Question 1: Define the term 'material properties' and explain why they are important when selecting materials for a product.

Answer: Material properties are characteristics such as strength, flexibility, durability, and weight that determine how a material behaves. They are important because they influence the product's functionality, safety, and suitability for its intended use.

Question 2: A manufacturer wants to produce a lightweight bicycle frame that is strong and resistant to corrosion. Which material would be most suitable: aluminium, steel, or plastic? Justify your choice.

Answer: Aluminium would be most suitable because it is lightweight, strong, and resistant to corrosion, making it ideal for bicycle frames.

Question 3: Describe two advantages and two disadvantages of using timber as a material for furniture making.

Answer: Advantages: 1) Timber is renewable and environmentally friendly. 2) It has a natural aesthetic and is easy to work with. Disadvantages: 1) It can be susceptible to warping and insect attack. 2) It is less durable compared to some metals or plastics.

Question 4: Sketch a simple design for a plastic storage container that needs to be stackable and durable. Label key features such as the walls, lid, and stacking mechanism.

Answer: A correct sketch would show a rectangular container with reinforced walls, a secure snap-on lid, and features like indentations or ledges on the lid and base to allow stacking. Labels should identify these features clearly.

Question 5: A company wants to develop a waterproof, flexible phone case. Which material(s) would you recommend? Explain your reasoning.

Answer: Silicone or thermoplastic elastomers would be suitable because they are flexible, waterproof, and provide good shock absorption, protecting the phone.

Question 6: Explain the difference between thermoplastics and thermosetting plastics, including their reusability and typical applications.

Answer: Thermoplastics can be melted and remoulded multiple times without changing their properties, making them reusable; they are used for containers, toys, and packaging. Thermosetting plastics, once cured, cannot be remelted or reshaped; they are used in electronic components and adhesives due to their heat resistance and strength.

Question 7: Design a plan for testing the suitability of a new composite material intended for sports equipment. Outline at least three tests you would perform.

Answer: Tests could include: 1) Tensile strength test to assess durability. 2) Impact resistance test to evaluate shock absorption. 3) Weathering test to determine resistance to environmental factors like moisture and UV exposure.

Question 8: Identify a scenario where bamboo could be a better material choice than metal. Justify your answer based on material properties.

Answer: Bamboo would be better for eco-friendly furniture or flooring because it is lightweight, renewable, has good strength, and is resistant to pests and moisture when treated properly.

Question 9: Draw a cross-section of a multi-layered packaging material designed to protect fragile items during transit. Label the layers and explain their functions.

Answer: A correct drawing would show multiple layers: an outer layer of corrugated cardboard for structural support, a middle layer of foam or bubble wrap for cushioning, and an inner liner of soft plastic or paper for surface protection. Labels should specify each layer and its purpose.

Question 10: Propose a material that would be suitable for a lightweight, heat-resistant cookware handle. Explain your choice and mention any properties that support your decision.

Answer: Silicone or high-temperature plastics are suitable because they are lightweight, heat-resistant, and provide a good grip, ensuring user safety and comfort.