For examiner’s use only

Section A 1 8

2 3

3 7

4 14

5 4

6 5

7 18

8 14

9 9

Section B 10 18

Total 100

Answer questions 1 to 9 any one question 10.

Section A

Answer all questions

This question is about ethics and the environment.

1. (a) Explain the following terms.

(i) Carbon footprint

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(ii) Fairtrade

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(b) Choose two words from the list below.

Explain what the words mean in relation to the environment.

Reuse Recycle

Reduce Repair

(i) Word ........................................................

Explanation ...............................................................................................................

................................................................................................................................... [2]

(ii) Word ........................................................

Explanation ...............................................................................................................

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This question is about energy.

2. A hen house on a farm is located with no mains electricity supply.

Suggest a renewable energy source that could open and close the hen house door at the beginning and end of the day. Explain why your chosen energy source is suitable.

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This question is about product life cycles.

3. Manufacturers need to consider the impact upon the environment when choosing materials.

Using notes and sketches complete the diagram to show

(a) how the material might be disposed of [2]

(b) how the life cycle of the material might be extended. [2]

Oil Refinery (Raw Material)

New Plastic Toy (Product)

The pictures which appeared here cannot be reproduced due to third-party copyright constraints.

Disposal of the material

Extending the life cycle of the material

(c) Why do some products have a lifecycle built into them?

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This question is about modern and smart materials.

4. (a) Name either a new or a smart material.

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(b) Describe the properties of the new or smart material you have named in part (a). Explain how it could be used in a product.

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(c) (i) Study the police uniform in the photograph below. Using a pen, link the text boxes to the police uniform to label the clothing.

[4]

(ii) Give one advantage of using these fabrics in the police uniform.

Reflective tape

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Fluorescent nylon

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Polyester / cotton non-iron fabric

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Stain resistant fabric with heat set crease

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(d) Name and describe one modern fabric different from those listed above.

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[14]

This question is about design and market influences.

5. Explain what is meant by the term market pull, technology push. Give examples of

products to illustrate your answer.

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[4]

This question is about Electronics and programmable components

6. (a) Complete the system diagram below by naming one input component and two output components for the toy.

Input component Process component Output components

[3]

(b) State two reasons why microcontrollers are increasingly used to replace other types of

circuit.

Reason 1 ................................................................................................................

Reason 2 ................................................................................................................ [2] [5]

This question is about materials.

7. Products are made from different types of material.

(a) Choose two products in the table and identify the main material type used in its manufacture. Draw a line to link the material type to the correct examples of specific materials in its group.

An example is given for you.

[4]

(b) State two reasons why corrugated cardboard is used as packaging for cooked pizzas.

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(c) Complete the table shown below by correctly naming each manufactured board.

Manufactured board Name

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[1]

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[1]

(d) Give three advantages of using Medium Density Fibreboard (MDF) instead of solid natural timber.

Explain each of your answers.

(i) Advantage: .....................................................................................................

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Explanation: ...................................................................................................

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(ii) Advantage: .....................................................................................................

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Explanation: ...................................................................................................

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(iii) Advantage: .....................................................................................................

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Explanation: ...................................................................................................

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(e) A designer has chosen to use a natural wood instead of the normal material used for

flooring.

The usual material costs £9.60 per square metre.

The natural wood costs 25% more.

(i) How much does 1 square metre of the natural wood cost?

Use this space for your working out:

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[2]

(f) The carpenter wants to lays 15 floors over one week. 1 floor requires 8 square metre of the

natural wood

(ii) How much is the total cost of the natural wood material for all 15 floors?

Use this space for your working out:

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[2]

[18]

8. (a) Choose one product in Figure 2 and describe two features that make it suitable for one-off

production.

Name of chosen product ………………………………………………………………….

Feature 1:

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Feature 2:

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[4]

(b) (i) Analyse your chosen product in terms of its environmental impact.

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[2]

Tailored suit Wedding ring Fibreglass sculpture

Wooden bureau Architectural model Personalised wheelchair

Figure 2

(ii) Evaluate your chosen product in terms of one safety considerations.

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[2]

(c) (i) You have been asked to redesign your chosen product. Describe one benefit of using

the design strategy of collaboration to carry out this task.

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[2]

(ii) For your chosen product, identify a type of drawing that could be used to:

I show your initial ideas for discussion; [1]

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II show your final proposal to a potential client; [1]

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III provide details for manufacture. [1]

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[14]

9. Figure 3: shows a hearing aid worn by an adult to assist with loss of hearing.

Specification

Very lightweight

Comfortable to wear

Low power consumption

Easy to replace the batteries

Adjustable volume control and an on/off switch

The data in the table, figure 4, shows the views of 120 business professionals who are hearing aid

users. They were asked to rank the features in the table to find out which were the most important to

them.

