Past Paper Questions | WJEC Product Design Revision

Summer 2024 sustainability 15m Q1

The image below shows greener take-away food containers and cutlery. It consists of wax-lined cardboard boxes and cutlery made from compostable materials.

(a)(i)

(a)(i) Explain how the compostable cutlery can be considered greener. [2]

[2]

(a)(ii)

(a)(ii) The food containers are made from cardboard which has a waxed coating applied to the inside. Describe the reason for the waxed coating. [3]

[3]

(b)(i)

(b)(i) The food containers have been mass produced using die cutting. Explain in detail how the die cutting process is suitable for producing the food containers. [4]

[4]

Mark Scheme

The food containers have been mass produced using die- cutting. Explain in detail how the die-cutting process is suitable for producing the food container. Answers relating to explaining how die cutting is suitable for the food container should be awarded up to 4 marks.

         Guidance:
         Candidates need to identify that die cutting allows the outline to be cut from
         sheet cardboard repetitively, and identically for mass production. The outer
         profile of the die features sharp edges to cut. The die cutting process also uses
         rounded blades to crease the internal features of the food container for folding.
         Shapes can be tessellated / arranged to reduce waste. Cuts and scores
         complex shapes easily. Reduces waste of card therefore costs of materials.
         Product can be stored easily afterwards as it stays flat. Quick process for mass
         production. DO NOT credit repetitive statements. Responses for 4 marks must
         include both cutting / outline and folding / creasing information.
         No answer or no relevant information presented or discussed.                         0
         Simplistic or basic response
         Allows lots of containers to be made

         Or
         Cuts the same shape repeatedly
         More detailed response
         Allows the same shape to be cut quickly and efficiently
         Or                                                                                   2
         The food container is quickly cut out of the sheet material in a quick and
         accurate process.
         Detailed explanation or response covering cut lines and fold lines
         Die cutting allows the shape to be cut from sheet material and also how the          3
         container folds together.
         Highly detailed response with explanation of both cut lines and fold lines
         Die cutting is a quick, efficient and suitable industrial process for making large
         numbers of containers. The die is designed to cut out the outline and the slot,      4
         and also crease the fold lines so the box can be easily constructed, repeatedly
         and identically so all boxes are the same.

(b)(ii)

(b)(ii) Describe the reason for the packaging feature shown below, labelled A. [2]

A

[2]

(c)

(c) The stainless steel drinking straw shown below is extendable and fits into a casing.

Explain how the stainless steel drinking straw provides a greener solution to a worldwide problem. [4]

[4]

Summer 2024 sustainability 10m Q2

The two chairs shown below have been produced using Life Cycle Analysis as a design strategy.

Chair A Chair B Made from used bicycle wheels and tyres Made from worn car tyres and seat belts Retail price £189 Retail price £229

(a)

(a) Chair A has been designed for teenage cyclists. Explain how Chair A will appeal to this target market. [2]

[2]

(b)

(b) Explain how Chair B provides an economic benefit to the manufacturer. [3]

[3]

(c)

(c) Describe how the Life Cycle Analysis strategy has been used to design and develop Chair A and Chair B. [5]

[5]

Mark Scheme

Describe how the Life Cycle Analysis strategy has been used to design and develop Chair A and B. Answers relating to how the LCA strategy has been used to produce the chairs should be awarded up to 5 marks.

         Guidance:
         • Life cycle analysis using ‘cradle to cradle’ principles
         • Tyres / seat belts at end of their useful life being re-used
         • Saving sourcing / processing new materials
         • Improving disposal of waste products
         • No recycling required / no reprocessing needed.
         • Avoiding ‘cradle to grave’ concept
         • More sustainable product development
         • Lower environmental footprint
         • Creative / innovative solution

         No answer or no relevant information presented or discussed
         Brief description, very little illustration of LCA, simplistic or basic response
         The chairs have been made from used / waste bicycle parts, wheels and tyres          1-2
         which saves finding new materials.
         More detailed description showing more understanding of LCA AND how this
         has been used to produce the chair
         As a result of LCA, when bicycles, or parts like wheels, tyres, and seatbelts
         come to the end of their useful life, they can be reused / recycled and used in      3-4
         another product. In this case, they are bonded together to create the chair frame
         / structure. This reduces waste and makes good use of previously used
         materials.
         A clear and detailed description of LCA AND how this has been used to create
         the chairs.
         As a result of LCA, when bicycles, or parts like tyres and wheels, come to the
         end of their useful life on the bicycle, they can be reused / recycled and used in
         another product. In this case, there is very little reprocessing of the reclaimed

         wheels, they are bonded together to create the chair frame / structure. This
         reduces waste and makes good use of previously used materials, producing a
         very small environmental footprint for the chairs, using a ‘cradle to cradle’
         approach.

                                                                                Total         10

Summer 2024 materials 20m Q3

The space-saving clothes dryer shown below can be wall mounted indoors or outdoors.

Product information:

• Mild steel body that opens and closes. magnet • 6 × aluminium clothes bars. • Steel wings that keep aluminium bars parallel. • Stainless steel M5 bolts, washers and locking nuts used as a hinge. • Product weight 4 kg. • Safety tested to hang up to 3 kg of clothing per bar. • Magnet fitted to the inside of the back of the clothes dryer.

(a)(i)

(a)(i) Give two reasons why mild steel is a suitable material for the body of the clothes dryer. 2 × [2]

Reason 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reason 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ii) Explain why a magnet is fitted to the back of the clothes dryer. [2]

(iii) The mild steel body parts have a paint finish applied. Describe two advantages this gives the clothes dryer. 2 × [2]

Advantage 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advantage 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[8]

(b)

(b) The image below shows the steel wings that hold each aluminium bar with a ‘U’-shaped feature.

‘U’-shaped feature

Enlarged view of ‘U’-shaped feature

(i) Explain why the ‘U’-shaped feature is necessary, and what would happen if this was not present. [4]

(ii) During manufacture, the mild steel parts have been pressed from a sheet and deformed using a bending jig. Explain two benefits of using a bending jig during the manufacturing process. 2 × [2]

Benefit 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Benefit 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[8]

Mark Scheme

Explain why the ‘U’ shape feature is necessary, and what would happen if this was not present Answers relating to the reason for the U shape feature, and what would happen if this was not present should be awarded up to 4 marks. DO NOT credit repetitive responses

           Guidance:
           The U-shaped feature in needed to allow the sides to rotate the 90 degrees
           when opening and closing, despite the aluminium bars. The U shape allows
           the bars some ‘movement’ otherwise the aluminium bars would ‘jam’ as the
           sides open and close. The U shape caters for the diameter of the rods and the
           amount of movement required, and also stops the bars from going too far
           backwards or forwards, locking them into place.

           No answer or no relevant information presented or discussed.                    0
           Simplistic or basic response
           To keep the bars in the right place                                             1
           Or
           Stop the bars falling out                                                       1
           More detailed response about the U-shaped feature OR what would happen
           To allow the steel wings to pass over the aluminium bars when opening or        2
           closing.
           A detailed explanation about the U-shaped feature and what would happen
           This U-shaped feature allows the bars to be retained and the steel wings to

           fold inwards or outwards with the rigid aluminium bars in place, without the
           aluminium bars becoming ‘stuck’.
           A highly detailed response which fully explains the need for U feature and
           what would happen if it was not present.
           This U-shaped feature allows the bars to be fixed in the correct position and
           the steel wings to fold inwards or outwards with the rigid aluminium bars in

           place, without the aluminium bars becoming ‘stuck’. Without the U-shaped
           feature, the aluminium bars would become jammed and the dryer would not
           be able to close.

Explain two benefits of using a bending jig during the ✓ 2 x [2] manufacturing process. Answers explaining two different benefits of using a bending jig should be awarded up to 2 x [2] marks.

           Guidance:
           DO NOT credit repetitive responses. The bending jig will increase efficiency
           and accuracy / reduce errors or mistakes, the wings will all be identical (left
           and right), non-skilled workers may be used (reducing costs), scale of
           production can be increased, replacement parts can be readily available, large
           numbers can be produced quickly, quality control / quality assurance is easier
           to secure, less waste as defects are minimised.

           No answer or no relevant information presented or discussed.                           0
           Simplistic or basic response
           A bending jig will control the shape better                                            1
           Or
           Using a jig will make the process easier or quicker (than by hand)                     1
           More detailed explanation or response
           The bending jigs will increase the speed at which the parts can be made and            2
           ensure that they are the correct shape every time.
           Or
           Using the bending jig will ensure repeatability and provide increased quality          2
           control / assurance as there will be no decisions made by workers / operators.

(c)(ii)

(c) The aluminium bars have a grooved finish as shown below.

Sectional diagram of aluminium bars

(i) Explain how the grooved finish has improved the performance of the aluminium bars. [3]

(ii) Each aluminium bar has been tested and guaranteed to hold up to 3 kg of clothing. Describe how this could influence sales. [2]

[2]

(d)

(d) A locking nut is used at the top and bottom of each side of the clothes dryer.

Describe why a locking nut has been used. [2]

[2]

Summer 2024 product analysis 20m Q4

The water bottles shown below include a fruit infuser to allow users to flavour the water they consume.

Product information:

• 650 ml capacity • Sports cap with spill-proof lid • Bottle is made from recycled polymer • Various colours available

Check out our 45 reviews

OFFICIALLY CERTIFIED

All products are 100% officially certified.

(a)(i)

(a)(i) Describe one way that the bottle can be considered ergonomic. [2]

[2]

(a)(ii)

(a)(ii) Explain how providing a variety of colours benefits the manufacturer. [2]

[2]

(a)(iii)

(a)(iii) The website where bottles can be purchased includes the ‘Officially Certified’ logo. Explain how this may influence potential consumers. [3]

[3]

(a)(iv)

(a)(iv) Explain the reasons the website encourages purchasers to review the product through Trustpilot. [3]

[3]

(b)(i)

(b) During the development stages of the water bottle, a number of rapid prototypes were produced for the sports cap, two of which are shown below.

(i) Analyse why the design team would produce a range of different sports caps during the development stages. [5]

[5]

Mark Scheme

Analyse why the design team would produce a range of different sports caps during the development stages. Answers analysing why the design teams would produce a range of sports caps during the development stages should be awarded up to 5 marks.

           Guidance:
           • During development, the ideas would need to be tested
           • There would be several ‘possible’ solutions and these would require
              prototyping
           • The target market / users would be given the physical prototypes as
              user trials, and feedback used to refine ideas
           • Physical outcomes would be produced to realise ideas
           • Function tests would be carried out to see how the different caps
              worked
           • Results of testing would be analysed and lead to modifications and
              further improvement.
           • Aspects that fail would be removed / altered to improve the design.
           • The iterative cycle requires testing of ideas in order for solution to be
              fully evolved / developed.

           No answer or no relevant information presented or discussed                     0
           Brief description, very little analysis, simplistic or basic response
           The design team would want to test a physical outcome so would make a           1
           prototype to carry out testing.
           More detailed analysis showing more understanding of reasons why a
           range of sports caps would be produced during development.
           The design team would produce prototypes of ideas that they thought had         2-3
           potential. These would be tested, used in user trials, and the results
           analysed to improve any defects.
           A clear and detailed analysis of the reasons the design team would
           produce a range of different sports caps during the development stages.
           The design team would produce physical prototypes of ideas that they
           thought had potential. These would then be fully tested, used in user trials,
                                                                                           4-5
           and the results analysed to improve any defects. This would allow a
           chosen sports cap to be finalised and remove any defects prior to
           production.

(b)(ii)

(b) During the development stages of the water bottle, a number of rapid prototypes were produced for the sports cap, two of which are shown below.

(ii) An additive manufacturing process was used to create the sports caps shown. Evaluate the benefits of additive manufacturing processes. [5]

[5]

Mark Scheme

Evaluate the benefits of additive manufacturing processes. Answers evaluating the impact additive manufacturing processes can have when rapid prototyping should be awarded up to 5 marks.

           Guidance:
           • Additive processes, like 3D printing, generate very little waste.
           • Lead in time is very short / reduced.
           • CAD files are converted quickly into CAM data / physical outcomes.
           • Very difficult shapes, like the sports cap, can be created quickly
           • Various sports caps can be produced in one-go / in one process for
              testing or realising the designs
           • Additive machines are very versatile and can make different shapes
              and forms
           • Colours can be changed easily and inexpensively
           • Additive machines can be left unattended / overnight for longer
              processes
           • Following expensive purchase, prototypes are produced relatively
              cheaply, which allows mistakes to be less costly than in full
              manufacture
           • Ideas can be tested with the target market quickly, with regular reviews,
              modifications and iterations

           No answer or no relevant information presented or discussed                   0
           Brief description, very little evaluation, simplistic or basic response
           The additive process allows an idea to be physically produced quickly for     1
           testing, and modifications can be made quickly and easily / cheaply.
           More detailed evaluation showing more understanding of impact of additive
           manufacturing processes when rapid prototyping.
           Additive processes produce very little waste and can create multiple
                                                                                         2-3
           identical or different complex shapes quickly and inexpensively. Additive
           processes can be easily adapted for different colours by changing the
           source material.
           A clear and detailed evaluation of impact of additive manufacturing
           processes when rapid prototyping.
           Additive manufacturing machines produce physical outcomes from CAD
           data quickly and efficiently. Initial costly investment of purchasing the
           machine is made, the production of items is very low. Additive processes      4-5
           produce very little waste and can create multiple identical or different
           complex shapes quickly and inexpensively. Additive processes can be
           easily adapted for different colours by changing the source material.

                                                                          Total          20

Summer 2024 product analysis 10m Q5

The modern smart home device shown below was designed to reflect user-centred design.

(a)

(a) Analyse the meaning of user-centred design and how this has influenced the smart home device. [5]

[5]

Mark Scheme

Analyse the meaning of ‘User Centred Design’ and how this has influenced the ‘Smart Home’ device. Answers analysing the meaning of user centred design’ and how this has influenced the ‘Smart Home’ device should be awarded up to 5 marks.

         Guidance
         • User centred design is about designing a product to fit the needs and
            wants of the target market
         • The requirements will be established before designing
         • For the ‘Smart Home’ device, the target market will have been integral
            to the iterative design process
         • User feedback will be used throughout designing and development
         • The shape of the device – slimline, circular / cylindrical, white / grey
            and other aesthetics will be pre-determined
         • Functions like Wi-Fi connectivity, Bluetooth, tactile buttons
         • Powered by 240V mains power
         • Ease of connectivity to home Wi-Fi and other devices.

         Note: Detailed knowledge of ‘Alexa’ or ‘Echo Dot’ is not critical.

         No answer or no relevant information presented or discussed                       0
         Brief description, very little analysis, simplistic or basic response
         The smart home device has been designed with the user in mind to ensure
         that all of the requirements of the user are met by the final product. No         1
         reference to user centred design just a list of the products features with
         little explanation of their benefits to the user.
         More detailed analysis showing more understanding of ‘User centred
         design’ and this influencing the smart home device.
         Placing the user at the forefront, the device will be designed with the
         specific needs and wants of the target market as the driving forces. This
                                                                                          2-3
         will result in the device functioning and looking exactly how the user
         expects / requires, because the designers will ensure that the device
         matches all of the requirements set out. List of features with some
         qualification of how these help the user.
         A clear and detailed analysis of ‘User centred design’ and this influencing
         the smart home device.
         Placing the user at the forefront, the device will be designed with the
         specific needs and wants of the target market as the driving forces. This
         will result in the device meeting the expectations of the user in terms of
         quality, style, shape, function, materials, aesthetics, connectivity and         4-5
         compatibility with other devices. User centred design ensures that the
         target market is included at every point during the product’s development,
         so that feedback allows the product to be refined ensuring it’s eventual
         success.

(b)

(b) The images show two accessories that can be controlled using the smart home device.

Smart plug Smart light bulb

Evaluate how the ability to control multiple home accessories provides an innovative solution. [5]

Marks will be awarded for the content of the answer and the quality of written communication.

[5]

Mark Scheme

Evaluate how the ability to control multiple home accessories provides an innovative solution Answers relating to evaluating how the ability to control multiple home accessories provides an innovative solution should be awarded up to 5 marks. QWC is also assessed here.

