Exam and Revision Centre

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Exam and Revision Centre
Treorchy Comprehensive School Design
Technology Department
Examination Practice and Techniques Booklet
Key Words
Pupil Name ______________________ Teacher
_________________________
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Exam and Revision Centre
Topic
Pages
Smart Materials
Pages
C.A.D. C.A.M.
Pages
Wood
Pages
Metal
Pages
Plastic
Pages
General Questions
Pages
Question
Pages
Additional Revision Notes
Pages
Contents Page
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Exam and Revision Centre
Tips and Notes for Revision
Topic This page looks at Smart Materials. They
can be used in a many number of ways. Make sure
you can identify a few of these and know where
they can be used and how they work.
Learn and understand at least three of the
following in detail. Make sure you can at least
recognise the names of the remaining
Smart Materials. You have been told
what they do. It is your job to find out where
they might be
used. Thermo chromic film changes colour when
heat is applied to it. Modified starch is able
to thicken a hot liquid without forming
lumps. Nitinol (muscle wire) changes its length
when an electrical current is passed through
it. Polymorph becomes soft and pliable in hot
water and moulded to specific shapes and sets
hard. Photo chromic dye changes colour when heat
is applied. Electro-luminescent sheet emits
light when a small electrical charge is applied.
Previous Exam Questions
A list of smart materials is shown below. Thermo
chromic film Modified starch
Nitinol (muscle wire) Polymorph
Photo chromic dye
Electro-luminescent sheet Choose one of these
smart materials and describe briefly how it
works. Name of the smart material . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . .
How it
works. . . . . . . . . . . . . . . . . . . . . .
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. . . . . .. 2
Paper 1 - 2006 - Question 1
Do you know how they work? Where they are used?
What they can do?

• Examination Tips
• Always read the question carefully.
• Be sure to understand the key words in a
  question, such as explain or identify.
• Check how many marks are available (in
  brackets). This will help you work out how much
  detail is required in your answer.

Key Words
Sensitive to changes in light conditions.
Photo
Thermo..
Sensitive to changes in temperature.
Changes take place when electrical charges are
added.
Electro
Morph
Can change shape and be set to that new shape.
Chromic
Colour is affected in some way.
Page 1
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Exam and Revision Centre
Tips and Notes for Revision
Topic This page looks at the use of C.A.D. /
C.A.M. in Design Technology. It will focus on
the advantages and disadvantages in both a school
and industrial environment.
Previous Exam Questions
Paper 1 - 2007 - Question 3
Paper 2 - 2007 - Question 3
Key Words
Computer Aided Design
C.A.D.

• Examination Tips
• Always read the question carefully.
• Be sure to understand the key words in a
  question, such as explain or identify.
• Check how many marks are available (in
  brackets). This will help you work out how much
  detail is required in your answer.

C.A.M.
Computer Aided Manufacture
C.I.M.
Computer Integrated Manufacture
C.N.C.
Computer Numerical Control
Page 2
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Exam and Revision Centre
CAD CAM - Previous Exam Questions Continued
Paper 2 - 2006 - Question 3
Page 3
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Exam and Revision Centre
CAD CAM - Previous Exam Questions Continued
Paper 2 - 2007 - Question 4
Paper 2 - 2008 - Question 4
Sample Questions New Specs
Page 4
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Exam and Revision Centre
CAD CAM - Previous Exam Questions Continued
Sample Questions New Specs
Page 5
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Exam and Revision Centre
CAD CAM - Previous Exam Questions Continued
Sample Questions New Specs
Page 6
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Exam and Revision Centre
CAD CAM - Previous Exam Questions Continued
Sample Questions New Specs
50
50
70
30
150
60
150
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Exam and Revision Centre
Tips and Notes for Revision
Topic This page looks at Wood and Wood Joints.
You will need to
recognise many and be able to describe a few in
detail. This means, how they are made, which
tools are used and why some joints are stronger
than others etc.
Previous Exam Questions
(c) Many garden centres and DIY outlets sell
garden benches flat packed. Give two advantages
for the retailer of selling furniture flat
packed. Reason 1 . . . . . . . . . . . . . . .
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. . . . . . . . . . 1 (d) A student has
designed a garden bench and wants to screw the
seat rails in place as shown in the diagram
below. Using notes and sketches, describe how you
would successfully do this.


