Design and Manufacture

1
Design and Manufacture

• Prelim Exam

2

• Prelim
• The paper will have 60 marks allocated.
• The paper will have two Sections.
• Section 1 will represent approximately 40 of the
  total marks for the question paper. It will
  consist of a single question, based on a product,
  and will require extended and reasoned responses.
  The question will focus on the manufacturing
  issues associated with a product, namely
  materials, tools and processes.
• Section 2 will represent approximately 60 of the
  total marks for the question paper. It will
  consist of five questions, based on a number of
  different products, and will require integration
  of knowledge and understanding from across the
  Course . The questions will mainly focus on
  design and issues relating to the design of
  products.

3

• Section 1 Topics which could be included are
• Materials Name different types and advantages
  of using them.
• Woods Softwood, Hardwood and Man Made Boards
• Metals Ferrous and Non-Ferrous
• Plastics Thermoplastic and Thermosetting
• Joining Materials recognise joint and explain
  processes.
• Wood Mortise and Tenon, Housing, Halving, dowel
  etc.
• Metal Welding, riveting, nuts and bolts etc.
• Plastic Gluing
• Shaping/Forming Materials
• Wood Wood Lathe Preparation for turning, tools
  used etc.
• Metal Metal Lathe different process of lathe
  (e.g. facing, parallel turning, knurling)
• Plastic Vacuum forming, strip heater etc
• Finishing Materials
• Wood Varnishing, painting, staining etc.

4

• Section 2 Topics which could be included are
• Design Explain in relation to products
• Design Factors Ergonomics, Aesthetics,
  Performance, Materials, Function, Safety etc.
• Product Evaluation Evaluation techniques user
  trials, questionnaire, observation etc.
• Modelling different types and advantages.
• Manual Modelling Card, clay, foam, polystyrene,
  foam board etc.
• Computer Aided Modelling 3D Computer modelling,
  Rapid Prototyping
• Materials and Processes
• Choosing materials for products and giving
  reasons for the choice.
• Naming suitable manufacturing processes for
  products and explaining your choice.