         Guidance:
         • Multiple devices can be centrally controlled using Smart Home device
            over Wi-Fi / Bluetooth
         • These can be voice controlled and remotely using App
         • The ability to control lighting, heating, curtain and blinds etc provides
            flexibility and effective autonomy for users.
         • Economical use of resources / save money on energy / fuels
         • The ease of managing devices without physically moving / operating
            them
         • The ability to add / remove additional devices makes the system very
            clever / useful
         • Provides opportunities to reduce costs / increase security at home
         • Gives home owner greater control of devices
         • Allows technology to provide a simpler / effective means of control

         (Note – not all of this indicative content is required to access 5 marks!)

         No answer or no relevant information presented or discussed.                     0
         Brief description, very little detail of evaluating how the ability to control
         multiple home accessories provides an innovative solution.
         Quality of Written Communication is basic, presenting occasionally               1
         appropriate material with some coherence, some errors of grammar,
         punctuation and spelling.
         Some detail with some evaluating how the ability to control multiple home
         accessories provides an innovative solution.
         Quality of Written Communication is good, presenting mainly appropriate          2-3
         material in a coherent manner, few errors of grammar, punctuation and
         spelling.
         A highly clear and fully detailed evaluating how the ability to control
         multiple home accessories provides an innovative solution.
         Quality of Written Communication is excellent, presenting wholly appropriate
                                                                                          4-5
         material in a coherent and logical manner, no errors of grammar,
         punctuation and spelling.

                                                                               Total      10

Summer 2024 materials 20m Q6

The portable tray below is designed for carrying refreshments and can securely fit onto most types of furniture.

(a)(i)

(a)(i) The four sides of the tray are made from medium density fibreboard (MDF). Describe two properties of MDF that make it suitable for the sides of the tray. 2 × [2]

Property 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Property 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[4]

(a)(ii)

(a)(ii) The legs of the tray are constructed using a dowelled butt joint. In the space below, produce a labelled sketch showing how you would manufacture a dowelled butt joint. [4]

[4]

(b)(i)

(b) The legs of the tray are hinged as shown below.

(i) Explain the role of the spring fitted to the centre of the hinge. [3]

The photograph below shows the tray disassembled.

[3]

(b)(ii)

(b) The legs of the tray are hinged as shown below.

(ii) Explain the reason for the four pilot holes. [2]

[2]

(b)(iii)

(b) The legs of the tray are hinged as shown below.

(iii) The hinges and screws are bought-in components. Explain how this benefits the manufacturer when producing the tray using high volume production. [4]

[4]

(c)

(c) The CAD drawing is used to manufacture the tray handles using a CAM router as shown below.

File Edit Draw View Setup Help Cut Open Select all

Copy path Edit Select none Copy Paste Move Copy Delete Rename New Properties Paste shortcut to to folder History Invert selection Clipboard Organize

ABC Design… layer 1

-

ABC

CLIP

ALL DEL

CAD drawing CAM router

Explain the difference between the red and black lines on the CAD drawing when manufacturing the tray handles using the CAM router. [3]

[3]

Summer 2023 product analysis 10m Q1

The auxiliary handle shown below has been designed to fit onto existing garden tools.

Auxiliary handle Fits existing garden tools

(a)

(a) Describe one ‘market pull’ factor that has resulted in the design of the auxiliary handle. [2]

[2]

(b)

(b) Anthropometrics involves studying human sizes. Explain two anthropometric considerations that the designer would need to include for the auxiliary handle to be successful. 2 × [2]

Consideration 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Consideration 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[4]

(c)

(c) The auxiliary handle retails at £4.00. Explain both the economic and social benefits that this brings the user. [4]

[4]

Mark Scheme

The auxiliary handle retails at £4.00. Explain both the ✓ [4] economic and social benefits that this brings the user. Answers relating to both social and economic benefits of the auxiliary handle should be awarded up to 4 marks.

         Guidance:
         Candidates could discuss the economic benefits as purchasing a £4
         additional product allows other product to be used more effectively.
         Economically this makes sense. It is far cheaper than buying a new
         different garden product; the usual garden products are still accessible. It is
         a very cost effective multi-purpose product that fits lots of other existing
         tool handles. Socially, this product allows users to work in the garden, at
         allotments, to be outdoors, to improve health / wellbeing / meet –work with
         others and therefore provides social benefits.. DO NOT credit repetitive
         statements. Responses for 4 marks must include both economic and social
         benefits.
         No answer or no relevant information presented or discussed.                       0
         Simplistic or basic response
         It is a cheap product to buy

         Or
         It allows users to continue to do gardening
         More detailed response covering one in detail or covering both superficially
         £4 is very reasonable to purchase and can be used with any existing tools
         such as spade, rake, sweeping brush.
         Or                                                                                 2
         The handle allows users with limited physical mobility to undertake outdoor
         activities themselves enhancing social possibilities working outside
         environment.
         Detailed explanation or response covering social and economic benefits.
         £4 is very reasonable to purchase and can be used with any existing tools

         such as spade, rake, sweeping brush, and allows users independence and
         continue gardening when it could be difficult.
         Highly detailed response with explanation of both social and economic
         benefits
         £4 is very reasonable to purchase and can be used with any existing tools
         such as spade, rake, sweeping brush. The handle allows users with limited          4
         physical mobility to undertake outdoor activities themselves enhancing
         social possibilities working outside environment.

                                                                             Total          10

Summer 2023 materials 20m Q2

The images below show a bicycle carrier which can be mounted to the roof of most vehicles.

(a)

(a) The frame of the bicycle carrier is made from aluminium tubing. Describe two benefits of using aluminium for the bicycle carrier. 2 × [2]

Benefit 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Benefit 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The clamp shown, which holds the bicycle frame, is made from ABS.

[4]

(b)

(b) Explain two properties of ABS that make it a suitable material for the clamp of the bicycle carrier. 2 × [2]

Property 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Property 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The two bicycle wheels are secured using a quick release rubber polymer strap as shown below.

[4]

(c)

(c) Describe the properties of the rubber polymer that make it appropriate for the quick release strap. [4]

[4]

(d)

(d) The bicycle carrier features two separate locks.

Bicycle frame Lock 1

Roof bar fitted to vehicle

Lock 2

Describe why two separate locks are necessary. [4]

[4]

Mark Scheme

The bicycle carrier features two separate locks. ✓ [4] Describe why two separate locks are necessary. Answers relating to the reason for 2 separate locks should be awarded up to 4 marks. DO NOT credit repetitive responses.

         Guidance:
         The lock attached to the clamping mechanism is to fully secure the bicycle
         when held by the cycle carrier on the roof of the car. This is an anti-theft
         feature so the user can leave the bicycle on top of the car secure and safe.
         The second lock provides a method of locking the cycle carrier to the roof bars
         of the car. This prevent theft and provides security so that the cycle carrier
         cannot be removed from the roof bars of the car.
         No answer or no relevant information presented or discussed.                           0
         Simplistic or basic response
         To keep the bike safe                                                                  1
         Or
         Stop the bike being stolen.                                                            1
         More detailed response about one or both locks
         To allow the user to be able to lock the carrier onto the bicycle once it is fitted    2
         so that it cannot be stolen.
         Or One locks the bike, the other locks the carrier to the car.                         2
         A Detailed explanation including both locks
         The clamp can be locked once the bicycle is fitted. This remains secure and

         cannot be stolen. The second lock allows the cycle carrier to be securely fitted
         to the car roof.
         A highly detailed response which fully explains the need for two separate
         locks.
         One lock allows the clamp to be locked once the bicycle is fitted. This remains
         secure and cannot be stolen. The user can then leave the vehicle with bicycle
         fitted with peace of mind. The second lock allows the cycle carrier to be              4
         securely fitted to the car roof. This means that when the bicycle is being used,
         the bicycle holder is securely locked to the car roof bars and cannot be
         removed / stolen.

(e)

(e) The roof bar shown below is made from aluminium using the extrusion process.

Explain why extrusion is an effective production method for the roof bar. [4]

[4]

Mark Scheme

The roof bar shown below is made from aluminium using the extrusion process. ✓ [4] Explain why extrusion is an effective production method for the roof bar. Answers explaining how extrusion is an effective production method for the roof bars should be awarded up to 4 marks.

         Guidance:
         DO NOT credit repetitive responses. Extrusion is effective because the
         cross-sectional shape of the roof bars is consistent and constant
         throughout its length. Extrusion allows the aluminium to be heated and
         pushed / pumped through the die, ensuring the consistent cross section as
         the material is drawn through in lengths. Extrusion works well with
         aluminium due to a lower melting point than some other metals. There is
         no waste, and the complex shape of the bars can be achieved using the
         extrusion process. Complex or difficult shapes are easily produced using
         extrusion. Extrusion is often self-finishing.
         No answer or no relevant information presented or discussed.                    0
         Simplistic or basic response

         Extrusion is useful because the bar is a difficult shape
         More detailed explanation or response
         Extrusion is useful because aluminium can be heated at lower                    2
         temperatures than other metals, and form the shape of the bars accurately.
         A detailed explanation or response
         Extrusion is useful because aluminium can be heated at lower

         temperatures than other metals, and form the cross section of the bars
         accurately and consistently.
         A highly detailed explanation or response
         Extrusion is useful because aluminium can be heated at lower
         temperatures than other metals, and a die will ensure that the cross section
         of the bars are accurate and consistent throughout the length of the roof       4
         bar for the car. Extrusion is an economical and reliable process for this
         type of material and shape.

                                                                           Total         20

Summer 2023 product analysis 25m Q3

Study the details below of the ‘power & play’ product.

Features:

• Includes a 4000 mAh power bank with LED display and torch feature. • 3-in-1 cable compatible with Apple Lightning, Apple 30-pin, and micro USB connections. • Earbud style in-ear headphones with in-line microphone.

(a)(i)

(a)(i) Explain why this product has been developed. [2]

[2]

(a)(ii)

(a)(ii) Describe the target market that the ‘power & play’ product was designed for. [2]

[2]

(a)(iii)

(a)(iii) Explain the reason for including the 3-in-1 charging cable. [3]

[3]

(b)(i)

(b) The LEDs shown in the image below indicate the charge in the power bank.

LEDs

(i) Explain one benefit for including the indicator in the power bank. [2]

[2]

(b)(ii)

(b) The LEDs shown in the image below indicate the charge in the power bank.

LEDs

(ii) Explain one limitation for including the indicator in the power bank. [2]

[2]

(c)(i)

(c) The ‘power & play’ is sold in a casing consisting of a two-part transparent outer shell.

(i) Give one reason why the manufacturer would choose to make the two-part casing transparent. [2]

(ii) Explain why transparent polycarbonate is a suitable material for injection moulding the two-part casing. [2]

[4]

(d)

(d) The white opaque insert fits inside the casing and securely holds the component parts of the ‘power & play’ product.

(i) State the name of a suitable thermoplastic sheet for making the insert. [1]

(ii) Name and describe in detail a suitable manufacturing process that could be used to make the insert in a school workshop.

Manufacturing process: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [1]

Detailed description of the named process: [4]

The power bank displays important information for the user. The RoHS symbol shown on the product refers to Restriction of Hazardous Substances.

[6]

(e)

(e) Explain the reason for the symbol and the impact that this has on the manufacturer. [4]

[4]

Summer 2023 manufacturing 15m Q4

The portable self-assembly hockey goals shown below have been designed for primary school indoor games lessons.

(a)

(a) Explain one advantage to the primary school for purchasing the self-assembly hockey goals. [2]

[2]

(b)(i)

(b) The product life cycle graph below shows how the sales of the self-assembly hockey goals occur over time.

Sales

Time

(i) Describe what happens to product sales at each of the 4 stages in the graph. 4 × [1]

A

B Sales

Time

[4]

(b)(ii)

(b) The product life cycle graph below shows how the sales of the self-assembly hockey goals occur over time.

Sales

Time

(ii) Explain the impact on the manufacturer of the hockey goals at point A. [3]

[3]

(b)(iii)

(b) The product life cycle graph below shows how the sales of the self-assembly hockey goals occur over time.

Sales

Time

(iii) Explain one possible benefit to the consumer of purchasing the product at point B. [2]

[2]

(b)(iv)

(b) The product life cycle graph below shows how the sales of the self-assembly hockey goals occur over time.

Sales

Time

(iv) Explain what options the manufacturer has once the product has reached point B on the life cycle graph. [4]

[4]

Summer 2023 product analysis 20m Q5

Study the images of Dyson products shown below.

(a)

(a) Analyse how the features of Dyson products have made them popular and successful, achieving market leader status. [5]

[5]

Mark Scheme

Analyse how the features of Dyson products have made them popular and successful, achieving market leader ✓ [5] status. Answers relating to analysing how features of Dyson products have made them popular and successful achieving market leader status should be awarded up to 5 marks

        Guidance:
        • Colour schemes very vibrant and gender neutral – attracts more male
           users
        • Cyclonic action improves suction – better performance than competitor
           products.
        • Centrifugal force to separate dust particles to avoid needing filters.
        • Bagless vacuum cleaner – transparent bin can be empties endlessly
        • Slick geometric futuristic shape and form which is more attractive /
           modern than current competitor products.
        • Bladeless fans which heat and cool, removing allergens using HEPA
           filters.
        • Very stylish products with high build quality
        • Ball features – 360-degree rotation for easier manoeuvrability.
        • Fans are easy to clean, no grills or blades unlike competitor.
        • Clean lines, simple shapes and forms, hygienic finish.
        • Market leader status due to brand loyalty because high level function /
           performance
        • After sales services are very effective / supportive, spare parts readily
           available.
        • Long life expectancy / reliability reputation.
        No answer or no relevant information presented or discussed                      0
        Brief description, very little analysis, simplistic or basic response
        Dyson products use very similar colour schemes like greys whites with some
                                                                                        1-2
        flashes of yellows. They are very geometric and symmetrical shapes which
        preform very well. They are the best products in their class.
        More detailed analysis showing more understanding of features that make
        products popular and successful AND contribute to market leader status.
        Dyson products are very high quality with excellent performance. This results
                                                                                        3-4
        in very high customer satisfaction and increased demand through high
        reputation. Dyson’s products are very high quality with clean lines and
        geometric shapes.
        A clear and detailed analysis of the features that make products popular and
        successful AND contribute to market leader status
        Dyson products are very high quality with excellent performance. This results
        in very high customer satisfaction and increased demand through high
        reputation. Dyson’s products are very high quality with clean lines and

        geometric shapes, and are scientifically very innovative. Neutral shades of
        main colour with flashes of bright colours like yellow are common. Dyson
        secures optimum performance and efficient user interface with all products,
        making them stand out well above competitor brands and products.

(b)

(b) Analyse how Dyson products reflect a ‘form follows function’ design approach. [5]

[5]

Mark Scheme

Analyse how Dyson products reflect a ‘form follows function’ ✓ [5] design approach. Answers relating to the analysis of how Dyson products reflect ‘form follows function’ design approach should be awarded up to 4 marks.

        Guidance:
        • Analysis of how the performance of Dyson’s products leads the way in
           product innovation.
        • Identification of key functional features that make Dyson products
           outstanding.
        • Analysis of how the function might be developed ‘first’ then the shape
           secondary.
        • Bladeless fan providing 30% increase in power
        • DC01 cyclonic action providing innovative performance of dust
           separation.
        • Ball technology allowing 360-degree steering and enhanced user control
        • Wireless developments allowing lighter more portable products.
        • Scientific principles provoking innovation rather than form, aesthetics or
           styling details.
        • Visual attributes taking a secondary importance to performance criteria.
        No answer or no relevant information presented or discussed                         0
        Simple or basic analysis of how Dyson product reflect ‘form follows function’.
        Dyson products always work well first and worry about looks afterwards because     1-2
        function is the priority.
        Some analysis of how Dyson product reflect ‘form follows function’.
        Dyson products all contain some scientific innovation which ensure that they
                                                                                           3-4
        perform very well. The visual shape of the Dyson product is not normally
        given the same attention.
        A clear and detailed analysis of how Dyson product reflect ‘form follows
        function’ with specific examples for reference.
        Dyson products all contain some scientific innovation which ensure that they
        perform very well. The DC01 required 5127 prototypes suggesting Dyson
        worked tirelessly to get it working perfectly. The ‘above the line’ visual shape    5
        and aesthetics of the Dyson product is not normally given the same attention
        to the same depth as below the line factors and so the statement is generally
        true of Dyson products.