5
Paper 2 2006 Question 4
Key Words
mm
Soft Wood

• Examination Tips
• Always read the question carefully.
• Be sure to understand the key words in a
  question, such as explain or identify.
• Check how many marks are available (in
  brackets). This will help you work out how much
  detail is required in your answer.

Hard Wood
mm
A joint which can be undone and put back together
if needed.
Temporary Joint
Permanent Joint
A joint which cannot be undone or taken apart.
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Exam and Revision Centre
Wood Joints
Sample Questions New Specs
1. The pupil has designed a number game using
blocks shown in the diagram below.
2. The drawing shows a design for a pull along
toy. The body of the car is made from
a solid block of softwood.
The blocks are housed in a base made from
softwood. Look at the close up of the corner
joint
Using notes and sketches, show how you would
attach the wheels to the body, allowing them to
spin freely.

(5)
In the space below, name and sketch one temporary
joint and one permanent joint for the corner.





(2x3)
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Exam and Revision Centre
Wood Joints
Sample Questions New Specs
5. The design for a table lamp is shown below.
The designer has chosen to make the body of the
lamp from layers of wood veneer.
3. (i) Chipboard and Plywood are commonly used
manufactured boards. Name two other manufactured
boards.


(2) I II.


(ii) The diagram shows three layers of
veneer used to construct Plywood. Complete the
diagram by showing clearly the direction of the
grain.
(2)


(i.) Name the process for manufacturing the body
of the lamp.
(1) ... (ii.) Name
a suitable adhesive for joining the veneers
together.
(1) .. (iii) Use
notes and sketches to describe how you would form
the curved shape of the body of the lamp





(6).




(iii) explain why the layers are glued together
this way
(2)
4. Give two reasons why chipboard is often
covered with a layer of plastic laminate or wood
veneer.
....(2)
..
..(2)
(iv) The base of the lamp is made from a solid
piece of wood. Use notes and sketches to explain
how you would join the body and base together.

(4)


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Exam and Revision Centre
Wood Joints
Sample Questions New Specs
6. Before wood can be used for making it needs
to be seasoned. Explain the purpose of
seasoning


(3) ......
......
..
.. Name the two methods of seasoning wood.



(2) Method 1 ................ Method
2 .
In the space below, name and sketch a suitable
permanent joint for the leg and cross rail.
(diagram A)



(5) Name of joint

7. Increasingly manufacturers will use wood from
manageable forests explain what you understand
by this term

(3)





9. Other than using a CAM machine, use notes
and/or sketches to explain the stages you would
follow to make the triangular hole in the body
of the toy.
4




8. The picture shows a Hardwood garden bench
together with a close up detail of the legs and
cross rail (diagram A)
diagram A
(i.) Name a suitable hardwood for making the
bench.



(1)
(ii.) Give a reason for your choice of material.

(2)



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Exam and Revision Centre
Wood Joints
Sample Questions New Specs
12. Drawings of four different wood joints are
shown below. (a) Insert the correct name for each
joint.
10.The photograph shows a toy suitable for
children aged 1 and over.
Joint 1
Joint 2
The toy is made of solid wood. Name a suitable
wood and give a reason for your choice. Wood
..