The table shows how many users ranked each point as the most important.

(a) Complete the table by calculating the two missing Number of users for 1 mark

and two percentages for 1 mark. [4]

Most important feature Number of

users Percentage of

total

Ultra-small size

Very long battery life 6 5%

Cost under £700 each 6

Rechargeable batteries 10%

Almost invisible to sense when worn

66 55%

Total 120 100%

Use this space for your working out:

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(b) Using the information in table figure 4, complete the bar chart below. [2]

(c) Explain how this data may influence the design of a newer version of the

hearing aid. [3]

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[9]

Percentage of users choosing most important features

Section B

Answer one of the questions in this section

10. Paper and Boards

(a) The photograph below shows a sketchbook.

(i) The sketchbook is A3 size and made from greyboard and 160gsm cartridge paper.

I Explain the meaning of the word 'gsm' in the sentence above. [1]

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II Give a reason why cartridge paper has been used for the sketchbook. [1]

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...………………………………………………………………………

(ii) Give one reason why the sketchbook has been designed to have a spiral binding and one example of how it the sketchbook is reinforced. [2]

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(iii) A new school wants to apply their logo onto the sketchbook and requires embossing similar to the image below.

Explain how the logo is applied by embossing. [4]

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(b) Details of the sketchbook are shown below:

Fill out the missing measurements and calculate the area of the cover.

(c) Explain how paper is made. [4]

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(d) It is important that designers consider the world we live in and the needs of future

generation

Evaluate how designers can lessen the impact on our environment when designing new

products which include papers and boards. [6]

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[18]

10. Natural and manufactured timber

(a) Study the chair below.

Chair

Body: Pine

Finish: Varnish

Self- assembly

(i) State one property of pine that makes it suitable for chair. [1]

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(ii) Give a reason why:

I each part of the chair is self-assembled. [2]

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II why a mortise and tenon joint is used. [2]

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(iii) Describe how you would prepare the surface of the MDF body before applying the

varnish lacquer finish. [4]

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(iv) Describe a method of making the four identical legs in of the chair in the workshop. [4]

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(b) The legs of the chair are 480mm tall, 40mm wide and 40mm deep, calculate the total

surface area of one and then of all 4 legs in order to estimate the amount of varnish to be

used [5]

Use this space for your working out:

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[18]

M1. (a)

Carbon Footprint

Impact on climate change e.g. primary processing, secondary processing, transportation, energy during use, disposal & global warming. Amount of carbon produced by any human activity. Measured in units of carbon dioxide. Carbon emissions produced during the manufacture of a product

One mark for an example to explain understanding. 2

Fairtrade Fair trade foundation set up to reduce poverty and hardship among farmers & workers around the world. Ensures workers receive a fair price for their products. Minimum price for sustainable production A partnership between traders and producers Investment in social or economic development projects. Often organic produce

Reference to farmer / worker = 1

Pay a fair price = 1 2

M1. (b)

Reuse Use the packaging again e.g. plastic carrier bag, wash out glass

bottle and refill, get the maximum use out of a product before disposing of it.

Recycle Process the materials from used products to be used to make new products. Put recyclable used products in recycling bins, materials will need to be separated; some are too difficult to separate and therefore cannot be recycled. Council collection processes.

Reduce Reduce the amount of raw materials used by reducing our

consumption of products, recycling and reusing existing products and materials. Reduction of energy consumption.

Repair Repair and maintain products rather than replace to minimise

use of non renewable resources, energy in manufacture and therefore reduce a products carbon footprint.

Sound response which makes reference to two of the ideas above in brief or one idea in detail.

2 marks

Brief / single word answer with reference to one idea only. 1 mark

Max 2 × 2

marks

M2. Suitable energy source suggested, e.g. (1 mark) • Water Power

• Solar Panel • Wind Turbine.

Weak response with reference to why it is suitable (1 mark)

Strong response Reference to the above, well explained with reference to storage of energy or that the door only operates in the daytime so solar panel appropriate. (2 marks) E.g. A wind turbine will charge a battery to power the motor even when it is not windy.