(c)

(c) The Design Council encourages designers to ‘Discover, Define, Develop and Deliver’.

Evaluate how this is reflected in the iterative design process. [10] Design Council Marks will be awarded for the content of the answer and the quality of written communication.

[10]

Mark Scheme

The Design Council encourages designers to ‘Discover, Define, Develop and Deliver’. Evaluate how this is reflected in the iterative design process. ✓ [10] Marks will be awarded for the content of the answer and the quality of written communication. Answers relating to the evaluation of how the iterative design process can be seen as discovering problems, defining specifics, developing and refining solutions and presenting a final outcome to solve the problem, should be awarded up to 10 marks. QWC is also assessed here.

        Guidance:
        • Discover can be seen in the iterative process when designers are seeking
           problems
        • The discovery of possible design tasks within contexts
        • The exploration of the needs and wants of the user allows designers to
           discover essential aspects of the problem
        • Define is to fix a design brief regarding an identified problem
        • Define will also include the design specification – a list of success criteria by
           which designing will be measured.
        • Develop is the generation of a wide range of initial ideas.
        • These are then modelled, tested and evaluated to identify areas for
           improvement.
        • As the iterative cycle continues, the solution improves and becomes refined.
        • Deliver is manufacturing the prototype and presenting this to the users
        • The testing and evaluation of the final prototype with the users allows the
           assessment of how well the solution answers the problem.
        No answer or no relevant information presented or discussed.                           0
        Brief description, very little detail of evaluating how ‘Discover, define, develop
        deliver’ relates to the iterative design process.
                                                                                              1-2
        Quality of Written Communication is basic, presenting occasionally appropriate
        material with some coherence, some errors of grammar, punctuation and spelling.
        Some detail with some evaluation of how ‘Discover, define, develop deliver’
        relates to the iterative design process.
                                                                                              3-4
        Quality of Written Communication is good, presenting mainly appropriate
        material in a coherent manner, few errors of grammar, punctuation and spelling.
        A clear and detailed evaluation of how ‘Discover, define, develop deliver’ relates
        to the iterative design process.
                                                                                              5-6
        Quality of Written Communication is good, presenting mainly appropriate
        material in a coherent manner, few errors of grammar, punctuation and spelling.
        A fully clear and very detailed evaluation of how ‘Discover, define, develop
        deliver’ relates to the iterative design process, with reference to stages of the
        iterative process and how they fulfil the 4 Ds.
                                                                                              7-8
        Quality of Written Communication is very good presenting wholly appropriate
        material in a coherent and logical manner, hardly any errors of grammar,
        punctuation and spelling.
        A highly clear and fully detailed evaluation of how ‘Discover, define, develop
        deliver’ relates to the iterative design process, with specific reference to stages
        and activities of the iterative process and how they fulfil the 4 Ds.
                                                                                              9-10
        Quality of Written Communication is excellent, presenting wholly appropriate
        material in a coherent and logical manner, no errors of grammar, punctuation
        and spelling.
                                                                                   Total      20

Summer 2023 sustainability 8m Q6

The images below show the final prototype of an eco menu holder designed and made by a student.

(i)

(i) The back of the menu holder is made from reclaimed laminate flooring. Explain how this can be considered sustainable. [4]

(ii) The legs of the menu holder are made using a laser machine and from 3 mm plywood. Describe two advantages to the designer of using laser cutting to make the legs. 2 × [2]

Advantage 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advantage 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(iii) Describe how a restaurant’s logo could be added to the legs when laser cutting. [2]

[8]

Mark Scheme

laminate flooring. Explain how this can be considered ✓ [4] sustainable. Answers relating to reasons for flat-packed box should be awarded up to 4marks.

        Guidance:
        • Reusing the reclaimed laminate flooring saved procurement of new
           materials.
        • Reusing reclaimed laminate reduces waste, saves waste at landfill or
           reprocessing energy.
        • Reusing reduces carbon footprint of the old and new product
        • Cradle to cradle approach
        • Supports Government initiatives to use less energy / materials
        • Waste laminate floor boards are not discarded or disposed of responsibly
           or not e.g. recycling centre / fly tipping.
        • Supports ‘eco’ approach as suggested.
        • Cheaper to reuse reclaimed material than to purchase new material
        • Supply is quick – no need to order materials / wait for delivery.
        No answer or no relevant information presented or discussed.                     0
        Simplistic or basic response
        Cheaper to use waste materials than buy new                                      1
        Or
        Better for the environment because it’s not thrown away                          1
        More detailed explanation or response.
        Reusing waste materials reduces waste that needs disposal and also               2
        reduces new materials required.
        A detailed explanation or response.
        Reusing the waste laminate flooring reduces waste which would go to

        recycling or landfill and also reduces the amount and cost of new materials
        required.
        A fully detailed explanation or response.
        Reusing the waste laminate flooring reduces waste which would go to
        recycling or landfill and also reduces the amount and cost of new materials

        required. This has a positive impact on carbon footprint by using a cradle to
        cradle approach.

Summer 2022 product analysis 10m Q1

The images below show a new game controller at different stages of design.

CAD model Foam model Final prototype

(i)

(i) Describe why the designer of the new game controller would choose to create the CAD model. [2]

[2]

(ii)

(ii) Explain how testing the foam model of the new game controller can help the designer identify areas for further improvement. [3]

[3]

(iii)

(iii) Explain in detail the importance of producing a fully functioning high quality final prototype before full scale production starts. [5]

[5]

Mark Scheme

Explain in detail the importance of producing a fully functioning high quality final prototype before full scale production starts. No answer or no relevant information presented or discussed. 0 Simplistic or basic response

       To make sure the product is right before making lots.
       More detailed response
       To make sure the product works fully before making large numbers which               2
       might waste money / materials.
       Detailed explanation or response
       The product can be fully tested under operating conditions to see if there are

       any faults that develop before making large numbers, which would cost lots
       and waste materials.
       Highly detailed response with explanation
       The product can be fully tested under operating conditions to see if there are

       any faults that develop during usage before making large numbers, which
       would waste money and waste materials and lead to product recalls / returns.
       The product can be fully tested under operating conditions to see if there are
       any faults that develop during usage before commencing large scale
       production, which is very expensive. Once production starts, the manufacturer
       would not want to stop production to make changes to the product, this would

       be very expensive, prevent sales / profit, and any products already sold would
       need to be recalled / sales refunded, possible litigation issues if users are hurt
       as a result of the failure / defect.

       Guidance:
       Candidates are required to produce a detailed and balanced response
       demonstrating the importance of ensuring that products function perfectly and
       reliably prior to production. DO NOT credit repetitive statements.

                                                                                Total       10

Summer 2022 energy 12m Q2

The new solar bicycle light below has been developed as a result of market pull.

(i)

(i) Explain the advantages to the user of using the solar bicycle light. [2]

[2]

(ii)

(ii) Describe the meaning of the term ‘market pull’ and how this may have changed the way the bicycle light has been designed. [4]

[4]

(iii)

(iii) Identify and explain two possible problems that users might experience when using the solar bicycle light. 2 × [2]

Problem 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Problem 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[4]

(iv)

(iv) The new solar bicycle light is intended to fit any bicycle. Explain how this has been achieved. [2]

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

[2]

Summer 2022 materials 13m Q3

A student has designed and made a range of pewter jewellery items aimed at surfers.

Stand Pendant

(a)(i)

(a)(i) Describe the properties of pewter that make it a suitable material for the pendant. [2]

[2]

(a)(ii)

(a)(ii) The student chose MDF (medium density fibreboard) to make the casting mould. Describe why MDF is an appropriate material for the mould before casting the pewter. [3]

(iii) Identify three possible hazards that the student would need to consider when casting the pewter. 3 × [1]

Hazard 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazard 3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[6]

(b)

(b) The jewellery items are displayed on transparent stands made from a thermoplastic.

(i) Name a specific thermoplastic suitable for making the stands. [1]

(ii) Describe a suitable process for cutting the stands from sheet material and achieving the shape of the stand shown above. [4]

[5]

Summer 2022 product analysis 20m Q4

Study, in detail, the products shown below.

(a)

(a) Analyse how designers have used different sources of inspiration to develop these products. [10] Marks will be awarded for the content of the answer and the quality of written communication.

[10]

Mark Scheme

Analyse how designers have used different sources of inspiration to develop these products. Note: No reference /knowledge to Memphis required. This question is NOT about the history or work of the Memphis Design Movement. It is about designing the

       products provided using creative strategies / stimulus material. No Recall.

       Simplistic or basic response
       Quality of written communication is limited or basic, presenting material with limited
       coherence, many errors of grammar, punctuation and spelling.
       A low-level response which is descriptive rather than analytical. Some reference to
       the product images identifying basic natural forms / human / animal shapes and
       colours / geometric forms/ abstract shapes that imitate other forms including
                                                                                                1-3
       animals / humans but response is not developed.
       The designers have looked at nature and natural forms and copied bits of these
       and used them in their products. The lamp in image 1 is based on a zebra, and a
       hedgehog type shape is seen in the light with wheels. A basic human shape is
       used in the chair and unit.

       Good quality of communication, presenting appropriate material in a coherent
       manner with few errors or grammar, punctuation and spelling.
       More detailed explanation or response with analysis of sources of inspiration.
       A more developed response with some description, explanation and analysis of
       how the designers have identified and used sources of inspiration in these
       products.
       The designers have looked at nature and natural forms and used the shape, form,
       colour, texture and symmetry of the natural sources in their products. They have
       used geometric and abstract shapes and forms and combined them to mimic or               4-6
       imitate natural form such as animals and humans. The lamp in image 1 is based
       on a zebra, with clear reference to black and white stripes, the long neck and even
       the trailing lead as a tail. A hedgehog or porcupine type shape is seen in the light,
       with lamps / bulbs positioned as spikes, and with wheels instead of feet. A basic
       human shape is used in the chair with a blue head representing a head and the
       arm of the chair being the arms of the source. A ‘stick man’ type shape is seen on
       the top of the book case.

       Excellent quality of communication, presenting highly appropriate material in a
       coherent and logical manner. Virtually no errors of grammar, punctuation and
       spelling.
       A fully detailed response clearly identifying sources of inspiration and analysis how
       the designers have incorporated these into products.
       The designers have researched shape, form, geometry, abstract shapes as well as
       nature and natural forms, this process is called biomimicry. The designers have
       used the shape, form, colour, texture, scale, proportion and symmetry of the
       natural sources in their products. All products are geometric and symmetrical
       forms that use combined shapes to reflect natural forms. The lamp in image 1 is          7-10
       based on a zebra, with clear reference to black and white stripes, the long neck
       and even the trailing lead as a tail. A hedgehog or porcupine type shape is seen in
       the light, with lamps / bulbs positioned as spikes, and with wheels instead of feet.
       A basic human shape is used in the chair with a blue head representing a head
       and the arm of the chair being the arms of the source. A ‘stick man’ type shape is
       seen on the top of the book case. The products are all brightly coloured and
       vibrant with an underlying ‘fun’ theme based on the animals or human characters
       identified during research, and used to inspire the end product.

(b)

(b) Evaluate the reasons why modern flat pack furniture is very popular with consumers. [10]

[10]

Mark Scheme

Evaluate the reasons why modern flat pack furniture is very popular with consumers. No answer or no relevant information presented or discussed. 0 Simplistic or basic response which is descriptive rather than evaluating why flat pack items are a popular choice. A low-level descriptive response defining ‘flat pack’ products and / or describing reasons for their purchase by the consumer. Flat pack items offer users cost effective multiple choices when furnishing e.g. 1-3 bedroom units, kitchen units, etc. Some consumers enjoy ‘building’ or putting together items (DIY) and feel a sense of ownership over the product. Due to low cost, flat pack items can be changed or replaced or updated when required.

       A more developed response with some description, explanation and evaluation
       of the reasons why flat pack furniture is popular.
       Flat pack items are often cheaper to purchase than other alternative products,
       as a result of being manufactured in sustainable materials in bulk. Flat pack
       items can be ordered and delivered, there is not always a necessity for
       consumers to visit a store to collect. Some consumers enjoy constructing their
       own products and this brings a sense of pride and achievement, more than              4-6
       purchasing an already assembled product. They are easy to transport and flat
       pack items are normally modular and can be added to form a variety of
       solutions, with a range of accessories to personalise products. Due to low cost,
       flat pack items can be changed or replaced or updated when required or if
       trends change.

       A fully detailed response clearly evaluating the reasons why flat pack furniture
       often very popular with consumers.
       Flat pack items are often cheaper to purchase than other alternative products,
       as a result of being mass produced. They are easy to transport and due to low
       cost, flat pack items can be changed or replaced or updated when required or
       if trends change. There is normally lots of flat pack items available and retailers
       stock standard items, so these can be added to by the consumer. Moral or
       ethical decisions can often influence consumers to purchase because items
       are manufactured from sustainable materials in bulk. Flat pack items can be           7-10
       ordered and delivered, there is not always a necessity for consumers to visit a
       store to collect. Some consumers are DIY fanatics and the satisfaction of
       constructing their own products brings a sense of pride and achievement, more
       than purchasing an already assembled product. It is also cheaper to self-
       assemble a flat pack product than pay a specialist fitter to construct units. Flat
       pack items are normally modular and can be added to form a variety of
       solutions, with a range of accessories to personalise products, and offer the
       ability to create unique solutions.

       Guidance:
       Candidates are required to evaluate why consumers choose flat pack furniture,
       and the depth of the response requires reasons which reflect consumers
       choices over other alternatives. Do not accept quicker, cheaper, faster or one-
       word descriptions which are not qualified or compared to another option. Flat
       pack is a manufacturing approach / system / scale and so links to cost are to
       be credited. Availability, modular options etc could all be included in
       responses.

                                                                                  Total      20

Summer 2022 materials 18m Q5

The new garden tool below has been designed to replace an existing garden tool for cutting and pruning plants and shrubs.

New garden tool Existing garden tool

(a)(i)

(a) The body of the new garden tool is made from aluminium with a Teflon coating.

(i) Describe two properties of aluminium that make it suitable for the body of the new garden tool. 2 × [2]

Property 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Property 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[4]

(a)(ii)

(a) The body of the new garden tool is made from aluminium with a Teflon coating.

(ii) Explain the reason for applying the Teflon coating to the body of the new garden tool. [2]

[2]

(b)

(b) The black cutting blade used in the new garden tool is made from carbon steel, and can be easily removed from the rest of the tool.

(i) Explain why carbon steel is an appropriate material for the cutting blade. [2]

(ii) Describe two benefits to the user of being able to remove the cutting blade easily. 2 × [2]

Benefit 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Benefit 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[4]

(c)

(c) A detachable cleaning brush is included in the new garden tool.

Describe the properties of nylon that make it suitable for the bristles of the cleaning brush. [3]

[3]

(d)

(d) Study the changes in the design of the handle of the new garden tool compared to the existing garden tool, explaining the impact these will have on the user. [5]

[5]

Mark Scheme

Study the changes in the design of the handle of the new garden tool compared to the existing garden tool, explaining the impact these will have on the user. No answer or no relevant information presented or discussed. 0 Simplistic or basic response The new tool is easier to carry Or The new tool is easier to hold

       Or
       The new tool is easier to grip
       Or
       The grip is safer for the user
       More detailed explanation or response.
       The new tool features a looped handle which will be easier to hold.
       Or
       The new tool will be easier to hold and use because the four fingers fit in the
       looped handle whereas on the old tool the handles are very straight making them         2
       harder to grip.
       Or
       The looped handle will be safer by protecting the user’s fingers from being hurt/cut
       where the existing tool does not have this.
       A detailed explanation or response
       The new tool features a looped handle which will be easier to hold. The users
       fingers can wrap around the loop which is also safer, which the thumb will sit on

       the red insert which has grooves for extra grip. The old tool is far less ergonomic
       with very straight handles and less fingers grip shapes, and the user is more likely
       to hurt / cut their fingers
       A detailed explanation or response with explanation
       The new tool features a more ergonomic looped handle which will be easier to
       hold and less chance of slipping or dropping during use. The users’ fingers can
       wrap around the loop which is safer keeping them from the blade which the thumb

       will sit on the red insert which has grooves for extra grip. The old tool is far less
       ergonomic with very straight handles and less fingers grip shapes. This looks
       much more likely to be dropped or for the users grip to slip, especially in wet
       conditions. Without the looped handle, the user could have a higher risk of injury.
       A fully detailed explanation or response with thorough explanation
       The new tool features far more ergonomic considerations than the old tool. A more
       ergonomic looped handle which will be easier to hold and less chance of slipping
       or dropping during use. The users’ fingers can wrap around the loop and kept
       away from the cutting blade which is much safer, which the thumb will sit on the
       red insert which has grooves for extra grip. The old tool is far less ergonomic with
       very straight handles and less fingers grip shapes. This looks much more likely to      5
       be dropped or for the users grip to slip, especially in wet conditions, and with no
       looped handle, more cuts / injuries could occur. The new tool has a catch which
       can keep the tool blades closed for safety when the tool is not in use, the old tool
       will be in the open position due to the spring, so this may be more difficult to cut
       with as more force may be required to cut the plant and close the spring.

