Question 1: Explain why plastics are commonly used in the manufacture of consumer electronic casings. Include at least two properties that make plastics suitable for this purpose.

Answer: Plastics are used because they are lightweight and can be easily molded into complex shapes. They are also generally cost-effective and provide good insulation for electronic components.

Question 2: A designer needs to create a lightweight, durable bicycle frame. Which material would you recommend: aluminium, steel, or carbon fibre? Justify your choice based on material properties.

Answer: Carbon fibre would be recommended because it is very lightweight and strong, making it ideal for a durable yet lightweight bicycle frame.

Question 3: Describe two environmental considerations that should influence the choice of materials in sustainable product design.

Answer: Considerations include the environmental impact of extracting and processing the material, and whether the material is recyclable or biodegradable.

Question 4: Imagine you are designing a children's toy that needs to be safe, durable, and colorful. Which material would you choose and why?

Answer: A suitable material would be a non-toxic plastic such as ABS because it is safe, durable, and can be produced in various colors.

Question 5: Sketch a simple plan for a phone case that uses recycled plastic material. Label key features of your design and explain why recycled plastic is appropriate.

Answer: A sketch should show a basic phone case outline with features such as a textured grip and cutouts for buttons. Labels should indicate the use of recycled plastic, highlighting its environmental benefits and suitability for molding.

Question 6: Identify and explain two advantages and two disadvantages of using wood as a material in furniture design.

Answer: Advantages include its natural appearance and ease of working with tools. Disadvantages include susceptibility to moisture and potential for warping over time.

Question 7: A company wants to produce a waterproof outdoor storage box. Which material would be most suitable and why? Consider properties such as water resistance and durability.

Answer: Polypropylene or another durable plastic would be suitable because it is water-resistant, weatherproof, and resistant to corrosion and rot.

Question 8: Draw a cross-section of a metal component that could be used in a structural frame. Your sketch should include the shape of the cross-section and indicate any features that improve strength.

Answer: A correct sketch would show a simple cross-section such as an I-beam or rectangular tube, with labels pointing out features like flanges or reinforcement ribs that improve structural strength.

Question 9: What are the main differences between natural and synthetic materials? Provide two examples of each and their typical applications.

Answer: Natural materials are obtained from nature, e.g., wood (used in furniture) and cotton (used in textiles). Synthetic materials are man-made, e.g., plastic (used in packaging) and nylon (used in textiles).

Question 10: Propose a material suitable for a lightweight, high-performance sports shoe sole. Justify your choice based on properties such as weight, durability, and grip.

Answer: EVA foam or rubber would be suitable because they are lightweight, provide good cushioning and grip, and are durable enough for sports activities.