[3]

M3. (a) A simple statement or drawing e.g. “put the toy in the bin” (1 mark)

An answer that displays a fuller understanding, e.g.“the material will be either put in a landfill site or incinerated”. (2 marks)

(2 marks)

(b) A simple statement or drawing, e.g.“melt the plastic down”. (1 mark)

An answer that displays a fuller understanding e.g. ‘the plastic could be re-cycled i.e. melted down, refined and re-used to make other plastic objects’. (2 marks)

(2 marks)

[4]

(c) Built in product life cycle - planned obsolescence, product designed to fail, to be

replaced or become out-dated, fashion / trends, technological advancements, consumer power etc. Do not accept shelf life or sell by date.

Good understanding 3 marks

Some understanding 2 marks

Limited understanding 1 mark

No attempt or confused 0 marks

[3]

M4. (a) Identification of new / smart material: e.g starch based polymers,

precious metal clays, quantum tunnelling composite, carbon fibre, thermochromic, hydrochromic, shape memory alloys, UV, phospherescent, photochromic etc.

1 mark

(b) Appropriate and detailed description of material’s properties including an example of its use in a real product.

3 marks

Sound description of material’s properties and an appropriate example of its use or detailed description with no example. 2 marks

Superficial description of material’s properties or example of use. 1 mark

Incorrect description of properties with no reference to use. 0 marks

(c) (i)

Marks awarded as follows: No answer worthy of credit

0 marks

1 mark for each correct label link to photo, up to 4 marks (4 marks)

(ii) Marks awarded as follows:

No answer worthy of credit 0 marks

Reflective tape – high visibility, reflects car headlights / street lights, seen at night, easily recognised. Fluorescent nylon - high visibility, easily seen, strong, dries quickly, non-iron Polyester / cotton non-iron fabric – easily laundering / fabric doesn’t crease, properties related to fibres – soft, strong, cool to wear, breathable, durable. Stain resistant fabric with heat set crease – easy to keep clean, smart appearance given, less laundering needed.

No to repeat points from question.

1 mark for each correct point, up to 1 mark for each fabric type. (4 marks)

(d) Named modern fabric must be different from above.

E.g.: Microfibres used to make fabrics, laminated fabrics such as Gortex, Fastskin, nanotextiles, phosphorescent, photochromatic printing / fabric, stomatex etc. Any other recognised modern fabric. See notes for (i) Modern Materials for more modern fabric examples.

Marks awarded as follows: No answer worthy of credit

0 marks

1 mark for a named fabric or a description of a fabric. 1 mark

Candidate names and describes fabric. 2 marks

4

3

2

1

4

M5

M6. (a)

Up to 3 marks 1 mark for each specific component named.

Input components could include PTM switch, reed switch, LDR, or other suitable response.

Output components could include LED, bi-colour or tri-colour LED, bulb or lamp, buzzer, piezo transducer, sounder, bell, or similar.

Note: if 2 light or 2 sound outputs are named, award only 1 mark.

[3]

M6. (b) Two reasons must be stated including any 2 of the following

PIC allows pre-programming PIC allows programme revisions / changes Greater complexity of programme function More outputs and inputs available More reliable switching Faster and or shorter sequences Fewer components required Smaller circuit size Or other suitable reasons

1 mark per reason [2]

M7. (a) One mark per correctly identified material group, one mark per correctly linked examples.

Max 4 marks

[4]

M7 (b).1 mark for each correct reason stated up to a maximum of 2 marks.

Indicative content:

• Strength to weight ratio so that it can be easily carried but supports the weight of the pizza

• Low cost in comparison to other packaging materials which makes it cost effective for retailers

• Can be printed on so takeaways and restaurants can display their logos • Rigid materials that won’t flex and bend as easily as other types of

cardboard – offers protection to the pizza • Thermal properties – keep pizza warm.

You should accept any other valid response.

M7 (c).

Manufactured board Name

Plywood / multiply

(1 mark)

Chipboard

(1 mark)

[2]

M7 (d). Use the following criteria to mark (i), (ii) and (iii).

Award one mark each, for an advantage of using MDF.

Possible responses:

• MDF is available in large sheets • MDF has a smooth surface • MDF is an environmentally friendly / sustainable material • MDF is a stable material • MDF is cost effective (cheap) • MDF does not have knots / defects • MDF can accept a veneer / ‘formica’ finish

(3 × 1 marks)

M7

(e)

(f)

M8

(b) (i)

Answers must be appropriate to the product chosen by the candidate and be specifically about its

likely environmental impact. 1 mark per relevant point.

The product(s) could be made of recycled materials which is good for the environment.