       Guidance:
       Responses need to address the reasons for powder coating which are related to
       aesthetic / colour coding the range of racks, and also protective finishing /
       durability.

                                                                                  Total        20

Summer 2022 materials 25m Q6

The images below show a new swimming aid that has been developed in a range of colours.

(a)(i)

(a)(i) Describe two reasons why the swimming aid is manufactured in a range of colours. 2 × [2]

Reason 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reason 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ii) State and explain the most appropriate scale of production for making the range of swimming aids. [1] + [3]

Scale of production: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

[8]

(b)(i)

(b) The swimming aid is made from an expanded foam and weighs 240 g. It will support users weighing between 15 kg and 100 kg.

(i) Describe why the properties of the expanded foam make it a suitable material for the swimming aid. [2]

[2]

(b)(ii)

(b) The swimming aid is made from an expanded foam and weighs 240 g. It will support users weighing between 15 kg and 100 kg.

(ii) The two adjustable straps used in the swimming aid have velcro fastenings.

Explain why velcro is an effective fastening for the swimming aid. [4]

[4]

(b)(iii)

(b) The swimming aid is made from an expanded foam and weighs 240 g. It will support users weighing between 15 kg and 100 kg.

(iii) The swimming aid has passed both Toy Safety and Buoyancy Aid International Safety Standards. Explain how this is important to the consumer. [2]

[2]

(c)(i)

(c) The strap can be adjusted using the buckle as shown.

(i) Buckles are bought in bulk as a standard part. Explain the benefits that this brings to the manufacturer of the swimming aid. [4]

[4]

(c)(ii)

(c) The strap can be adjusted using the buckle as shown.

(ii) A range of differently sized straps are available for the swimming aid. Explain how this both benefits the consumer and extends the product’s life. [5]

[5]

Summer 2019 new technologies 10m Q1

Study the images shown below. One is of a new smart watch with activity tracker. It has been designed to replace a traditional watch like the one in the other image.

New smart watch with Traditional watch activity tracker

(a)

(a) Explain one aesthetic change used in the new smart watch with activity tracker that will improve the product for the target market. [2]

[2]

(b)

(b) When consumers purchase the new smart watch with activity tracker, they are likely to dispose of the traditional watch. Explain two ways consumers could do this sustainably. 2 × [2]

[4]

(c)

(c) During the development of the new smart watch with activity tracker, designers used CAD to produce iterations of ideas. Describe in detail the benefits of using CAD to develop the new smart watch with activity tracker. [4]

[4]

Summer 2019 product analysis 10m Q2

The image below shows a new coffee mug. The outside of the mug displays two different faces depending on its contents.

(a)

(a) State the name of a suitable smart material that could be used in the new coffee mug and describe how this material functions appropriately. [2]

Name of smart material: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[2]

(b)

(b) Explain two advantages of using this material to the user. [4]

Advantage 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advantage 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[4]

(c)(i)

(c) A set of new mugs has been designed with a glass container held in a separate coloured holder. When designing the new mug, the designer produced a number of 3D printed models using rapid prototyping as shown below.

(i) State the name of one suitable 3D printing material to make the coloured holders. [1]

[1]

(c)(ii)

(c) A set of new mugs has been designed with a glass container held in a separate coloured holder. When designing the new mug, the designer produced a number of 3D printed models using rapid prototyping as shown below.

(ii) Explain the advantages to the designer of using 3D printing when rapid prototyping the new mug. [3]

[3]

Summer 2019 energy 15m Q3

Study the images of renewable energy sources shown below.

Generating Station

Cold water Steam and pumped hot water

Energy Source A Energy Source B

(a)(i)

(a)(i) State the names of renewable Energy Sources A and B.

Energy Source A: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Energy Source B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [2]

(ii) Describe how Energy Source B is intended to generate renewable energy. [2]

(iii) Explain two disadvantages of using Energy Source A to generate renewable energy. [2]

Disadvantage 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disadvantage 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(iv) Explain why modern manufacturing and production systems now use renewable energy sources where possible. [2]

[8]

Mark Scheme

(i) State the names of renewable Energy sources A and B.  2 No answer or no relevant information presented or discussed. 0

    Energy Source A: Tidal energy system                                                    1
    Energy Source B: Geothermal energy system                                               1
    (ii) Describe how Energy source B is intended to generate renewable

    energy.
    Answers relating to energy production using geothermal sources can be
    awarded up to 2 marks.

    Guidance:
     • Water or working fluid is heated (or used directly in case
        of geothermal dry steam power plants), and then sent through a steam
        turbine where the thermal energy (heat) is converted to electricity with a
        generator through a phenomenon called electromagnetic induction.

    Accept responses that include negatives such as Geothermal power is cost-
    effective, reliable, sustainable, and environmentally friendly, but has historically
    been limited to areas near tectonic plate boundaries.
    No answer or no relevant information presented or discussed.                            0
    Simplistic or basic response

    Heat from the earth warms up water.
    More detailed response
    People can capture geothermal energy through Geothermal power plants,
    which use heat from deep inside the Earth to generate steam to make
    electricity.                                                                            2
    Or
    Geothermal heat pumps, which tap into heat close to the Earth's surface to
    heat water or provide heat for buildings.

(iii) Explain two disadvantages of using energy source A to generate 2 renewable energy. Answers relating to disadvantages of tidal power should be awarded up to 2 x 2 marks.

    Guidance:
     • Look to credit two disadvantages. Tidal systems can change coastal
        structures, increase silt deposits, affect marine migration, they are prone
        to damage in high seas / stormy conditions, the suitable locations are
        highly limited and tidal systems can cut off shipping lanes / access to
        rivers.
     • Changing patterns of coastal erosion. Coastal erosion has increased in
        areas directly around tidal barrage, as wave and tide patterns are
        interfered with and moved onto different parts of the coastline.
     • Local eco systems are also affected as the river mouth that sit behind
        the tidal lagoon see a drop in spawning fish and other marine life,
        affecting birds, insects and plant life.
    No answer or no relevant information presented or discussed.                      0
    One Simplistic or basic response
    Only productive twice per day

    Or
    Tidal systems are expensive to install
    More detailed explanation or response
    Tidal systems have initial set up costs which are very high.                      2
    Tidal turbines can be harmful to wildlife / fish affecting local eco systems.
    (iv) Explain why modern manufacturing and production systems now use

    renewable energy sources where possible.
    Answers relating to reasons why modern manufacturing / production
    systems use renewable energy where possible should be awarded up to 2
    marks.
    Guidance:
     • Look for detailed understanding of reasons why harnessing ‘green’
         energy is increasing.
     • Government backed schemes with financial incentives, public relations
         boost for the company as perception will improve, could create more
         jobs and stimulate the economy, there could be less service disruption /
         improved supply.
     • increasing return as energy bills increase, greener sources will continue
         to provide a healthy return.
     • there will also be fewer / reduced global warming emissions.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response

    It’s cheaper to use renewable energy sources
    More detailed explanation or response
    Greener energy sources will reduce energy costs e.g. fossil fuels, and            2
    therefore reduce production costs.

(b)(i)

(b) Many products, like the refrigerator shown below, are supplied with energy labels.

280 kWh/annum

155 L 54 L 38 dB

(i) Describe why manufacturers must now supply energy labels with many products. [2]

[2]

Mark Scheme

(i) Describe why manufacturers must now supply energy  2 labels with many products. Answers relating to the need for providing information about the product in use should awarded up to 2 marks.

    Guidance:
     • Look for detailed understanding.
     • Energy labels allow consumers to compare products prior to
        purchasing.
     • Decisions may be made on an efficiency basis, consumers should
        ethically / morally be made aware of the running costs of products prior
        to purchase.
     • Directive 2010/30/EU “on the indication by labelling and standard
        product information of the consumption of energy and other resources
        by energy-related products” sets a framework for the adoption of
        product-specific directives on the proper energy efficiency labelling for
        each concerned product.
     • This law is undergoing review; the proposed legislation, simplifying
        labelling categories and extending the scope will likely be adopted in
        2017.
     • Suppliers are to supply free of charge labels or product fiches
        containing information about consumption of electric or other energy
        sources to their dealers. Dealers display labels in a visible and legible
        way, and make the fiche available in product brochures or other
        literature.
    No answer or no relevant information presented or discussed.                    0
    Simplistic or basic response                                                    1
    Energy labels are needed to give customers information
    Or
    It is a mandatory requirement to have a label                                   1
    More detailed explanation or response
    Manufacturers are required to provide energy data with new products so that     2
    customers / purchasers can clearly see the energy consumption of products.

(ii) Explain in detail the benefits of energy labels to the  5 consumer when purchasing products. Answers relating to benefits to the consumer of energy labels should be awarded up to 5 marks.

    Guidance:
     • Consumers can clearly see the energy rating of the product.
     • Labels simplify running costs, the higher the A rating the more
        economical / efficient the product is.
     • Consumers can compare products using the labelling system.
     • Consumers are made fully aware of running costs of the product.
     • Consumers can make more informed judgements based on eco factors.
     • Consumers can also be informed of noise generation of products.
     • Consumers can judge products on rrp and runnings costs – a cheaper
        product to purchase may cost more to run in the long term.
    No answer or no relevant information presented or discussed.                    0
    Brief or basic explanation, very little detail.

    Consumer can see how much energy the product will use
    Description with some explanation and some detail of the impact on
    consumer

    Consumer can see how much energy will be used and can compare to
    another product.
    More detailed explanation with a clear understanding of the impact on
    consumer.
    Consumer can see how much energy is likely to be used and can estimate          3
    running costs / bills effectively. The customer can compare similar products
    to evaluate energy use.
    A detailed explanation with a clear understanding of impact on the
    consumer.
    Consumer can see how much energy is likely to be used and can manage            4
    bills effectively. The consumer can compare similar products and consider
    their energy rating / efficiency prior to purchasing.
    A highly detailed and comprehensive explanation of both positive and
    negative impact on the consumer.
    Consumer can see how much energy will be used and can manage bills
    effectively. The consumer can be confident when purchasing products
    because all energy ratings are comparable and transparent preventing any        5
    surprises regarding energy consumption once products are purchased and
    used. Energy labels are mandatory in EU and so the consumer is likely to
    have increasingly efficient products to choose from due to the competitive
    market established as a result of labelling.
                                                                        Total       15

(b)(ii)

(b) Many products, like the refrigerator shown below, are supplied with energy labels.

280 kWh/annum

155 L 54 L 38 dB

(ii) Explain in detail the benefits of energy labels to the consumer when purchasing 07 products. [5]

[5]

Mark Scheme

(i) Describe why manufacturers must now supply energy  2 labels with many products. Answers relating to the need for providing information about the product in use should awarded up to 2 marks.

    Guidance:
     • Look for detailed understanding.
     • Energy labels allow consumers to compare products prior to
        purchasing.
     • Decisions may be made on an efficiency basis, consumers should
        ethically / morally be made aware of the running costs of products prior
        to purchase.
     • Directive 2010/30/EU “on the indication by labelling and standard
        product information of the consumption of energy and other resources
        by energy-related products” sets a framework for the adoption of
        product-specific directives on the proper energy efficiency labelling for
        each concerned product.
     • This law is undergoing review; the proposed legislation, simplifying
        labelling categories and extending the scope will likely be adopted in
        2017.
     • Suppliers are to supply free of charge labels or product fiches
        containing information about consumption of electric or other energy
        sources to their dealers. Dealers display labels in a visible and legible
        way, and make the fiche available in product brochures or other
        literature.
    No answer or no relevant information presented or discussed.                    0
    Simplistic or basic response                                                    1
    Energy labels are needed to give customers information
    Or
    It is a mandatory requirement to have a label                                   1
    More detailed explanation or response
    Manufacturers are required to provide energy data with new products so that     2
    customers / purchasers can clearly see the energy consumption of products.

(ii) Explain in detail the benefits of energy labels to the  5 consumer when purchasing products. Answers relating to benefits to the consumer of energy labels should be awarded up to 5 marks.

    Guidance:
     • Consumers can clearly see the energy rating of the product.
     • Labels simplify running costs, the higher the A rating the more
        economical / efficient the product is.
     • Consumers can compare products using the labelling system.
     • Consumers are made fully aware of running costs of the product.
     • Consumers can make more informed judgements based on eco factors.
     • Consumers can also be informed of noise generation of products.
     • Consumers can judge products on rrp and runnings costs – a cheaper
        product to purchase may cost more to run in the long term.
    No answer or no relevant information presented or discussed.                    0
    Brief or basic explanation, very little detail.

    Consumer can see how much energy the product will use
    Description with some explanation and some detail of the impact on
    consumer

    Consumer can see how much energy will be used and can compare to
    another product.
    More detailed explanation with a clear understanding of the impact on
    consumer.
    Consumer can see how much energy is likely to be used and can estimate          3
    running costs / bills effectively. The customer can compare similar products
    to evaluate energy use.
    A detailed explanation with a clear understanding of impact on the
    consumer.
    Consumer can see how much energy is likely to be used and can manage            4
    bills effectively. The consumer can compare similar products and consider
    their energy rating / efficiency prior to purchasing.
    A highly detailed and comprehensive explanation of both positive and
    negative impact on the consumer.
    Consumer can see how much energy will be used and can manage bills
    effectively. The consumer can be confident when purchasing products
    because all energy ratings are comparable and transparent preventing any        5
    surprises regarding energy consumption once products are purchased and
    used. Energy labels are mandatory in EU and so the consumer is likely to
    have increasingly efficient products to choose from due to the competitive
    market established as a result of labelling.
                                                                        Total       15

Summer 2019 product analysis 20m Q4

The images below show a new range of kitchen products designed to encourage young children to prepare food at family meal times.

(a)

(a) Analyse how the designer would gather information on the target market to use during the generation of ideas for the kitchen products. [4]

[4]

Mark Scheme

Analyse how the designer would gather information on the target market before starting to generate ideas for the kitchen  4 products. Answers relating to researching the target market should be awarded up to 4 marks.

    Guidance:
     • The designer would seek to establish the user’s needs and wants from the
        product/s.
     • A questionnaire could be used to gather responses, this would be
        analysed to give the designer a clear picture of the scenario.
     • Research on anthropometric data would be conducted to establish sizes
        for products to be ergonomically effective.
     • Interview / speak to parents / children about home cooking, uncover type
        of products they already use, and what type of cooking activities children
        undertake.
     • The designer might establish dietary requirements / healthy eating
        patterns in families.
     • The designer may use a survey to gather opinions on existing products
        and how they can be improved.
     • The designer could measure children’s hands to establish correct sizes for
        grips, handles, etc.
     • Find out data on carrying objects, weights of items that can be carried
        safely by children.

No answer or no relevant information presented or discussed. 0 Simple understanding of research. Little, if any, understanding of how the designer could research and gather information to analyse the target market. Quality of Written Communication is limited, presenting material with limited coherence, many errors of grammar, punctuation and spelling.

    Conduct a survey of users to make sure the handles are the right size to hold
    Or
    Find out anthropometric data to make sure the kitchen products are
    comfortable to hold
    Some description of research.
    Some understanding of how the designer could research and gather information to
    analyse the target market.
    Quality of Written Communication is basic, presenting occasionally appropriate
    material with some coherence, some errors of grammar, punctuation and spelling.

