bosses
 Bayonet fittings
 Asymmetric standard components
 Symmetrical casings
 Labelled/numbered parts
 Self assembly features

Question 5

Describe the advantages 3D printing has over traditional modelling techniques.

3 marks

Answer 5

Advantages of 3D printing may include:
 Allows better communication of the concept with
production engineers because 3D printing can
utilise CAD data
 Allows, due to accuracy, testing with other
components and parts such as the lens housing and
batteries
 Quicker for complex models
 Less labour intensive process than traditional
modelling methods
 Allows for a degree of repeatability which means
incremental changes can be made to models as
there is no interpretation or human error
 Can use similar mechanically performing materials
 Can speed up production because the CAD data can
also be used by production engineers

Question 6

Development of products like the Panono can be driven by manufactures’ desire to
use new technologies, or due to changing demands from consumers.
(a) Describe the benefits of these two approaches. You should use examples of
products to illustrate your answer.
(refer to image three)

4 marks

Answer 6

Maintain consumer interest
 Increased market share
 Enhanced reputation
 Less investment in research and development
 Reduced risk incorporating technologies developed in
other fields
 Focussed research and development
 Less marketing as demand is established
 Consumer gets what they want

Question 7

Explain why launching new products onto the market can be a risk for a
company.

4 marks

Answer 7

Time to market (takes too long, beaten to market
by competitors)
 Technology reliability (early versions perform
poorly in terms of reliability, lower sales due to
negative feedback)
 Marketing and advertising (lack of advertising or
ineffective marketing- wrong audience)
 Quality of product (overall a poor product)
 Reliability of product (early failures due to poor
manufacture/assembly can lead to poor sales/
poor build quality an issue in early reviews)
 Potential unforeseen IPR challenges from other
companies

Question 8

Describe how the following issues may have influenced The Shield Extinguisher:
• Ergonomics
Conditions in which it is used.
(refer to image four)

5 marks

Answer 8

Ergonomics
 Handle sizes and location need to be easy to access
 Looks recognisable
 Intuitive to operate
 Height of product to allow it to be held and used
effectively
Conditions in which it used
 Fire in the environment has influenced the shield
shape
 The need to protect the user influenced the shape and
size
 The need to be used in a hazardous emergency
situation influenced the easy to locate handles
 Emergency situation influenced the fire extinguisher
red colour
 Materials would have to be suitable

Question 9

Describe how a company could ensure their products are manufactured to the
highest standard.

4 marks

Answer 9

 Effective investment in early development
 Consultation with outside experts
 Effective quality control of material
 Sampling and testing product during manufacture
 Training staff
 Motivating staff
 Maintain machinery

Question 10

Describe the key stages of questionnaires and user trips which would ensure
appropriate information is gathered about issues facing visually impaired
people
(refer to image five)

5 marks

Answer 10

Questionnaire
 Clearly identifying the information to be gathered
 Identifying suitable questions
 Refining of questions to be asked
 Adding control questions
 Identifying a suitable spread of people to ask
 Ensuring the questionnaire is in an accessible format for blind
people
 Identifying ways to distribute questionnaire and ways to
ensure useful numbers are returned
 Distributing and collecting/gathering
 Collating the data from the questionnaire
 Converting into useful formats (charts/graphs)
User trip
 Identify methods to simulate blindness
 Consult blind people to identify specific areas where
improvements are needed
 Design tasks to carry out related to the identified areas
 Analyse the findings and present a summary

Question 11

Describe how the problems associated with manufacturing high-tech products in
small numbers may be overcome.

5 marks

Answer 11

 Seeking financial support through sponsorship
 Consult experts in the early stages to minimise
redesigns and wasted time to decrease initial costs
 Outsource parts of the design process for efficiency
 Outsource manufacturing
 Buy in tried and tested technology or components
 Use of flexible manufacturing techniques
 Use of rapid manufacture

Question 12

Explain the benefits of using sketching, physical models, and computer
modelling when refining a design. You should refer to your own design
experience to support your answer.
(refer to image six)

6 marks

Answer 12

 Sketching — quick, freedom to express, not technology dependant
 Physical modelling — accurate physical feedback, testing ability, 3D visualisation, aesthetic capability, tactile, informative to
clients
 Computer modelling — change and adapt quickly, electronic communication, potential for CAD/CAM prototyping, simulation
capability
Any other appropriate explanations.