(1)

As a 'use once' product, it is less environmentally friendly than a re-usable version (1)

The metal base products should have a long life, lessening the need to use energy or material

resources to replace it

(1)

As a basic metal product, the ring should be straightforward to recycle at the end of its life (1)

As a partially electronic product, the wheelchair should be disposed of in accordance with

environmental regulations (1)

The bureau is made in small numbers, limiting the product's overall impact on the environment (1)

It would be better for the environment if the wood for the sides of the table was obtained from a

sustainable source (1)

The suit is made from textile materials, which could be recycled at the end of its life (1)

As a bespoke/ one-off design, the suit may be a fad product that is replaced before it is worn out

causing a bigger environmental impact than if it had a longer life. (1)

As a bespoke/ one-off design, the sculpture may be a fad product that is replaced causing a bigger

environmental impact than if it hadn’t. (1)

Credit any other appropriate response.

(ii)

Answers must be appropriate to the product chosen by the candidate and give an evaluative response about the product in terms of safety considerations.

The architectural model should have been created safely with relevant cutting materials such as cutty mat, craft knife if done by hand (1)

The bureau/ sculpture/ model should be stable when in use (1) so that it will not topple over (1). All

surfaces should be smooth and any protruding parts should be protected (1) stop the user getting

injured or possibly cut (1).

The wheelchair should have approved BSI or CE marking (1) which informs the consumer that the

wheelchair design has passed all electrical safety requirements (1). The consumer should not be

able to access any electrical parts when in use (1) to stop any possibility of an electrical shock (1).

The ring must support the diamond securely (1) to help ensure the diamond does not move in use /

fall off (1).

The suit should be made of a material that will be strong enough to hold the expected contents (1)

to reduce any possibility of the suit breaking when in use (1). All bought in components, clips etc.

should be BSI/CE approved (1) to reduce the risk of the user getting injured due to substandard

parts (1).

The model should be made of a material that will be strong enough to hold the expected contents

(1)

Credit any other appropriate response.

(c) (i)

Answers must be appropriate to the product chosen by the candidate and related to design

collaboration. 1 mark for the benefit and 1 mark for justification.

Collaboration allows many people to contribute to the design (1) drawing upon their different

expertise and perspectives so that these can be taken into consideration (1).

Credit any other appropriate response.

(c) (ii)

Answers must be appropriate to the product chosen by the candidate. 1 mark for each correct type

of drawing.

Candidates could make reference to:

(I) Sketched illustrations, rendered 2D 3D images; CAD 2D or 3D drawings, exploded

drawings.

(II) (II) Presentation drawing.

(III) (III) Working drawing.

Credit any other appropriate response.

M9

M10 Paper and Boards

(a)

(i) (I) gsm means grams per square metre (gsm). Paper thickness is measured in grams per

square metre (gsm). This is the weight of one square metre of the paper.

(II) good quality white paper/ available in different weights/ general purpose work/

medium cost

(ii) Spiral binding - Good for binding large documents/ Pages can be moved and/or replaced

easily.

Laminating/ Encapsulating.

Laminating is when a thin, shiny, clear layer of plastic is applied to one surface through

heat and an adhesive.

Encapsulating is when the page is completely enclosed in a plastic wallet so that all

sides and edges are covered.

(iii) Embossing:-

• When part of a surface is raised, giving a 3D effect/ raised impression

• It is achieved by stamping into the back of a piece of card or paper

• Requires special press tools to be made

• The shape is pressed into the paper or card using steel dies

• Can give higher quality appearance

• Gives visual and tactile effect

(b)

(c) Any valid combination of main points listed

Paper & board is made from wood pulp (trees) and waste paper (recycling). This pulp is grey/brown in colour. Wood Chips are ground up and mixed with water or water and chemicals Steam can be added to reduce the damage done to the fibres Chemicals are added to add strength and to change colour The pulp must be bleached to make it white

420mm

297mm

Bleaching makes the paper/card more expensive to make, but if you are printing onto the paper/board, it must be white to avoid discolouration and poor printing quality. Wood Chips are ground up and mixed with water to create a slurry The pulp is combined with fillers and colours Forms a wet web of fibre Water is removed from the pulp by squeezing the mixture through rollers Some water is also removed through a vacuum This begins to smooth /flatten the pulp Steam heated rollers reduce the remaining water content from approx. 65% to 5% Glues, starch and resins are added here to make the paper more water resistant Rollers are used for further smoothing of the material A uniform thickness is achieved The pressure placed on the rollers determine the thickness of the material It is important that designers consider the world we live in and the needs of future generations.

(d)

Band descriptors and mark allocations

AO3 2b 6 marks

BAND 3

A coherent answer demonstrating detailed, relevant knowledge and understanding,

to evaluate how designers can lessen the impact on the environment when

designing products which include papers and boards. There will be evidence of

relevant examples and well-developed substantiated judgements in a response

which is logically structured.