    Find out anthropometric data on children so that the circumference / diameter
    of the handles that the children need to hold are be to be gripped by children
    using right or left hands.
    Or
    Measure the children’s hand do that the positioning of the blade on the
    vegetable scraper can be far away from the handle to prevent any injuries.
    Description and understanding of research.
    Some understanding of the how the designer could research and gather
    information to analyse the target market, and how this would clarify the user needs
    and wants.
    Quality of Written Communication is good, presenting mainly appropriate
    material in a coherent manner, few errors of grammar, punctuation and

    spelling.

    Carry out a survey on families to find out the type of cooking activities children
    take part in. Find out hand sizes of users so that the circumference / diameter
    of the handles that need to be gripped by children using right or left hands are
    the correct size.
    Clear and detailed understanding and description of research.
    Clear and detailed understanding of how the designer could research and gather
    information to analyse the target market, and how this would clarify the user needs
    and wants to form a design specification.
    Quality of Written Communication is excellent, presenting wholly appropriate
    material in a coherent and logical manner, hardly any errors of grammar,
    punctuation and spelling.

    Research the target market by using a questionnaire to find out what type of
    cooking, cutting or preparation children undertake at family meal times.
    Interview / ask children what colours / shapes they would like best for the new
    products. Look up anthropometric sizes to create comfortable ergonomic
    feature on products including large carrying handles so items can be used and
    transported. Handles are all coloured differently to items with cutting blades –
    this allows the user to distinguish between parts of objects and intended use.

(b)

(b) The kitchen products are injection moulded using high density polythene, and finished with a rubberised handle. Evaluate how this impacts on the environmental footprint of the product. [6]

[6]

Mark Scheme

The kitchen products are injection moulded using high density polyethylene (HDPE), and finished with a rubberised handle. Evaluate how this impacts on the 6 environmental footprint of the product. Answers relating to the environmental impact of using injection moulded HDPE should be awarded up to 6 marks.

    Guidance:
     • Candidates could be focussing on the combination of materials
     • Injection moulding uses power / energy possibly from non-renewable sources.
     • Processing two different materials and combining them, possibly with glue /
        adhesive / resin makes separation and reusing difficult.
     • Disposal issues of the product because polymers and thermosetting materials
        are difficult to recycle.
     • Life Cycle Analysis could be used here to consider recycling, reusing, and
        disposal.
     • Plastics are bad because they come from finite resources and require
        significant processing which uses energy, and creates pollution.
     • HDPE is non-biodegradable and will take centuries to decompose at landfill
        once products are discarded.
     • The rubberised handle is made from possibly natural materials (latex) or
        synthetic rubber which is a by-product of petroleum. Both sources require
        significant processing.
     • HDPE and Rubber are long-lasting materials, robust and durable so will no
        break easily.
    No answer or no relevant information presented or discussed.
    Quality of Written Communication is limited, presenting material with limited

    coherence, many errors of grammar, punctuation and spelling.

    Brief description, very little detail of environmental footprint.
    Quality of Written Communication is basic, presenting occasionally appropriate
    material with some coherence, some errors of grammar, punctuation and spelling.
                                                                                             1-2
    The products / materials are difficult to recycle
    Or
    The product is difficult to separate for recycling and parts would be difficult to re-
    use.
    Some detail with some understanding of environmental footprint.
    Quality of Written Communication is good, presenting mainly appropriate
    material in a coherent manner, few errors of grammar, punctuation and
    spelling.

    The HDPE is not biodegradable and should not be thrown away and go in to
    landfill.
    HDPE is non-biodegradable and can take centuries to decompose, so it is                  3-4
    imperative that it is recycled and used again. It is more cost efficient to produce a
    product from recycled HDPE than it is to manufacture 'virgin' plastic
    Or
    Rubber can be produced from natural resources like plants that include latex. This
    is a non-renewable source and should be avoided.
    Or
    Some rubbers are synthetic and do not come straight from natural resources, and
    are therefore more sustainable.

A clear and detailed understanding of the environmental footprint of the products. Quality of Written Communication is excellent, presenting wholly appropriate material in a coherent and logical manner, hardly any errors of grammar, punctuation and spelling.

    The sources of the materials are important to consider. HDPE is a non-renewable
    material coming from finite resources. Heavy processing and energy costs are            5-6
    involved in processing it to product stage. HDPE is a difficult material to re-use or
    recycle after product disposal. More energy will be required to separate and break
    down the materials. The rubberised parts would be bonded to products, probably
    using chemical components. This would not be environmentally friendly. Rubber
    could be natural or synthetic, but would require heavy processing and bonding to
    the kitchen products.

(c)(i)

(c) A student has designed and made a concept model of a new handheld torch in blue modelling foam.

On / off switch Handle

Lens / bulb compartment

Main body / battery compartment

(i) Evaluate the advantages to the student of using blue modelling foam to make the concept model in a school workshop. [4]

[4]

Mark Scheme

(i) Evaluate the advantages to the student of using blue modelling foam to make the concept model in a school  4 workshop. Answers relating to the advantages to the student of using blue modelling foam should be awarded up to 4 marks.

    Guidance:
     • Blue modelling foam is available in a range of sizes (thicknesses) suitable
        for all projects.
     • Blue modelling foam is quite cheap and readily available, so easy to
        access to model with.
     • Blue foam is soft and easy to work. Commonly cut with hot wire cutters /
        craft knives, fine coping saw blades.
     • Less time consuming than using other modelling materials e.g. mdf.
     • Blue foam is easy to draw / mark lines on in preparation for cutting and
        shaping.
     • Blue foam can be cut on bandsaw and shaped using disc sanders which
        are common in D&T workshops.
     • Blue foam models can be primed and painted if needed.
     • Blue foam is rigid and resistant enough to handle / test the torch.
     • A smooth finish can be achieved fairly easily / quickly to achieve a realistic
        product.
     • Blue foam has no grain, the texture and density is consistent throughout
        its section.
     • Blue foam is very easy to file after cutting, and glasspaper to smooth
        finish.

No answer or no relevant information presented or discussed. 0 Simple understanding of advantages to the student of using blue modelling foam. Quality of Written Communication is limited, presenting material with limited coherence, many errors of grammar, punctuation and spelling.

    Blue foam is easy to cut and shape to make the model
    Or
    Blue foam is a quick way of modelling
    Some understanding of advantages to the student of using blue modelling foam.
    Blue modelling foam is an affordable material easy to work when cutting,
    forming, shaping into the torch design. It can look professional when primed
    and sprayed.                                                                      2
    Or
    Blue modelling foam is available in a range of forms and thickness. It has no
    grain. It will offer a realistic feel for concept models.
    Description and understanding of advantages to the student of using blue
    modelling foam.

    Blue modelling foam is an affordable material easy to work when cutting,          3
    forming, shaping into the torch design. It can look professional when primed
    and sprayed. Blue modelling foam is available in a range of forms and
    thickness.
    Clear and detailed understanding of advantages to the student of using blue
    modelling foam.

    Blue modelling foam is an affordable material easy to work when cutting,          4
    forming, shaping into the torch design. It can look professional when primed
    and sprayed. Blue modelling foam is available in a range of forms and
    thickness. It has no grain. It will offer a realistic feel for concept models.

(ii) Analyse the benefits that modelling will have for the eventual success the

    concept model of a new handheld torch.
    Answers relating to the analysis of modelling on the eventual success of the
    torch should be awarded up to 6 marks.

    Guidance:
     • Benefits include that ideas can be tested fully prior to production, saving
        time, money and reducing errors.
     • Modifications / changes can be identified and implemented as a result of
        modelling.
     • Models can be tested by target market, and analysed to improve next
        iteration.
     • Modelling will allow the shape, form, aesthetics and ergonomics to be
        developed fully / perfectly.
     • During modelling, the designer can ‘feel’ how the idea would work, not a
        simulation but a real-life test.
     • Materials and components, sizes and costs can be estimated from the
        model.
     • The model could be scanned and CAD to be used to generate CAM files
        for production.
    No answer or no relevant information presented or discussed.                          0
    Brief description, very little detail of analysing the benefits of modelling on the
    eventual success of the torch.
    Modelling helps the designer to see if it’s a good idea.                              1-2
    Or
    The product can be tested to see if it works well or needs to change.
    Some detail with some understanding of the benefits of modelling on the
    eventual success of the torch.
    Modelling allows testing of the torch so that good features can be kept and           3-4
    changes identified to improve the torch. The model prevents the product being
    manufactured with defects or problems.
    A clear and detailed analysis of the benefits of modelling on the eventual
    success of the torch.
    Modelling allows testing of the torch by the designer and the target market so
    that good features can be kept and changes identified to improve the torch.           5-6
    This will ensure that the final product is successful and meet all of the market’s
    needs and wants. The model prevents the product being manufactured with
    defects or problems, which would be costly for the manufacturer.
                                                                               Total      20

(c)(ii)

(c) A student has designed and made a concept model of a new handheld torch in blue modelling foam.

On / off switch Handle

Lens / bulb compartment

Main body / battery compartment

(ii) Analyse the benefits that modelling will have for the eventual success of the new handheld torch. [6]

[6]

Mark Scheme

(i) Evaluate the advantages to the student of using blue modelling foam to make the concept model in a school  4 workshop. Answers relating to the advantages to the student of using blue modelling foam should be awarded up to 4 marks.

    Guidance:
     • Blue modelling foam is available in a range of sizes (thicknesses) suitable
        for all projects.
     • Blue modelling foam is quite cheap and readily available, so easy to
        access to model with.
     • Blue foam is soft and easy to work. Commonly cut with hot wire cutters /
        craft knives, fine coping saw blades.
     • Less time consuming than using other modelling materials e.g. mdf.
     • Blue foam is easy to draw / mark lines on in preparation for cutting and
        shaping.
     • Blue foam can be cut on bandsaw and shaped using disc sanders which
        are common in D&T workshops.
     • Blue foam models can be primed and painted if needed.
     • Blue foam is rigid and resistant enough to handle / test the torch.
     • A smooth finish can be achieved fairly easily / quickly to achieve a realistic
        product.
     • Blue foam has no grain, the texture and density is consistent throughout
        its section.
     • Blue foam is very easy to file after cutting, and glasspaper to smooth
        finish.

No answer or no relevant information presented or discussed. 0 Simple understanding of advantages to the student of using blue modelling foam. Quality of Written Communication is limited, presenting material with limited coherence, many errors of grammar, punctuation and spelling.

    Blue foam is easy to cut and shape to make the model
    Or
    Blue foam is a quick way of modelling
    Some understanding of advantages to the student of using blue modelling foam.
    Blue modelling foam is an affordable material easy to work when cutting,
    forming, shaping into the torch design. It can look professional when primed
    and sprayed.                                                                      2
    Or
    Blue modelling foam is available in a range of forms and thickness. It has no
    grain. It will offer a realistic feel for concept models.
    Description and understanding of advantages to the student of using blue
    modelling foam.

    Blue modelling foam is an affordable material easy to work when cutting,          3
    forming, shaping into the torch design. It can look professional when primed
    and sprayed. Blue modelling foam is available in a range of forms and
    thickness.
    Clear and detailed understanding of advantages to the student of using blue
    modelling foam.

    Blue modelling foam is an affordable material easy to work when cutting,          4
    forming, shaping into the torch design. It can look professional when primed
    and sprayed. Blue modelling foam is available in a range of forms and
    thickness. It has no grain. It will offer a realistic feel for concept models.

(ii) Analyse the benefits that modelling will have for the eventual success the

    concept model of a new handheld torch.
    Answers relating to the analysis of modelling on the eventual success of the
    torch should be awarded up to 6 marks.

    Guidance:
     • Benefits include that ideas can be tested fully prior to production, saving
        time, money and reducing errors.
     • Modifications / changes can be identified and implemented as a result of
        modelling.
     • Models can be tested by target market, and analysed to improve next
        iteration.
     • Modelling will allow the shape, form, aesthetics and ergonomics to be
        developed fully / perfectly.
     • During modelling, the designer can ‘feel’ how the idea would work, not a
        simulation but a real-life test.
     • Materials and components, sizes and costs can be estimated from the
        model.
     • The model could be scanned and CAD to be used to generate CAM files
        for production.
    No answer or no relevant information presented or discussed.                          0
    Brief description, very little detail of analysing the benefits of modelling on the
    eventual success of the torch.
    Modelling helps the designer to see if it’s a good idea.                              1-2
    Or
    The product can be tested to see if it works well or needs to change.
    Some detail with some understanding of the benefits of modelling on the
    eventual success of the torch.
    Modelling allows testing of the torch so that good features can be kept and           3-4
    changes identified to improve the torch. The model prevents the product being
    manufactured with defects or problems.
    A clear and detailed analysis of the benefits of modelling on the eventual
    success of the torch.
    Modelling allows testing of the torch by the designer and the target market so
    that good features can be kept and changes identified to improve the torch.           5-6
    This will ensure that the final product is successful and meet all of the market’s
    needs and wants. The model prevents the product being manufactured with
    defects or problems, which would be costly for the manufacturer.
                                                                               Total      20

Summer 2019 materials 18m Q5

An eco-furniture company has launched a range of flat-packed stools and chairs made from corrugated cardboard.

(a)(i)

(a)(i) Give one reason for the stools and chairs being delivered to the customer as a flat-pack. [2]

(ii) Describe how the properties of high quality corrugated cardboard make it suitable for the flat-packed stools and chairs. [2]

(iii) The stools and chairs do not require any glue or fixtures during assembly. Explain two advantages this will bring for the consumer. 2 × [2]

Advantage 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advantage 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The eco-furniture company also sells lighting products as shown below.

[6]

Mark Scheme

(i) Give one reason for the stools and chairs being delivered to  2 the customer as a flat-pack. Answers relating to reasons for flat-packed box should be awarded up to 2 marks.

    Guidance:
     • Cheaper for the retailer to ship / lower costs for the customer to pay for
        delivery
     • Easier to transport / ship / distribute.
     • Less prove to damage as it is a flat shape, multiple packs could be held
        together.
     • The product is made from a series of flat shapes that fit together, so
        storing them flat is very appropriate.
     • The main reasons are the DIY nature, but other factors such as
        transporting multiple products bought as a bundle are acceptable. Storage
        at the factory NOT acceptable.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response
    Cheaper to transport / ship / post.

    Or
    Will not get damaged as it is flat.
    More detailed explanation or response.
    The range are flat packed products, therefore require self-assembly by the          2
    customer.

(ii) Describe how the properties of high quality corrugated cardboard make it

    suitable for the flat packed stools and chairs.
    Answers relating to the properties of high quality corrugated card being
    suitable should be awarded up to 2 marks.

    Guidance:
     • Several areas where candidates could gain credit.
     • Can withstand the forces applied when user sits down, stiff, rigid structure
        for posting.
     • The eco furniture company will want a green material – corrugated card
        could be made from 100% recycled materials
     • The products would be 100% recyclable at the end of their useful life.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response
    The corrugated structure is strong
    Or
    It will be strong enough to sit on

    Or
    It is fully recyclable after use
    Or
    It will hold the weight of the user
    More detailed explanation or response.
    The corrugated cardboard is reinforced and is rigid and can withstand forces
    applied when placed upright as shown in the products.
    Or
    It is a cheap sheet material which can be cut as required by CAM machines for     2
    the stool and chair designs.
    Or
    It is a strong and lightweight material which can be shipped flat as shown for
    the products to be removed and assembled.

(iii) The stools and chairs do not require any glue or fixtures during assembly. 2x[2] Explain two advantages this will bring for the consumer. Answers relating to the advantages to the customer for using no glue or fixtures should be awarded up to 2 x 2 marks.

    Guidance:
     • Products are cheaper to purchase due to less components / parts.
     • No specialist tools or equipment needed to assemble products, so this is
        simpler for the consumer.
     • Quicker to assemble than products with fixtures and glue.
     • More environmentally friendly / smaller footprint due to less parts.
     • Can be fully recycled at the end of its life / disposal.
     • Instant product once assembled – no need to wait for glue to dry.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response
    The products are quicker to assemble

    Or
    No specialist tools or equipment is needed
    More detailed explanation or response.
    The assembly is simple because parts slot together so the product can be
    used immediately once fully assembled.