Question 13

Explain why the selected materials are suitable for the different components of
the Easybreath mask.
(Refer to image six)

4 marks

Answer 13

Elastomer
 improving the comfort to the user
 enhancing the seal
 durability issues
Polymer
 provides structural strength to the mask
 light weight (strength-to-weight ratios)
 durability issues
Accept correct references to corrosion resistance,
deterioration, UV degradation.

Question 14

Describe, with reference to the Easybreath mask, the issues which would
influence the choice of manufacturing and assembly methods.
(refer to image six)

5 marks

Answer 14

 waterproof for sealing aspects
 waterproof materials, comfort
 choice of materials
 combining of materials
 flexibility of materials
 optical properties
 determination of joints (de-bonding)

Question 15

Describe two effective techniques the designer could use to gather ergonomic
information for the Flume bath.
(refer to image seven)

4 marks

Answer 15

Two different techniques are appropriately described.

Question 16

Explain ways in which the manufacturer could ensure this product was
manufactured and assembled to the required standard.
refer to image seven)

3 marks

Answer 16

Explanations of methodology are likely to make reference to a selection from:
 the use of outside agencies for safety testing — BSI/Kite mark
 reliable quality assurance policy — testing raw materials & increased random sampling throughout the manufacture process
 through the testing of concepts prior to manufacture — computer simulation
 quality of staff/employee training
 calibration of manufacturing machinery and equipment
Accept any other appropriate step

Question 17

Explain the advantages of “Just in Time” production.

4 marks

Answer 17

Explanations will link low volume production to
advantages such as:
 zero lead times
 zero stock levels
 level of demand
 limited storage required
 efficient cash flow

Question 18

Explain the challenges faced by a designer when generating a radical design
concept, compared to generating an incremental change.

4 marks

Answer 18

 understanding/analysing the problem
 generating solutions/rethinking traditional concepts
 research/gathering information
 applying technologies for a new purpose
 working with the unknown
 time
 economics

Question 19

Explain the advantages to a company associated with the development of a
radical design concept.

4 marks

Answer 19

Explanations are likely to include references to:
 potential market
 brand awareness
 IPR of new concepts
 knowledge of new technological concepts

Question 20

Identify three potential risks in launching radical products, like the Air
Umbrella, and explain how they may be overcome.
(refer to image eight)

6 marks

Answer 20

 Three potential risks are identified.
 Clear reference is made to the launch
of radical products.
 Clear understanding of the potential
risks.
 Clear understanding of strategies to
overcome the three identified risks.

Question 21

Describe the ways in which idea generation techniques can be used in the
development of products. Use examples to support/illustrate your answer.

4 marks

Answer 21

Answers are likely to refer to the use of a range of idea generation techniques such as:
Morphological analysis, lifestyle or mood boards, technology transfer, bio mimicry, lateral thinking, and describe uses in
development such as:
 generating creative solutions
 enabling divergent thinking
 exploring the unknown
 identifying and/or exploring unusual combinations
 making connections
 inspiring aspects of design (aesthetics/function, etc)
 identifying and/or exploring alternatives

Question 22

Explain why 3D printing the body segments of the RoboWorm, resulted in a
reduction in cost.
(refer to image nine)

3 marks

Answer 22

 machinery
 tooling
 reduction in parts
 reduction in assembly
 less material used
 complex/moving parts
 volume of production

Question 23

Describe the factors which would influence a designer’s choice of material.

3 marks

Answer 23

 economics
 complexity of parts
 requirements for manufacturing process
 sustainability
 availability
 properties (functional, aesthetic, performance,
safety requirements)
Any other acceptable answer.

