Question 1: Explain why aluminium is a good choice for manufacturing a lightweight bicycle frame.

Answer: Aluminium is lightweight, strong, resistant to corrosion, and easy to shape, making it ideal for bicycle frames where weight reduction and strength are important.

Question 2: A company wants to design a durable outdoor bench that can withstand weather conditions. Which material would you recommend and why?

Answer: I would recommend treated timber or stainless steel because they are durable, weather-resistant, and require minimal maintenance for outdoor use.

Question 3: Describe three key properties you would look for in selecting a material for making a food storage container.

Answer: Properties should include being food-safe (non-toxic), resistant to corrosion or staining, and having good barrier properties to preserve food freshness.

Question 4: Design Brief: You need to create a lightweight, portable luggage handle that can withstand frequent use. Which material would you choose and why?

Answer: A suitable choice would be reinforced plastic or aluminium because they are lightweight, durable, and resistant to impact and corrosion.

Question 5: Sketch a design for a ergonomic handle for a garden tool. Label the key features that make it comfortable to hold.

Answer: A correct sketch would show an oval or contoured handle with soft grip areas, possibly with textured surfaces for grip, and a shape that fits comfortably in the hand.

Question 6: Identify and explain two reasons why plastics are often used in consumer products.

Answer: Plastics are versatile because they can be easily moulded into complex shapes and are generally lightweight, making them ideal for various consumer products.

Question 7: Draw a plan for a small, eco-friendly storage box. Indicate the choice of material and justify your selection.

Answer: A plan should show a simple box with a lid, made from sustainable wood or recycled cardboard. The justification should mention environmental benefits, strength, and recyclability.

Question 8: A manufacturer wants to produce a high-strength, impact-resistant helmet. Which material would you recommend and why?

Answer: Polycarbonate plastic would be recommended because it is impact-resistant, strong, and lightweight.

Question 9: Explain the difference between thermoplastics and thermosetting plastics, including one example of each.

Answer: Thermoplastics can be melted and reshaped multiple times, e.g., polypropylene. Thermosetting plastics set permanently when heated and cannot be reshaped, e.g., epoxy resin.

Question 10: Design Brief: You are tasked with creating a decorative lamp that uses minimal energy. Suggest a suitable material for the lamp's outer casing and explain your choice.

Answer: Recycled plastic or glass would be suitable due to their aesthetic qualities, light weight, and potential for good heat resistance. Recycled materials also support sustainability.