    Or
    The products are completely eco-friendly and use no additional materials or
    components other than the parts supplied.
    (iv) Explain how the designer has used corrugated cardboard in an innovative

    way.
    Answers relating to the innovative package idea being re-used as the lamp
    shade should be awarded up to 2 marks.

    Guidance:
     • The eco furniture company has been innovative by giving the packaging a
        second function – to act as the lamp shade after transporting the bulb
        safely.
     • The eco furniture company has been innovative by reducing waste
        packaging, 100% of this product and packaging is used.
     • Cutting the shapes in the package is innovative, to allow light to projects
        through pre-cut holes / gaps.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response
    The package can be fully recycled once opened

    Or
    The package is a light shade too.
    More detailed explanation or response.
    The package doubles as a light shade, so there is no waste whatsoever when          2
    the product is purchased and opened.

(a)(iv)

(a)(iv) Explain how the designer has used corrugated cardboard in an innovative way. [2]

[2]

Mark Scheme

(i) Give one reason for the stools and chairs being delivered to  2 the customer as a flat-pack. Answers relating to reasons for flat-packed box should be awarded up to 2 marks.

    Guidance:
     • Cheaper for the retailer to ship / lower costs for the customer to pay for
        delivery
     • Easier to transport / ship / distribute.
     • Less prove to damage as it is a flat shape, multiple packs could be held
        together.
     • The product is made from a series of flat shapes that fit together, so
        storing them flat is very appropriate.
     • The main reasons are the DIY nature, but other factors such as
        transporting multiple products bought as a bundle are acceptable. Storage
        at the factory NOT acceptable.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response
    Cheaper to transport / ship / post.

    Or
    Will not get damaged as it is flat.
    More detailed explanation or response.
    The range are flat packed products, therefore require self-assembly by the          2
    customer.

(ii) Describe how the properties of high quality corrugated cardboard make it

    suitable for the flat packed stools and chairs.
    Answers relating to the properties of high quality corrugated card being
    suitable should be awarded up to 2 marks.

    Guidance:
     • Several areas where candidates could gain credit.
     • Can withstand the forces applied when user sits down, stiff, rigid structure
        for posting.
     • The eco furniture company will want a green material – corrugated card
        could be made from 100% recycled materials
     • The products would be 100% recyclable at the end of their useful life.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response
    The corrugated structure is strong
    Or
    It will be strong enough to sit on

    Or
    It is fully recyclable after use
    Or
    It will hold the weight of the user
    More detailed explanation or response.
    The corrugated cardboard is reinforced and is rigid and can withstand forces
    applied when placed upright as shown in the products.
    Or
    It is a cheap sheet material which can be cut as required by CAM machines for     2
    the stool and chair designs.
    Or
    It is a strong and lightweight material which can be shipped flat as shown for
    the products to be removed and assembled.

(iii) The stools and chairs do not require any glue or fixtures during assembly. 2x[2] Explain two advantages this will bring for the consumer. Answers relating to the advantages to the customer for using no glue or fixtures should be awarded up to 2 x 2 marks.

    Guidance:
     • Products are cheaper to purchase due to less components / parts.
     • No specialist tools or equipment needed to assemble products, so this is
        simpler for the consumer.
     • Quicker to assemble than products with fixtures and glue.
     • More environmentally friendly / smaller footprint due to less parts.
     • Can be fully recycled at the end of its life / disposal.
     • Instant product once assembled – no need to wait for glue to dry.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response
    The products are quicker to assemble

    Or
    No specialist tools or equipment is needed
    More detailed explanation or response.
    The assembly is simple because parts slot together so the product can be
    used immediately once fully assembled.

    Or
    The products are completely eco-friendly and use no additional materials or
    components other than the parts supplied.
    (iv) Explain how the designer has used corrugated cardboard in an innovative

    way.
    Answers relating to the innovative package idea being re-used as the lamp
    shade should be awarded up to 2 marks.

    Guidance:
     • The eco furniture company has been innovative by giving the packaging a
        second function – to act as the lamp shade after transporting the bulb
        safely.
     • The eco furniture company has been innovative by reducing waste
        packaging, 100% of this product and packaging is used.
     • Cutting the shapes in the package is innovative, to allow light to projects
        through pre-cut holes / gaps.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response
    The package can be fully recycled once opened

    Or
    The package is a light shade too.
    More detailed explanation or response.
    The package doubles as a light shade, so there is no waste whatsoever when          2
    the product is purchased and opened.

(b)(i)

(b) A range of concept bicycle racks has been designed to offer schools and offices security for owners to leave bicycles.

(i) The bicycle rack is made from mild steel. Explain why this material is suitable for the bicycle rack. [2]

[2]

Mark Scheme

(i) The bicycle rack is made from mild steel. Explain why this material is

    suitable for the bicycle rack.
    Answers relating to the suitability of mild steel for the bicycle rack should be
    awarded up to 2 marks.

    Guidance:
     • Mild steel is a strong rigid material able to support the bicycles.
     • Mild steel is available in tubular form and can achieve the shapes
        required.
     • Mild steel is suitable for outdoor use as it is corrosive resistant when
        finished appropriately.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response

    Mild steel won’t rust easily if coated.
    More detailed explanation or response.
    The mild steel is suitable for outdoors because it will not corrode easily when
    finished appropriately.
    Or                                                                                     2
    Mild steel is strong, sturdy and robust and will be secure to lock bicycles to.
    Or
    Mild steel tubing can be shaped into the range of bicycle racks pictured.
    (ii) The mild steel has been powder coated. Describe the main
                                                                                          2
    function of this finish.
    Answers relating to the function of powder coated finish should be awarded up
    to 2 marks.

    Guidance:
     • Responses need to address the reasons for powder coating which are
        related to aesthetic / colour coding the range of racks.
     • Powder coating provides a protective finishing preventing scratching the
        bicycles locket to it, making it more durable.
     • Different colours can be applied to achieve the range required by the
        manufacturer.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The make the bicycle rack look nicer
    Or

    The bike lock will be a brighter colour
    Or
    To get a range of colours for user choice
    More detailed explanation or response.
    The powder coating provides aesthetic and mechanical qualities, making the
    racks look more attractive and become available in a variety of colours, and           2
    the powder coating provides a hard wearing, durable and scratch /scuff
    resistant wearing coat.

(iii) Explain how providing a range of bicycle racks might appeal to the

    consumer and the impact this may have on the manufacturer.
    Answers relating to how the range might appeal to consumers and the impact
    this may have on the manufacturer should be awarded up to 6 marks.

    Guidance:
     • The range of racks available provide more sales because there will be
        more choice to suit consumer tastes.
     • More choice can give consumer more freedom to make personalised
        shapes / spaces fitted with certain racks. Added flexibility solutions.
     • This could be related to colour influencing consumer choice, greater
        freedom over creating a specific solution using one or more of the racks
        available.
     • Applying a modular approach where consumer who purchases one
        initially may return to make further purchases.
     • The manufacturer may have to increase production as items sell / become
        more popular.
     • The manufacturer will have an increase in profit margins as more will sell.
     • The manufacturer may have returning customers who initially purchase
        and then re-order a similar of different rack.
     • The manufacturer may have to semi-automate production / increase
        workforce to keep up with demand.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response showing little explanation.
    Customers might prefer one colour over another
    Or                                                                                  1-2
    Different colour for different sized racks allows the manufacturer to colour code
    the options.
    More detailed explanation or response showing more understanding of appeal
    to the customer AND impact on manufacturer.
    The racks are colour coded as part of a suite of products, so customers can
    mix and match products, or purchase similar racks for consistency depending
                                                                                        3-4
    on the number users. This means the manufacturer is likely to sell more racks.

    A clear and detailed explanation showing full understanding towards the
    consumer AND manufacturer.
    The racks are colour coded as part of a suite of products, so customers can
    mix and match products, or purchase similar racks for consistency depending
    on the number users. This means the manufacturer is likely to sell more racks
    and make more profit.                                                               5-6
    This will give consumers a greater choice providing flexibility for the solutions
    of storing bicycles, allowing custom bicycle storing arrangements suitable for
    different spaces and locations.
                                                                               Total    20

(b)(ii)

(b) A range of concept bicycle racks has been designed to offer schools and offices security for owners to leave bicycles.

(ii) The mild steel has been powder coated. Describe the main function of this finish. [2]

[2]

Mark Scheme

(i) The bicycle rack is made from mild steel. Explain why this material is

    suitable for the bicycle rack.
    Answers relating to the suitability of mild steel for the bicycle rack should be
    awarded up to 2 marks.

    Guidance:
     • Mild steel is a strong rigid material able to support the bicycles.
     • Mild steel is available in tubular form and can achieve the shapes
        required.
     • Mild steel is suitable for outdoor use as it is corrosive resistant when
        finished appropriately.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response

    Mild steel won’t rust easily if coated.
    More detailed explanation or response.
    The mild steel is suitable for outdoors because it will not corrode easily when
    finished appropriately.
    Or                                                                                     2
    Mild steel is strong, sturdy and robust and will be secure to lock bicycles to.
    Or
    Mild steel tubing can be shaped into the range of bicycle racks pictured.
    (ii) The mild steel has been powder coated. Describe the main
                                                                                          2
    function of this finish.
    Answers relating to the function of powder coated finish should be awarded up
    to 2 marks.

    Guidance:
     • Responses need to address the reasons for powder coating which are
        related to aesthetic / colour coding the range of racks.
     • Powder coating provides a protective finishing preventing scratching the
        bicycles locket to it, making it more durable.
     • Different colours can be applied to achieve the range required by the
        manufacturer.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The make the bicycle rack look nicer
    Or

    The bike lock will be a brighter colour
    Or
    To get a range of colours for user choice
    More detailed explanation or response.
    The powder coating provides aesthetic and mechanical qualities, making the
    racks look more attractive and become available in a variety of colours, and           2
    the powder coating provides a hard wearing, durable and scratch /scuff
    resistant wearing coat.

(iii) Explain how providing a range of bicycle racks might appeal to the

    consumer and the impact this may have on the manufacturer.
    Answers relating to how the range might appeal to consumers and the impact
    this may have on the manufacturer should be awarded up to 6 marks.

    Guidance:
     • The range of racks available provide more sales because there will be
        more choice to suit consumer tastes.
     • More choice can give consumer more freedom to make personalised
        shapes / spaces fitted with certain racks. Added flexibility solutions.
     • This could be related to colour influencing consumer choice, greater
        freedom over creating a specific solution using one or more of the racks
        available.
     • Applying a modular approach where consumer who purchases one
        initially may return to make further purchases.
     • The manufacturer may have to increase production as items sell / become
        more popular.
     • The manufacturer will have an increase in profit margins as more will sell.
     • The manufacturer may have returning customers who initially purchase
        and then re-order a similar of different rack.
     • The manufacturer may have to semi-automate production / increase
        workforce to keep up with demand.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response showing little explanation.
    Customers might prefer one colour over another
    Or                                                                                  1-2
    Different colour for different sized racks allows the manufacturer to colour code
    the options.
    More detailed explanation or response showing more understanding of appeal
    to the customer AND impact on manufacturer.
    The racks are colour coded as part of a suite of products, so customers can
    mix and match products, or purchase similar racks for consistency depending
                                                                                        3-4
    on the number users. This means the manufacturer is likely to sell more racks.

    A clear and detailed explanation showing full understanding towards the
    consumer AND manufacturer.
    The racks are colour coded as part of a suite of products, so customers can
    mix and match products, or purchase similar racks for consistency depending
    on the number users. This means the manufacturer is likely to sell more racks
    and make more profit.                                                               5-6
    This will give consumers a greater choice providing flexibility for the solutions
    of storing bicycles, allowing custom bicycle storing arrangements suitable for
    different spaces and locations.
                                                                               Total    20

(b)(iii)

(b) A range of concept bicycle racks has been designed to offer schools and offices security for owners to leave bicycles.

(iii) Explain how providing a range of bicycle racks might appeal to the consumer and the impact this may have on the manufacturer. [6]

[6]

Mark Scheme

(i) The bicycle rack is made from mild steel. Explain why this material is

    suitable for the bicycle rack.
    Answers relating to the suitability of mild steel for the bicycle rack should be
    awarded up to 2 marks.

    Guidance:
     • Mild steel is a strong rigid material able to support the bicycles.
     • Mild steel is available in tubular form and can achieve the shapes
        required.
     • Mild steel is suitable for outdoor use as it is corrosive resistant when
        finished appropriately.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response

    Mild steel won’t rust easily if coated.
    More detailed explanation or response.
    The mild steel is suitable for outdoors because it will not corrode easily when
    finished appropriately.
    Or                                                                                     2
    Mild steel is strong, sturdy and robust and will be secure to lock bicycles to.
    Or
    Mild steel tubing can be shaped into the range of bicycle racks pictured.
    (ii) The mild steel has been powder coated. Describe the main
                                                                                          2
    function of this finish.
    Answers relating to the function of powder coated finish should be awarded up
    to 2 marks.

    Guidance:
     • Responses need to address the reasons for powder coating which are
        related to aesthetic / colour coding the range of racks.
     • Powder coating provides a protective finishing preventing scratching the
        bicycles locket to it, making it more durable.
     • Different colours can be applied to achieve the range required by the
        manufacturer.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The make the bicycle rack look nicer
    Or

    The bike lock will be a brighter colour
    Or
    To get a range of colours for user choice
    More detailed explanation or response.
    The powder coating provides aesthetic and mechanical qualities, making the
    racks look more attractive and become available in a variety of colours, and           2
    the powder coating provides a hard wearing, durable and scratch /scuff
    resistant wearing coat.

(iii) Explain how providing a range of bicycle racks might appeal to the

    consumer and the impact this may have on the manufacturer.
    Answers relating to how the range might appeal to consumers and the impact
    this may have on the manufacturer should be awarded up to 6 marks.

    Guidance:
     • The range of racks available provide more sales because there will be
        more choice to suit consumer tastes.
     • More choice can give consumer more freedom to make personalised
        shapes / spaces fitted with certain racks. Added flexibility solutions.
     • This could be related to colour influencing consumer choice, greater
        freedom over creating a specific solution using one or more of the racks
        available.
     • Applying a modular approach where consumer who purchases one
        initially may return to make further purchases.
     • The manufacturer may have to increase production as items sell / become
        more popular.
     • The manufacturer will have an increase in profit margins as more will sell.
     • The manufacturer may have returning customers who initially purchase
        and then re-order a similar of different rack.
     • The manufacturer may have to semi-automate production / increase
        workforce to keep up with demand.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response showing little explanation.
    Customers might prefer one colour over another
    Or                                                                                  1-2
    Different colour for different sized racks allows the manufacturer to colour code
    the options.
    More detailed explanation or response showing more understanding of appeal
    to the customer AND impact on manufacturer.
    The racks are colour coded as part of a suite of products, so customers can
    mix and match products, or purchase similar racks for consistency depending
                                                                                        3-4
    on the number users. This means the manufacturer is likely to sell more racks.

    A clear and detailed explanation showing full understanding towards the
    consumer AND manufacturer.
    The racks are colour coded as part of a suite of products, so customers can
    mix and match products, or purchase similar racks for consistency depending
    on the number users. This means the manufacturer is likely to sell more racks
    and make more profit.                                                               5-6
    This will give consumers a greater choice providing flexibility for the solutions
    of storing bicycles, allowing custom bicycle storing arrangements suitable for
    different spaces and locations.
                                                                               Total    20

Summer 2019 materials 23m Q6

A portable tennis game has been launched aimed at 3 to 5 year olds. The game can be played by one or two players and on any surface.

Tennis game with Clips to hang bats Contents stored in ABS base used as rotating spinner ABS base carry case

Product Features:

• Height adjustable PVC tubes for upright stand. • ABS spinner with nylon cord allows tennis ball to rotate around upright stand. • All products pack away into the large ABS base and carry case. • Clips to hang bats onto when not in use. • Recommended Retail Price (RRP) £25.99.

(a)(i)

(a)(i) Describe the properties of PVC that make it a suitable material for the tubes used to create the upright stand. [2]

(ii) The tennis game needs to be easily assembled and disassembled. Explain how this has been achieved. [2]

(iii) Explain two advantages of using injection moulding to make the ABS base and carry case. 2 × [2]

Advantage 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advantage 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

[6]

Mark Scheme

(i) Describe the properties of PVC that make it a suitable  [2] material for the tubes used to create the upright stand. Answers relating to properties of PVC should be awarded up to 2 marks.