5-6

BAND 2

Answer has some coherence, demonstrating partial knowledge and understanding,

to evaluate how designers can lessen the impact on the environment when

designing products which include papers and boards. There will be some evidence

of mostly relevant examples and partly-substantiated judgements in a response

which is generally well structured.

3-4

BAND 1

Answer demonstrates only basic knowledge and understanding, to evaluate how

designers can lessen the impact on the environment when designing products

which include papers and boards. There will be limited evidence of relevant

examples or judgements in a response which demonstrates little structure.

1-2

Award 0 marks for incorrect or irrelevant answers

Indicative content

This content is not prescriptive and candidates are not expected to refer to all the material identified

below.

Designers can lessen the impact on the environment when designing products which include papers and boards by:

considering how to minimise waste in the manufacture of component parts of products

in the case of products including papers and boards, using recycled materials where possible

in the case of products including papers and boards, where new material is required, ensuring this comes from managed, sustainable resources wherever possible

in the case of products including papers and boards, where new material is required, ensuring this comes from managed, sustainable resources wherever possible

including information with the product to encourage recycling of paper/board (materials) after use

reducing the need for unnecessary packaging

by considering the 6 Rs – including reuse of materials

considering renewable energy sources during manufacture

designing products (even products made from paper and card) to have a long life so that replacement parts/products should not be needed for some time

Credit any other appropriate response. M10 Natural and manufactured timber

(a) (I) Pine wood is medium-weight

relatively soft. Its strength and elasticity are good. good natural durability except where it is in direct contact with earth or moisture can be worked easily by hand or machine. It can be sliced or peeled. Nailed, screwed or glued connections are straightforward. The surface can be finished with all kinds of paints. light weight, straight grained and lacks figure. It resists shrinking and swelling. Easily worked Credit any other appropriate response.

(ii) (I) They're much cheaper than ready-to-use furniture. Their price is so low it compensates for the lower durability. They're easy to dismantle and transport. This means companies can reduce the amount of trucks/lorries they use to transport goods and customers can take them apart when they need to, e.g. if they are moving house. They're highly customizable. You can easily paint them a different colour or drill a hole or two into them to make them serve a completely different purpose. They are easier to carry into your house as they are in boxes and flat packed instead of being an awkward, fixed shape. Manufacturers can carry more products in a single truck, which reduces the cost, journeys, amount of trucks used and fuel consumption. The retailer can store the products on flat shelves, maximizing the storage space. The products can be produced using a CNC milling machine. This means they are not made by craftsmen which reduces the labour costs as the company doesn't have to pay for skilled labour. (II) Clean, strong corner joint Strong Neat joint Once glued and fitted, the pieces will not move and are difficult to separate. High quality finish Large surface area for gluing Most of the joint is hidden in the wood Takes/ holds a lot of weight

(iii) The description should be about the preparation of the surface of MDF.

Accept answers based on: Use glass paper to create a smooth surface; different graded paper, working from rough / high grit to fine lower grit; use of a sanding block. The surface of the MDF would be gently sanded using glass paper wrapped around a sanding block (1). This process would start off with a heavier graded paper before finishing with a smooth finished grade (1). The surface of the MDF would be down using glass paper (1). Credit any other appropriate response.

(iv) A candidate should show an understanding of the method of making the legs. Accept 1 mark for each appropriate response up to a total of 4 marks. Accept answers based on: Bandsaw method Mark out the wood into 4 equal pieces (1). Set up bandsaw blade (1). Set up the bandsaw distance/ gauge(1). Attach a jig before cutting (1). Cut the wood (1). Remove the legs (1). Sand the surface to the required finish (1). Mitre saw method Mark out the wood into 4 equal pieces (1).

Set up mitre saw to 90 (1). Clamp the wood in (1). Cut the wood (1). Remove the legs (1). Sand the surface to the required finish (1). Tenon saw method Mark out the wood into 4 equal pieces (1). Set up bench hook and bench/ carpenters vice (1). Clamp the wood in with a G clamp(1). Cut the wood (1). Remove the legs (1). Sand the surface to the required finish (1). Credit any other appropriate response.

(b) The legs of the chair are 480mm tall, 40mm wide and 40mm deep, calculate the total surface area of one and then of all 4 legs in order to estimate the amount of varnish to be used [5] 480mm x 40mm x 4 = 76,800mm² (1) 40mm x 40mm x 2 = 3,200mm² (1) 76,800mm² + 3,200mm² = 80,000mm² (1) extra 1 mark for unit 80,000mm² x 4 = 320,000mm² (1) extra 1 mark for unit