1 Reason .
2
Name .. Name

Joint 3
Joint 4
(b) The wheels of the toy turn freely so that the
child can pull the toy along. Using notes and
sketches, show how you would attach the wheels to
the body. 4
Name .. Name

(b) four basic steps for making joint 3 are shown
below. Describe clearly how each step is carried
out. Include the names of the correct tools used.
11. Wooden greenhouses are often made from
Cedar. Explain why this is a suitable wood.
(2)

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Exam and Revision Centre
Wood Joints
Sample Questions New Specs
13. Complete the table by inserting the correct
answer in the sentence.
(7)

14. Explain the differences between Hardwoods and
Softwoods
(3)

..
.
.
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Exam and Revision Centre
Tips and Notes for Revision
Topic This page looks at Metals and Metal
Work. It is important that you understand the
properties and characteristics of various
metals. Be able to discuss at least a few
different types.
Previous Exam Questions
Paper 2 2007 Question 1
(b) Use the following words to complete the
sentences below. Iron Mild Steel Brass
Stainless Steel Lead (i) All ferrous
metals contain . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . 1 (ii)
Cutlery is often made from . . . . . . . . . . .
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1 (iii) . . . . . . . . . . . . . . . . . . .
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. . . . . . .. is an example of a non ferrous
metal. 1 (iv) . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . is a very
heavy metal with a low melting point. 1
(b) Complete the table below by describing three
important stages you would follow when drilling a
10mm hole in steel.


3 Stage 1 2 3
(c) List four safety precautions that should
be followed when drilling metal. (i) . . . . . .
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Paper 2 2007 Question 4
Key Words
mmm
Ferrous Metals
Non-Ferrous Metals
mmm
mmm
Alloys
mm
mmm
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Exam and Revision Centre
Metals
Paper 2 2006 Question 2
(ii) Using notes and sketches, explain how you
would attach the extra part you have drawn in
part (i) to the bracket.


5
(b) The diagram shows a design for a hanging
basket bracket (Diagram A). The designer
has found that the weight of the basket causes
the bracket to bend (Diagram B).
(iii) The bracket is to be used outside. (I)
Name one suitable finish for the bracket.

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. . . . . . . . . . . . . . . . . . . (II) Give
one reason why a finish is needed.

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(III) Explain how you would apply the finish to
the mild steel bracket to get a high quality
finish.

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(i) Improve the design of the bracket shown below
in order to prevent it bending. Label your
design.

2
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Exam and Revision Centre
Metals
Paper 2 2006 Question 2
Paper 2 2007 Question 3
(c) List four important safety precautions that
need to be followed when drilling metal.
4 Precaution 1 . . . . . . . . . . . . .
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3. The photograph shows a greenhouse constructed
from Aluminium.
Paper 2 2007 Question 3
(d) Metals can be classed as Ferrous and
Non-ferrous metals. Place each of the metals
below in the correct column.


5 Stainless Steel Gold Copper
Iron Lead
(a) Explain two reasons why Aluminium is a
suitable material for the greenhouse. Reason 1
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Exam and Revision Centre
Metals
Sample Questions New Specs
(a) The part A must pivot from side to side. In
the space below, use sketches and notes to show
in detail how you would do this.

(5)



1. Write the correct material alongside its
description below. Aluminium Lead
Stainless steel Iron Copper
Brass Zinc high
speed steel
(b). The bracket design is to be made from mild
steel. (i) Name a suitable finish you could
apply to the metal in school
(1)
..
In the space below, describe with notes and
sketches, the stages you would follow to apply
the finish to the steel.


(4)
2. A design for a wall mounted bracket made
from ferrous metal is shown below.
(c). Name a method of permanently attaching part
B to part C ..

(1)
Page 17
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Exam and Revision Centre
Metals
Sample Questions New Specs
9. The diagram shows part of an axle for a
childs bike. It is manufactured from a single
piece of 10mm mild steel bar.
3. Explain what is meant by an alloy

. (2)
4. Give an advantage of an alloy over a pure metal
.
. (2)
All measurements in mm.
5. The pins of a plug are made from brass. Give
two reasons for this choice of material. Reason
1 .
. (2) Reason 2
.
.. (2)
Use notes and sketches to explain how you
would (i.) reduce the diameter of the end of
the bar to 6mm.
(4)
6. Explain why router cutters are often made from
Tungsten Carbide rather than steel
(2)
..
..
7. Name two different types of
steel. ..