    Guidance:
     • Understanding of PVC including ability to be extruded in tubular form.
     • Collars / flared end to connect to similar tube components.
     • Economic to use, able to be manufactured in red (or other colours)
     • Flexible with good tensile strength to withstand forces as ball rotates
        around upright.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    PVC is strong and wouldn’t break easily.
    Or
    PVC is a strong stiff material for the stand
    More detailed explanation or response.                                              2
    PVC is very dense compared to most plastics, with extremely good tensile
    strength suitable for the upright stand.
    Or
    PVC is readily available, fairly cheap to manufacture and easy to colour for the
    red tubing required.
    Or
    PVC has good strength weight ratio easy to collapse for portability, and is
    water / weather resistant for use outdoors.
    (ii) The tennis game needs to be easily assembled and disassembled. Explain         [2]
    how this has been achieved.
    Answers relating to how the tennis game can easily assembled and
    disassembled should be awarded up to 2 marks.

    Guidance:
     • Responses need to address the quickly erected and collapsed intention.
     • All joints are push fit, standard identical joints.
     • No specialist tools, equipment or knowledge needed.
     • All parts separate to fit inside storage / carry case.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    The PVC parts fit together tightly and quickly
    Or
    The tennis game is made up from a small number of PVC parts.
    More detailed explanation or response.                                              2
    There are individual parts which fit together easily without any fittings or
    fixtures and dismantle to fit inside in the base which becomes the carry case to
    be portable.

(iii) Explain two advantages of using injection moulding to make the ABS base 2x[2] and carry case. Answers relating to using injection moulding to make the ABS base and carry case should be awarded up to 2 x 2 marks.

    Guidance:
     • Look for two different answers.
     • Avoid double awarding similar responses.
     • ABS is a strong material, suitable for the injection moulding process to
        make this case.
     • Injection moulded ABS will be impact and water resistant, important
        features for the base / carry case.
     • Colour changes can easily be added by using different colour granules in
        the injection moulding process.
     • These are made in high volume – each is identical.
     • Economical production method for mass/volume.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response
    The ABS is a strong material for the base / case
    Or

    Is water resistant for outdoor use
    Or
    Can be filled with water to add weight to the base.
    More detailed explanation or response.
    The ABS is a robust, tough, strong and rigid material suitable for the knocks
    and bangs that the carry case / base might experience
    Or
    Injection moulding would be a quick and efficient process with no waste. Any
    defects could be reused in the next moulding.

    Or
    Due to injection moulding, all joints would be identical standard components
    with high quality assurance, perfect for large scale production.
    Or
    The manufacturer could change the colour easily / release special edition with
    a change in coloured granules using the same die / mould.

(iv) Analyse how the physical properties of nylon make it a suitable for the cord [3] attached to the tennis ball. Answers relating to the physical properties of nylon suitable for the cord should be awarded up to 3 marks.

    Guidance:
     • Look for explanation of nylon’s properties including lightweight for
        portability,
     • Woven into cord, flexible and high tensile strength.
     • Durable for outdoors, washable, synthetic material so does not fail quickly,
     • Soft on the hand, no sharp edges or hazards.
     • Abrasion resistant if hit / grazed with a bat.
     • Low friction.
     • Resistant to snapping or fraying despite under constant blows from bats.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The string will need to be strong to take the impact of the ball being hit at high
    speed or hard. Nylon is a strong material.                                             1
    Or
    Nylon is flexible and not too rigid.
    More detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break easily
    Or
    Nylon has excellent resistance to weathering; it does not corrode in wet               2
    conditions.
    Or
    Nylon if flexible, durable and strong with excellent abrasion resistance
    A highly detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break when the
    impact of the ball being hit occurs. Nylon is lightweight with excellent strength
    weight ratio.
    Or
    Nylon has excellent resistance to weathering, it does not corrode in wet               3
    conditions. It is sunlight resistant for use outdoors, and abrasion resistant if hit
    with one of the bats.
    Or
    Nylon if flexible so easy to fit when erecting the tennis game and folding flat /
    small into the carry case and is lightweight to carry for portability.

(v) Different parts of the product are manufactured in different countries and shipped to a central location for assembly. [4] Describe the winners and losers created by manufacturing in this way. Answers related to manufacturing in different countries and shipping to a central location for assembly should be awarded up to 4 marks. Answers must include winner/s and loser/s to achieve maximum 4 marks.

    Guidance:
     • Winners are consumers who get access to a cheaper product due to
        overseas manufacture.
     • Winners are local / overseas businesses who get contracted to produce
        parts, benefitting their economy.
     • Losers could be environment due to transporting parts from country of
        manufacture, to assembly and then on to retailer.
     • Losers could be workers in less economically developed countries who
        could be exploited
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail of winners and losers.
    Winners are local businesses where some parts might be made or sourced.
    Or                                                                                 1
    Losers are the environment / environmentalists because shipping involves
    energy usable.
    More detailed explanation with some explanation of winners and losers.
    Winners are the consumers who will be able to buy a cheaper product because
    the parts will be made competitively and therefore a lower RRP.
    Or                                                                                 2
    Losers are the local business because some parts are sourced elsewhere
    therefore trade is lost. Workers / jobs may be less than if all parts were made
    at same location.
    A detailed explanation including a number of explanations of impact on winners
    and losers.
    Winners would be suppliers who win contacts to provide parts, the country /
    government economy of the supplier would benefit from this trade. The buyer        3
    would get the product for a lower purchase price. Losers would be other
    suppliers or countries for not securing the trade and missing the opportunity to
    sell and make profit.
    A highly detailed and comprehensive explanation of both positive and negative
    impact on the consumer.
    The market would be competitive, and supplier would need to bid to secure the
    contract to supply. This would benefit the manufacturer to secure cheaper
    parts, and the end user would have to pay a lower purchase price. Losers

    would be other suppliers or countries for not securing the trade and missing the
    opportunity to sell and make profit. The environment would also be a loser due
    to shipping globally. Losers could be workers in one a less economically
    developed country where there could be workforce issues or poor pay /
    working conditions.

(vi) Explain why, initially, the manufacturer of the tennis game would produce a [3] limited number of products using batch production. Answers relating to reasons why a limited number of tennis games would be produced using batch production should be awarded up to 2 marks.

    Guidance:
     • Credit candidates identifying the reasons for batch production.
     • A limited edition version might be created, as an anniversary product /
        collector's item etc.
     • Testing the market if product is new.
     • Promoting an event e.g. a tennis tournament, so limited number ordered /
        made.
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail.

    To see if the product would sell / be popular without making too many.
    More detailed explanation.
    The manufacturer will be testing the market to ensure there is sufficient          2
    demand for the product.
    A detailed and full explanation
    The manufacturer will be anticipating the likely number of sales and making
    just enough to supply the demand. If demand is high, further batches or mass       3
    production would begin. If sales were low, no more products would be
    manufactured.

(a)(iv)

(a)(iv) Explain how the physical properties of nylon make it suitable for the cord attached to the tennis ball. [3]

[3]

Mark Scheme

(i) Describe the properties of PVC that make it a suitable  [2] material for the tubes used to create the upright stand. Answers relating to properties of PVC should be awarded up to 2 marks.

    Guidance:
     • Understanding of PVC including ability to be extruded in tubular form.
     • Collars / flared end to connect to similar tube components.
     • Economic to use, able to be manufactured in red (or other colours)
     • Flexible with good tensile strength to withstand forces as ball rotates
        around upright.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    PVC is strong and wouldn’t break easily.
    Or
    PVC is a strong stiff material for the stand
    More detailed explanation or response.                                              2
    PVC is very dense compared to most plastics, with extremely good tensile
    strength suitable for the upright stand.
    Or
    PVC is readily available, fairly cheap to manufacture and easy to colour for the
    red tubing required.
    Or
    PVC has good strength weight ratio easy to collapse for portability, and is
    water / weather resistant for use outdoors.
    (ii) The tennis game needs to be easily assembled and disassembled. Explain         [2]
    how this has been achieved.
    Answers relating to how the tennis game can easily assembled and
    disassembled should be awarded up to 2 marks.

    Guidance:
     • Responses need to address the quickly erected and collapsed intention.
     • All joints are push fit, standard identical joints.
     • No specialist tools, equipment or knowledge needed.
     • All parts separate to fit inside storage / carry case.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    The PVC parts fit together tightly and quickly
    Or
    The tennis game is made up from a small number of PVC parts.
    More detailed explanation or response.                                              2
    There are individual parts which fit together easily without any fittings or
    fixtures and dismantle to fit inside in the base which becomes the carry case to
    be portable.

(iii) Explain two advantages of using injection moulding to make the ABS base 2x[2] and carry case. Answers relating to using injection moulding to make the ABS base and carry case should be awarded up to 2 x 2 marks.

    Guidance:
     • Look for two different answers.
     • Avoid double awarding similar responses.
     • ABS is a strong material, suitable for the injection moulding process to
        make this case.
     • Injection moulded ABS will be impact and water resistant, important
        features for the base / carry case.
     • Colour changes can easily be added by using different colour granules in
        the injection moulding process.
     • These are made in high volume – each is identical.
     • Economical production method for mass/volume.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response
    The ABS is a strong material for the base / case
    Or

    Is water resistant for outdoor use
    Or
    Can be filled with water to add weight to the base.
    More detailed explanation or response.
    The ABS is a robust, tough, strong and rigid material suitable for the knocks
    and bangs that the carry case / base might experience
    Or
    Injection moulding would be a quick and efficient process with no waste. Any
    defects could be reused in the next moulding.

    Or
    Due to injection moulding, all joints would be identical standard components
    with high quality assurance, perfect for large scale production.
    Or
    The manufacturer could change the colour easily / release special edition with
    a change in coloured granules using the same die / mould.

(iv) Analyse how the physical properties of nylon make it a suitable for the cord [3] attached to the tennis ball. Answers relating to the physical properties of nylon suitable for the cord should be awarded up to 3 marks.

    Guidance:
     • Look for explanation of nylon’s properties including lightweight for
        portability,
     • Woven into cord, flexible and high tensile strength.
     • Durable for outdoors, washable, synthetic material so does not fail quickly,
     • Soft on the hand, no sharp edges or hazards.
     • Abrasion resistant if hit / grazed with a bat.
     • Low friction.
     • Resistant to snapping or fraying despite under constant blows from bats.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The string will need to be strong to take the impact of the ball being hit at high
    speed or hard. Nylon is a strong material.                                             1
    Or
    Nylon is flexible and not too rigid.
    More detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break easily
    Or
    Nylon has excellent resistance to weathering; it does not corrode in wet               2
    conditions.
    Or
    Nylon if flexible, durable and strong with excellent abrasion resistance
    A highly detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break when the
    impact of the ball being hit occurs. Nylon is lightweight with excellent strength
    weight ratio.
    Or
    Nylon has excellent resistance to weathering, it does not corrode in wet               3
    conditions. It is sunlight resistant for use outdoors, and abrasion resistant if hit
    with one of the bats.
    Or
    Nylon if flexible so easy to fit when erecting the tennis game and folding flat /
    small into the carry case and is lightweight to carry for portability.

(v) Different parts of the product are manufactured in different countries and shipped to a central location for assembly. [4] Describe the winners and losers created by manufacturing in this way. Answers related to manufacturing in different countries and shipping to a central location for assembly should be awarded up to 4 marks. Answers must include winner/s and loser/s to achieve maximum 4 marks.

    Guidance:
     • Winners are consumers who get access to a cheaper product due to
        overseas manufacture.
     • Winners are local / overseas businesses who get contracted to produce
        parts, benefitting their economy.
     • Losers could be environment due to transporting parts from country of
        manufacture, to assembly and then on to retailer.
     • Losers could be workers in less economically developed countries who
        could be exploited
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail of winners and losers.
    Winners are local businesses where some parts might be made or sourced.
    Or                                                                                 1
    Losers are the environment / environmentalists because shipping involves
    energy usable.
    More detailed explanation with some explanation of winners and losers.
    Winners are the consumers who will be able to buy a cheaper product because
    the parts will be made competitively and therefore a lower RRP.
    Or                                                                                 2
    Losers are the local business because some parts are sourced elsewhere
    therefore trade is lost. Workers / jobs may be less than if all parts were made
    at same location.
    A detailed explanation including a number of explanations of impact on winners
    and losers.
    Winners would be suppliers who win contacts to provide parts, the country /
    government economy of the supplier would benefit from this trade. The buyer        3
    would get the product for a lower purchase price. Losers would be other
    suppliers or countries for not securing the trade and missing the opportunity to
    sell and make profit.
    A highly detailed and comprehensive explanation of both positive and negative
    impact on the consumer.
    The market would be competitive, and supplier would need to bid to secure the
    contract to supply. This would benefit the manufacturer to secure cheaper
    parts, and the end user would have to pay a lower purchase price. Losers

    would be other suppliers or countries for not securing the trade and missing the
    opportunity to sell and make profit. The environment would also be a loser due
    to shipping globally. Losers could be workers in one a less economically
    developed country where there could be workforce issues or poor pay /
    working conditions.

(vi) Explain why, initially, the manufacturer of the tennis game would produce a [3] limited number of products using batch production. Answers relating to reasons why a limited number of tennis games would be produced using batch production should be awarded up to 2 marks.

    Guidance:
     • Credit candidates identifying the reasons for batch production.
     • A limited edition version might be created, as an anniversary product /
        collector's item etc.
     • Testing the market if product is new.
     • Promoting an event e.g. a tennis tournament, so limited number ordered /
        made.
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail.

    To see if the product would sell / be popular without making too many.
    More detailed explanation.
    The manufacturer will be testing the market to ensure there is sufficient          2
    demand for the product.
    A detailed and full explanation
    The manufacturer will be anticipating the likely number of sales and making
    just enough to supply the demand. If demand is high, further batches or mass       3
    production would begin. If sales were low, no more products would be
    manufactured.

(a)(v)

(a)(v) Different parts of the product are manufactured in different countries and shipped to a central location for assembly.

Describe the winners and losers created by manufacturing in this way. [4]

[4]

Mark Scheme

(i) Describe the properties of PVC that make it a suitable  [2] material for the tubes used to create the upright stand. Answers relating to properties of PVC should be awarded up to 2 marks.

    Guidance:
     • Understanding of PVC including ability to be extruded in tubular form.
     • Collars / flared end to connect to similar tube components.
     • Economic to use, able to be manufactured in red (or other colours)
     • Flexible with good tensile strength to withstand forces as ball rotates
        around upright.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    PVC is strong and wouldn’t break easily.
    Or
    PVC is a strong stiff material for the stand
    More detailed explanation or response.                                              2
    PVC is very dense compared to most plastics, with extremely good tensile
    strength suitable for the upright stand.
    Or
    PVC is readily available, fairly cheap to manufacture and easy to colour for the
    red tubing required.
    Or
    PVC has good strength weight ratio easy to collapse for portability, and is
    water / weather resistant for use outdoors.
    (ii) The tennis game needs to be easily assembled and disassembled. Explain         [2]
    how this has been achieved.
    Answers relating to how the tennis game can easily assembled and
    disassembled should be awarded up to 2 marks.

    Guidance:
     • Responses need to address the quickly erected and collapsed intention.
     • All joints are push fit, standard identical joints.
     • No specialist tools, equipment or knowledge needed.
     • All parts separate to fit inside storage / carry case.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    The PVC parts fit together tightly and quickly
    Or
    The tennis game is made up from a small number of PVC parts.
    More detailed explanation or response.                                              2
    There are individual parts which fit together easily without any fittings or
    fixtures and dismantle to fit inside in the base which becomes the carry case to
    be portable.

(iii) Explain two advantages of using injection moulding to make the ABS base 2x[2] and carry case. Answers relating to using injection moulding to make the ABS base and carry case should be awarded up to 2 x 2 marks.

    Guidance:
     • Look for two different answers.
     • Avoid double awarding similar responses.
     • ABS is a strong material, suitable for the injection moulding process to
        make this case.
     • Injection moulded ABS will be impact and water resistant, important
        features for the base / carry case.
     • Colour changes can easily be added by using different colour granules in
        the injection moulding process.
     • These are made in high volume – each is identical.
     • Economical production method for mass/volume.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response
    The ABS is a strong material for the base / case
    Or

    Is water resistant for outdoor use
    Or
    Can be filled with water to add weight to the base.
    More detailed explanation or response.
    The ABS is a robust, tough, strong and rigid material suitable for the knocks
    and bangs that the carry case / base might experience
    Or
    Injection moulding would be a quick and efficient process with no waste. Any
    defects could be reused in the next moulding.