Question 24

Explain the issues that may influence the manufacturer’s decision to use CNC
machining.
(refer to image ten)

4 marks

Answer 24

• economy of scale
• details/complexity/accuracy of part
• no secondary processes required
• low operator skill levels required
(cutting cost)
• run machines 24/7 — increased production
• increased flexibility in manufacturing options
• high initial set-up cost
• reduction in strength
• inefficiency of material
• training costs
• availability of trained staff

Question 25

Explain the ways in which the manufacturer could ensure the product is produced to the highest standards
(refer to image ten)

5 marks

Answer 25

• quality control
• total quality management
• product testing
• quality of raw materials
• quality checks
• training and monitoring of staff
• highly skilled labour force
• random sampling
• BSI testing
• any other suitable response

Question 26

With reference to products with which you are familiar, describe what features
have been incorporated into them to ensure ease of assembly. You may use
sketches to illustrate your answer, if desired.

4 marks

Answer 26

Two or more issues identified and described, displaying:
• clear understanding of contributing issues/assembly method
• examples clearly used to illustrate and support the answer

Question 27

Explain how the design issues below may have influenced the design of the
bicycle and its docking station:
•	 function
•	 obsolescence
•	 safety
(refer to image eleven)

6 marks

Answer 27

• function; simplicity, basic primary functions,
limited function, ease of use
• obsolescence; durability, constant use and abuse,
lifespan, replacement costs, frequency of use
• safety; different user groups, legislation, health
and safety, accountability

Question 28

Explain why economic issues may influence the decision on whether or not to
import products from different countries.
(refer to image eleven)

4 marks

Answer 28

overseas locations may offer less expensive
manufacturing — hence lower costs/higher profit
• cheap labour and exploitation of workforce (long
hours, poor conditions of service) may justify not
importing on an ethical basis or alternatively,
high pay and good working conditions may be cost
prohibitive
• transportation costs may be low enough to justify
importation of products with higher profit
margins or alternatively, costs may be prohibitive
on products with low profit margins
• economic growth — this may assist in stimulating
mutually-beneficial trade and markets

Question 29

Describe activities a design company could carry out to generate creative and
innovative products

4 marks

Answer 29

effective market research
• suitable idea-generation techniques
• research into materials and technologies
• use of design teams
• any other suitable response

Question 30

Describe ways a manufacturing company could reduce product impact on the
environment.

5 marks

Answer 30

• use of bio-plastics
• use of biodegradable plastics
• use of recycled materials
• reducing materials
• sustainable materials
• changing production processes
• reducing pollution during manufacture
• quality control
• reducing waste
• labelling materials
• use of sustainable energy
• any other suitable response

Question 31

Explain the advantages of using a variety of communication techniques when
designing, planning and presenting new products.

5 marks

Answer 31

• sketches; quick, efficient, simple to execute,
easy to change
• computer generated; facilities change,
3D visualisation, modelling, simulations
• block models; human interactions, instant
feedback
• scale drawings; detail

Question 32

Explain how the use of branding reduces the risks associated with launching a
new product.

3 marks

Answer 32

• customer confidence
• familiarity
• recognition
• reputation
• advertising/endorsement
• brand loyalty

Question 33

Discuss how the different balance between aesthetics and ergonomics may
influence consumer reaction to each of the extinguishers.
(refer to image twelve)

4 marks

Answer 33

Standard fire extinguisher
• functional, easy to use and understand
• recognisable
• stands out in any environment
• familiarity
• associated with fire and danger
• consumer trust
• may not want to buy it for the home
environment
Home Hero
• unfamiliar
• not recognisable
• possible uncertainty of how it should be used
• lack of visual impact
• aesthetics lend themselves to the home
environment

Question 34

Describe how the information gained from each of the following may have
influenced the design of the Home Hero:
•	 survey
•	 user trip
•	 expert appraisal
(refer to image twelve)

6 marks

Answer 34

Surveys
• demand — volume of production, price
• common faults — new features
• buying trends — production runs
• reasons for purchase
• aesthetics
User trips
• difficulty in use
• comfort of use
• position of buttons and handles
• visual impact
• ease of use
Expert appraisals
• technical information
• safety requirements
• manufacturing considerations
• ergonomics