1 ..
1
(ii.) produce a thread on the end of the bar to
attach a metal nut.
(4)
8. Explain how you would accurately and safely
drill a 10mm hole into a steel plate.
4


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Page 18
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Exam and Revision Centre
Metals
Sample Questions New Specs
10. The diagram shows a 5mm thick piece of
steel marked out for drilling and shaping.
11. The photograph shows a greenhouse constructed
from Aluminium.
Other than strength describe two properties of
Aluminium that make it a suitable material for
the greenhouse. Property 1

(2) Property 2

(2) The greenhouse comes
flatpacked and is constructed using nuts and
bolts. Give two advantages of this type of
construction Advantage 1
Advantage 2
(2)
Name the tool used to mark the centre of the 50mm
radius.

1 Name a tool used to mark
out the 50mm radius curve.
1
.. Using notes and sketches,
explain how you would remove the waste material
and finish the radius.


4



...
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Exam and Revision Centre
Tips and Notes for Revision
Topic This page looks at Plastics and how they
can be used to create forms, shapes etc. Make
sure you learn a few different types in detail
and can think of uses for these types of
plastics.
Previous Exam Questions
(c) A disposable plastic sandwich container is
shown below.
(i) From the list below, underline the correct
process used to manufacture the
sandwich container. 1 Blow Moulding Vacuum
Forming Press Moulding (ii) Name a suitable
plastic material for the sandwich container.
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. . . . . . . (iii) Give two reasons why the
material you named in part (ii) is suitable for
the sandwich container. Reason 1 . . . . . . .
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Key Words
mm
Thermo Plastics
Thermo Setting Plastics
mm
Page 20
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Exam and Revision Centre
Plastics
Sample Questions New Specs
1. From the list, select the most appropriate
material and process for the following products.
(6) ABS PET Strip heating
Injection moulding Blow moulding
Acrylic
Study the diagram closely and state two design
faults with the mould and give two ways the mould
could be improved. Fault
. Improvement
. (2) Fault
. Improvement
(2) Explain why Chipboard would be
less suitable for making the mould than MDF.
(2)
..
..
3. The design for a desk clock is shown below.
The designer has chosen to make the clock from
plastic.
2. A mould for vacuum forming is shown below.
(i) Name a suitable plastic for the clock body
and give a reason for your choice Plastic
..

(1) Reason ..
(2)
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Exam and Revision Centre
Plastics
Sample Questions New Specs
(ii) A former or jig is used to make an accurate
curve for the clock. Using notes and sketches,
show a design for a former to make the body of
the clock. (5)
5. The diagram shows a replacement 3 pin plug and
cable.
(i) The body of the plug is made from Urea
Formaldehyde. Give two reasons for this choice of
material. Reason 1

Reason 2
(4) (ii)
The pins of the plug are made from brass. Give
two reasons for this choice of material. Reason
1
Reason 2

(4) (iii.)
Name the process for manufacturing the Body of
the plug
(2)

4. The diagram shows a design for a computer disk
holder made from one piece of 3mm
Acrylic. Describe the main stages necessary to
manufacture the holder
(10)
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Exam and Revision Centre
Plastics
Sample Questions New Specs
6. A disposable plastic sandwich container is
shown below
7. Explain in detail the difference between a
Thermoplastic and a Thermosetting
plastic.


(3)
8. Place the following processes into the table
to indicate whether they are used to form
Thermoplastic or thermosetting plastic products.
Plastic extrusion Compression moulding
Blow moulding Injection moulding
(i) Name the process used to manufacture the
product.
(1) (ii)
Name a suitable plastic for the
container .
(1) (iii.)
Give two reasons why this material is
suitable. reason 1
.
.(1) reason 2
.
(1)
(4)
9. Acrylic and Foamex (PVC) are commonly used
thermoplastics. Name two other
thermoplastics. (i)

1 (ii)

1
(iv.) Describe two important design
considerations that the designer would need to
think about when designing this
product. Consideration 1
......................................
(2) Consideration
1 .......................
...............
(2)
10. Plastic is often used instead of glass in
greenhouses. Name a suitable plastic and describe
why it is so suitable to use instead of
glass. Name of plastic .. Reasons
for choice
. .
(4)
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Exam and Revision Centre
Plastics
Sample Questions New Specs
11. A mould used for press moulding 3mm Acrylic
or Foamex is shown below.
12. The photo below shows a fresh fruit product
sold in a supermarket. The tray and the fork are
made from plastic.
Study the diagram and describe three features or
considerations necessary to make a successful
mould. Feature 1