    Or
    Due to injection moulding, all joints would be identical standard components
    with high quality assurance, perfect for large scale production.
    Or
    The manufacturer could change the colour easily / release special edition with
    a change in coloured granules using the same die / mould.

(iv) Analyse how the physical properties of nylon make it a suitable for the cord [3] attached to the tennis ball. Answers relating to the physical properties of nylon suitable for the cord should be awarded up to 3 marks.

    Guidance:
     • Look for explanation of nylon’s properties including lightweight for
        portability,
     • Woven into cord, flexible and high tensile strength.
     • Durable for outdoors, washable, synthetic material so does not fail quickly,
     • Soft on the hand, no sharp edges or hazards.
     • Abrasion resistant if hit / grazed with a bat.
     • Low friction.
     • Resistant to snapping or fraying despite under constant blows from bats.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The string will need to be strong to take the impact of the ball being hit at high
    speed or hard. Nylon is a strong material.                                             1
    Or
    Nylon is flexible and not too rigid.
    More detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break easily
    Or
    Nylon has excellent resistance to weathering; it does not corrode in wet               2
    conditions.
    Or
    Nylon if flexible, durable and strong with excellent abrasion resistance
    A highly detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break when the
    impact of the ball being hit occurs. Nylon is lightweight with excellent strength
    weight ratio.
    Or
    Nylon has excellent resistance to weathering, it does not corrode in wet               3
    conditions. It is sunlight resistant for use outdoors, and abrasion resistant if hit
    with one of the bats.
    Or
    Nylon if flexible so easy to fit when erecting the tennis game and folding flat /
    small into the carry case and is lightweight to carry for portability.

(v) Different parts of the product are manufactured in different countries and shipped to a central location for assembly. [4] Describe the winners and losers created by manufacturing in this way. Answers related to manufacturing in different countries and shipping to a central location for assembly should be awarded up to 4 marks. Answers must include winner/s and loser/s to achieve maximum 4 marks.

    Guidance:
     • Winners are consumers who get access to a cheaper product due to
        overseas manufacture.
     • Winners are local / overseas businesses who get contracted to produce
        parts, benefitting their economy.
     • Losers could be environment due to transporting parts from country of
        manufacture, to assembly and then on to retailer.
     • Losers could be workers in less economically developed countries who
        could be exploited
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail of winners and losers.
    Winners are local businesses where some parts might be made or sourced.
    Or                                                                                 1
    Losers are the environment / environmentalists because shipping involves
    energy usable.
    More detailed explanation with some explanation of winners and losers.
    Winners are the consumers who will be able to buy a cheaper product because
    the parts will be made competitively and therefore a lower RRP.
    Or                                                                                 2
    Losers are the local business because some parts are sourced elsewhere
    therefore trade is lost. Workers / jobs may be less than if all parts were made
    at same location.
    A detailed explanation including a number of explanations of impact on winners
    and losers.
    Winners would be suppliers who win contacts to provide parts, the country /
    government economy of the supplier would benefit from this trade. The buyer        3
    would get the product for a lower purchase price. Losers would be other
    suppliers or countries for not securing the trade and missing the opportunity to
    sell and make profit.
    A highly detailed and comprehensive explanation of both positive and negative
    impact on the consumer.
    The market would be competitive, and supplier would need to bid to secure the
    contract to supply. This would benefit the manufacturer to secure cheaper
    parts, and the end user would have to pay a lower purchase price. Losers

    would be other suppliers or countries for not securing the trade and missing the
    opportunity to sell and make profit. The environment would also be a loser due
    to shipping globally. Losers could be workers in one a less economically
    developed country where there could be workforce issues or poor pay /
    working conditions.

(vi) Explain why, initially, the manufacturer of the tennis game would produce a [3] limited number of products using batch production. Answers relating to reasons why a limited number of tennis games would be produced using batch production should be awarded up to 2 marks.

    Guidance:
     • Credit candidates identifying the reasons for batch production.
     • A limited edition version might be created, as an anniversary product /
        collector's item etc.
     • Testing the market if product is new.
     • Promoting an event e.g. a tennis tournament, so limited number ordered /
        made.
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail.

    To see if the product would sell / be popular without making too many.
    More detailed explanation.
    The manufacturer will be testing the market to ensure there is sufficient          2
    demand for the product.
    A detailed and full explanation
    The manufacturer will be anticipating the likely number of sales and making
    just enough to supply the demand. If demand is high, further batches or mass       3
    production would begin. If sales were low, no more products would be
    manufactured.

(a)(vi)

(a)(vi) Explain why, initially, the manufacturer of the tennis game would produce a limited number of products using batch production. [3]

[3]

Mark Scheme

(i) Describe the properties of PVC that make it a suitable  [2] material for the tubes used to create the upright stand. Answers relating to properties of PVC should be awarded up to 2 marks.

    Guidance:
     • Understanding of PVC including ability to be extruded in tubular form.
     • Collars / flared end to connect to similar tube components.
     • Economic to use, able to be manufactured in red (or other colours)
     • Flexible with good tensile strength to withstand forces as ball rotates
        around upright.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    PVC is strong and wouldn’t break easily.
    Or
    PVC is a strong stiff material for the stand
    More detailed explanation or response.                                              2
    PVC is very dense compared to most plastics, with extremely good tensile
    strength suitable for the upright stand.
    Or
    PVC is readily available, fairly cheap to manufacture and easy to colour for the
    red tubing required.
    Or
    PVC has good strength weight ratio easy to collapse for portability, and is
    water / weather resistant for use outdoors.
    (ii) The tennis game needs to be easily assembled and disassembled. Explain         [2]
    how this has been achieved.
    Answers relating to how the tennis game can easily assembled and
    disassembled should be awarded up to 2 marks.

    Guidance:
     • Responses need to address the quickly erected and collapsed intention.
     • All joints are push fit, standard identical joints.
     • No specialist tools, equipment or knowledge needed.
     • All parts separate to fit inside storage / carry case.
    No answer or no relevant information presented or discussed.                        0
    Simplistic or basic response                                                        1
    The PVC parts fit together tightly and quickly
    Or
    The tennis game is made up from a small number of PVC parts.
    More detailed explanation or response.                                              2
    There are individual parts which fit together easily without any fittings or
    fixtures and dismantle to fit inside in the base which becomes the carry case to
    be portable.

(iii) Explain two advantages of using injection moulding to make the ABS base 2x[2] and carry case. Answers relating to using injection moulding to make the ABS base and carry case should be awarded up to 2 x 2 marks.

    Guidance:
     • Look for two different answers.
     • Avoid double awarding similar responses.
     • ABS is a strong material, suitable for the injection moulding process to
        make this case.
     • Injection moulded ABS will be impact and water resistant, important
        features for the base / carry case.
     • Colour changes can easily be added by using different colour granules in
        the injection moulding process.
     • These are made in high volume – each is identical.
     • Economical production method for mass/volume.
    No answer or no relevant information presented or discussed.                      0
    Simplistic or basic response
    The ABS is a strong material for the base / case
    Or

    Is water resistant for outdoor use
    Or
    Can be filled with water to add weight to the base.
    More detailed explanation or response.
    The ABS is a robust, tough, strong and rigid material suitable for the knocks
    and bangs that the carry case / base might experience
    Or
    Injection moulding would be a quick and efficient process with no waste. Any
    defects could be reused in the next moulding.

    Or
    Due to injection moulding, all joints would be identical standard components
    with high quality assurance, perfect for large scale production.
    Or
    The manufacturer could change the colour easily / release special edition with
    a change in coloured granules using the same die / mould.

(iv) Analyse how the physical properties of nylon make it a suitable for the cord [3] attached to the tennis ball. Answers relating to the physical properties of nylon suitable for the cord should be awarded up to 3 marks.

    Guidance:
     • Look for explanation of nylon’s properties including lightweight for
        portability,
     • Woven into cord, flexible and high tensile strength.
     • Durable for outdoors, washable, synthetic material so does not fail quickly,
     • Soft on the hand, no sharp edges or hazards.
     • Abrasion resistant if hit / grazed with a bat.
     • Low friction.
     • Resistant to snapping or fraying despite under constant blows from bats.
    No answer or no relevant information presented or discussed.                           0
    Simplistic or basic response
    The string will need to be strong to take the impact of the ball being hit at high
    speed or hard. Nylon is a strong material.                                             1
    Or
    Nylon is flexible and not too rigid.
    More detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break easily
    Or
    Nylon has excellent resistance to weathering; it does not corrode in wet               2
    conditions.
    Or
    Nylon if flexible, durable and strong with excellent abrasion resistance
    A highly detailed explanation or response.
    Nylon has good tensile strength and will not deform or snap / break when the
    impact of the ball being hit occurs. Nylon is lightweight with excellent strength
    weight ratio.
    Or
    Nylon has excellent resistance to weathering, it does not corrode in wet               3
    conditions. It is sunlight resistant for use outdoors, and abrasion resistant if hit
    with one of the bats.
    Or
    Nylon if flexible so easy to fit when erecting the tennis game and folding flat /
    small into the carry case and is lightweight to carry for portability.

(v) Different parts of the product are manufactured in different countries and shipped to a central location for assembly. [4] Describe the winners and losers created by manufacturing in this way. Answers related to manufacturing in different countries and shipping to a central location for assembly should be awarded up to 4 marks. Answers must include winner/s and loser/s to achieve maximum 4 marks.

    Guidance:
     • Winners are consumers who get access to a cheaper product due to
        overseas manufacture.
     • Winners are local / overseas businesses who get contracted to produce
        parts, benefitting their economy.
     • Losers could be environment due to transporting parts from country of
        manufacture, to assembly and then on to retailer.
     • Losers could be workers in less economically developed countries who
        could be exploited
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail of winners and losers.
    Winners are local businesses where some parts might be made or sourced.
    Or                                                                                 1
    Losers are the environment / environmentalists because shipping involves
    energy usable.
    More detailed explanation with some explanation of winners and losers.
    Winners are the consumers who will be able to buy a cheaper product because
    the parts will be made competitively and therefore a lower RRP.
    Or                                                                                 2
    Losers are the local business because some parts are sourced elsewhere
    therefore trade is lost. Workers / jobs may be less than if all parts were made
    at same location.
    A detailed explanation including a number of explanations of impact on winners
    and losers.
    Winners would be suppliers who win contacts to provide parts, the country /
    government economy of the supplier would benefit from this trade. The buyer        3
    would get the product for a lower purchase price. Losers would be other
    suppliers or countries for not securing the trade and missing the opportunity to
    sell and make profit.
    A highly detailed and comprehensive explanation of both positive and negative
    impact on the consumer.
    The market would be competitive, and supplier would need to bid to secure the
    contract to supply. This would benefit the manufacturer to secure cheaper
    parts, and the end user would have to pay a lower purchase price. Losers

    would be other suppliers or countries for not securing the trade and missing the
    opportunity to sell and make profit. The environment would also be a loser due
    to shipping globally. Losers could be workers in one a less economically
    developed country where there could be workforce issues or poor pay /
    working conditions.

(vi) Explain why, initially, the manufacturer of the tennis game would produce a [3] limited number of products using batch production. Answers relating to reasons why a limited number of tennis games would be produced using batch production should be awarded up to 2 marks.

    Guidance:
     • Credit candidates identifying the reasons for batch production.
     • A limited edition version might be created, as an anniversary product /
        collector's item etc.
     • Testing the market if product is new.
     • Promoting an event e.g. a tennis tournament, so limited number ordered /
        made.
    No answer or no relevant information presented or discussed.                       0
    Description with some explanation and some detail.

    To see if the product would sell / be popular without making too many.
    More detailed explanation.
    The manufacturer will be testing the market to ensure there is sufficient          2
    demand for the product.
    A detailed and full explanation
    The manufacturer will be anticipating the likely number of sales and making
    just enough to supply the demand. If demand is high, further batches or mass       3
    production would begin. If sales were low, no more products would be
    manufactured.

(b)

(b) Rather than extrude 300 mm red PVC tubes for the upright stand, the manufacturer decided to purchase 3.1 m lengths of standard 30 mm diameter tubing from an external source.

Explain how this will benefit the manufacturer when producing the tennis game. [3]

[3]

(c)(i)

(c) The manufacturer uses a semi-automated production line when making the parts for the tennis game.

(i) Describe the benefits to the manufacturer of using a semi-automated production line. [2]

[2]

Mark Scheme

(i) Describe the benefits to the manufacturer of using a semi-automated [2] production line. Answers relating to the benefits of a semi-automated production line should be awarded up to 2 marks.

    Guidance:
     • Benefits must be related to manufacturer as a result of automation.
     • Increased reliability, continuous flow production as a result of less workers
        required,
     • increased productivity,
     • increased efficiency less mistakes errors or rejects.
    No answer or no relevant information presented or discussed.                       0
    Simplistic or basic response
    Automation will replace manual worker with machines
    Or

    Automation will be more accurate than workers
    Or
    Semi-automated will be quicker than manual.
    More detailed explanation or response.
    Using semi automation will increase accuracy and less money is spent on
    workers' wages.

    Or
    Slight changes can be made easily and quickly by adjusting automated
    machine set up or operations.
    (ii) Explain why the manufacturer uses manual workers as part of the
                                                                                       [2]
    production process.
    Answers relating to the need for some manual workers should be awarded up
    to 2 marks.
    Guidance:
     • Manual workers will be need to operate / monitor machinery.
     • Manual workers will need to oversee production and quality control / check      0
         outcomes for defects.
     • Manual workers would be needed to interrupt production in case of a fault.
     • Manual workers would need to ensure machinery is running safely and
         operational.
    No answer or no relevant information presented or discussed.                       0
    Simplistic or basic response
    Automation cannot replace all workers
    Or

    Some workers will still be needed to check machinery
    Or
    Some workers will need to check quality of product.
    More detailed explanation or response.
    Some manual workers will be required to carry out basic operations and check

    productivity. Some decisions require humans, machinery cannot operate
    complete production lines.
                                                                              Total    25

3603U10-1 GCSE Design and Technology - Product Design MS S19/DM

(c)(ii)

(c) The manufacturer uses a semi-automated production line when making the parts for the tennis game.

(ii) Explain why the manufacturer uses manual workers as part of the production process. [2]

[2]

Mark Scheme

(i) Describe the benefits to the manufacturer of using a semi-automated [2] production line. Answers relating to the benefits of a semi-automated production line should be awarded up to 2 marks.

    Guidance:
     • Benefits must be related to manufacturer as a result of automation.
     • Increased reliability, continuous flow production as a result of less workers
        required,
     • increased productivity,
     • increased efficiency less mistakes errors or rejects.
    No answer or no relevant information presented or discussed.                       0
    Simplistic or basic response
    Automation will replace manual worker with machines
    Or

    Automation will be more accurate than workers
    Or
    Semi-automated will be quicker than manual.
    More detailed explanation or response.
    Using semi automation will increase accuracy and less money is spent on
    workers' wages.

    Or
    Slight changes can be made easily and quickly by adjusting automated
    machine set up or operations.
    (ii) Explain why the manufacturer uses manual workers as part of the
                                                                                       [2]
    production process.
    Answers relating to the need for some manual workers should be awarded up
    to 2 marks.
    Guidance:
     • Manual workers will be need to operate / monitor machinery.
     • Manual workers will need to oversee production and quality control / check      0
         outcomes for defects.
     • Manual workers would be needed to interrupt production in case of a fault.
     • Manual workers would need to ensure machinery is running safely and
         operational.
    No answer or no relevant information presented or discussed.                       0
    Simplistic or basic response
    Automation cannot replace all workers
    Or

    Some workers will still be needed to check machinery
    Or
    Some workers will need to check quality of product.
    More detailed explanation or response.
    Some manual workers will be required to carry out basic operations and check

    productivity. Some decisions require humans, machinery cannot operate
    complete production lines.
                                                                              Total    25

3603U10-1 GCSE Design and Technology - Product Design MS S19/DM