2 Feature 2

2 Feature 3
2
(i) Name the process used to make the tray
..
(1) (ii) Name the process used to make the
plastic fork
(1) (iii.) A mould is needed to make the tray.
Describe three features or considerations
necessary to make a successful mould. Feature
1
2 Feature 2

2 Feature 3

2
(iii) Name a suitable specific material for
making the mould and give a reason for your
answer. Material ..

1 Reason
.
. 2
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Exam and Revision Centre
General Questions
Sample Questions New Specs
1. (a) Complete the table by placing the
materials listed below under the correct heading.
5 Aluminium Pine
Stainless steel Mahogany
Red Cedar
2. The photograph below shows a model that has
been made out of card.
(b) (i) From the list below, select the correct
name for each marking out tool.
4 (ii) Underline the correct use of each tool
from the statements given.
4 Marking Gauge Tri Square
Centre Punch Scriber
(a) Give two advantages of making a card model
when developing a design. 2 2 Advantage 1 .
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Advantage 2 . . . . . . . . . . . . . . . . .
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Page 25
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Exam and Revision Centre
General Questions
Sample Questions New Specs
1. a) Complete the resistant materials table
using the materials provided.



(6) Urea formaldehyde Oak
Stainless steel PVC parana pine
copper
5. Safety is very important when designing for
young children. Identify four important safety
precautions you would need to consider before
designing a product for a child
(4) .
..
..
..
6. Select the correct machine from the list below
to make each of the products shown. Woodworking
lathe Metalworking lathe Strip heater
Milling machine Vacuum former

• 2. A DT student has chosen to design an
  educational toy for a local primary school for
  her project. The children are aged between 4-6
  years old.
• Suggest two different areas of research she can
  carry out that will help her with the project.
• Research
  (1)
• Reason
• 
  .. (2)
• Research
  (1)
• Reason .
• 
  ... (2)

(5)
7. Complete the table by placing the joining
methods listed below under the correct heading.
One example has been done for you. Screw
weld Rivet Knock down fitting
3. Name a suitable adhesive for joining the
following materials
(3)
(4)
Page 26
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Exam and Revision Centre
General Questions
Sample Questions New Specs
8. A lot of furniture and kitchen units are sold
flat packed Give two reasons for
this i

(2) ii

(2) 9. Many products we buy today are made in
China and other countries in Asia. Give a reason
for this

(2) 10. Explain why we should try to
recycle everyday products like bottles and drink
cans.
(2)
13. The diagram shows a bookcase manufactured
from veneered Chipboard together with details of
a corner fastening.
Steel bolt tightened with an Alun key
Steel fastening inserted into chipboard
(a) (i.) The bookcase is bought flat packed
explain what you understand by this
term.
(2)
(ii.) Explain the meaning of the term Knock down
fitting (KDF)

(2) (iii.) Explain the advantages of using the
corner fastening shown to construct the
bookcase.
(2)
11. State the exact name for each of the holding
devices shown below
(3)
12. Increasingly manufacturers will use wood from
manageable forests explain what you understand
by this term.




(3)
Page 27
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Exam and Revision Centre
General Questions
Sample Questions New Specs

• (b) The bookcase is to be sold with two shelves
  that can be adjusted for different sizes of
  books. The manufacturer does not want the shelf
  supports to be visible when viewing the design
  front on.
• Use notes and sketches, show
• how the shelves can be supported yet
  adjustable.
• how the supports can be made less visible
  
  (5)

15. Many garden centres and DIY outlets sell
garden benches flat packed. Give three reasons
why such products are often much cheaper to buy
than pre-assembled products.



(3x2) Reason 1

Reason 2
Reason 3

.
16. The greenhouse is a modular design which is
available in a range of sizes. Describe some of
the important cost effective design criteria the
designer would need to consider so that the same
basic design could be offered in a range of
sizes.



(3)
14. Name each of the marking out tools pictured
below and state what each is used for.
17. Name one permanent and one temporary method
of joining the parts in each of the examples
shown below. Each method can only be used once.
6
(8)
Page 28
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Exam and Revision Centre
General Questions
Sample Questions New Specs
19. The photograph shows a computer workstation
sold in a retail store.

• From the list below, select the correct name for
  each of the following saws and explain what each
  saw is used for.
  
  
• 
  
  
  (8)
• Coping saw Hacksaw Fretsaw
  Tenon Saw Jigsaw

Saw
Name
Use
Give four specification points the designer would
have considered before designing the product.
Specification point 1
.
.. 2 Specification point 2
.
..
2 Specification point 3
.
.. 2 Specification point 4
.
..
2 (b) The workstation is made from laminated
chipboard. Explain what you understand by
the term laminated chipboard.


3
Page 29
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Exam and Revision Centre
Question 5
Sample Questions New Specs
The School catering company has asked you to
design a portable display board for the entrance
to the school canteen, in order to advertise the
menu and the meal of the day. The A4 size menus
are protected by 3mm clear acrylic covers.

• Specification The design must
• Be portable and stable because the dining hall is
  used by the school throughout the day.
• Be easily erected and dismantled by the canteen
  staff because storage space is limited.
• Allow canteen staff to easily change the menus
  every day.
• Be 100cm off the ground
• (a) Sketch your solution on the opposite page.
• Marks will be awarded for
• constructional details of a well designed,
  portable and stable stand.
  (4)
• Details of how the design can be easily
  dismantled and erected.
  (5)
• A method of changing the menu cards daily.
  
  (5)
• Quality of communication
  
  (5)
• Two important dimensions.
  
  (2)

Page 30
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Exam and Revision Centre
Question 5
Sample Questions New Specs
The diagram shows a design for a space saving
table. You have been asked to complete the
design.

• Specification. The table must
• Be hinged
• Be strong
• Fold vertical against the wall to save space.
• Be wall mounted.
• (a) Sketch your solution on the opposite page.
• Marks will be awarded for
• Construction details showing how the table top is
  moved from a vertical (closed) position to a
  horizontal (open) position and back.
  
  (6)
• Showing clearly how the table is kept horizontal
  when being used (sketch A)
  (6)
  
  
• Naming two suitable materials used
  
  (2)
• Quality of communication
  
  (5)
• (b) In the space below show how you would attach
  the table to the wall
  (6)

Page 31
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Exam and Revision Centre
Question 5
Sample Questions New Specs
A lightweight portable stand is needed for a
classroom projector, as shown below.

• Specification
• The stand must
• Be easily transported between classrooms.
• Hold the projector securely in place.
• Enable the projector to be supported at least
  800mm above the ground.
• (a) Sketch your solution on the opposite page.
• Marks will be awarded for
• (i) Showing clear labelled sketches of your
  design for the stand, including construction
  details and material(s) used
  7
• (ii) Showing the features that allow the stand
  to be moved easily
  3
• (iii) Showing clear details of how the projector
  is held securely in place
  3
• (iv) Including two important dimensions on your
  design 2
• (v) Quality of communication.
  
  4
  
  

(b) In the space below, show clearly how the top
of the stand could be adapted to allow the front
of the projector to be adjustable, to a maximum
height of 50mm.
6
Page 32
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Exam and Revision Centre
Question 5
Sample Questions New Specs
The diagram shows the basic design for a rotating
stand to display A4 size School brochures in the
reception area in a secondary school. You have
been asked to complete the design.

• The stand must
• Be freestanding
• Be able to rotate through 360 degrees.
• Allow visitors to easily remove the A4
  brochures.

(a) Sketch your solution on the opposite page.
Marks will be awarded for (i.) Showing clear
details of how the box is constructed

(3) (ii.) Showing clear details of how the
stand is constructed
(4) (ii.)
showing clear details of how the design will be
able to rotate through 360 degrees