Question 1: Describe three physical properties of metals that make them suitable for structural components in products.

Answer: Metals are strong, durable, and have high tensile strength, making them suitable for load-bearing parts. They also have good thermal and electrical conductivity, and are malleable and ductile, allowing them to be shaped into various forms.

Question 2: Explain two advantages and two disadvantages of using plastics in product design.

Answer: Advantages include being lightweight and versatile, allowing for complex shapes. Disadvantages include environmental concerns due to non-biodegradability and potential degradation of mechanical properties over time.

Question 3: Identify a material that is suitable for making a container that needs to be lightweight, transparent, and resistant to chemicals. Justify your choice.

Answer: Polycarbonate is suitable because it is lightweight, transparent, and resistant to chemicals and impact, making it ideal for chemical containers.

Question 4: Design Brief: A company wants to produce a durable, lightweight bicycle helmet that provides comfort and protection. Sketch a rough design of the outer shell, indicating the type of material you would choose and why.

Answer: A sketch showing the shape of a helmet with a label pointing to the outer shell. The material chosen should be expanded polystyrene (EPS) or polycarbonate, justified by its impact resistance, lightweight nature, and cushioning properties.

Question 5: Draw a cross-section of a wooden chair leg, labeling the type of wood you would suggest and explaining its properties that make it suitable.

Answer: A cross-section sketch showing the shape of the leg. The wood should be a hardwood like oak or beech, noted for its strength, hardness, and durability, making it suitable for supporting weight.

Question 6: List and describe two thermal properties of ceramics that are important in their use in products.

Answer: Ceramics have high thermal resistance, meaning they can withstand high temperatures without deforming. They also have low thermal conductivity, making them good insulators.

Question 7: Suggest a material suitable for a flexible, stretchable wristband for a fitness tracker and justify your choice.

Answer: Silicone rubber is suitable because it is flexible, elastic, hypoallergenic, and resistant to sweat and environmental factors.

Question 8: Identify a material that is environmentally friendly and suitable for packaging food. Justify your answer.

Answer: Recycled cardboard or paperboard is environmentally friendly, biodegradable, and suitable for packaging food due to its lightweight nature and ease of printing.

Question 9: Design Brief: A manufacturer needs to produce a lightweight and strong handle for a tool that will be used outdoors in wet conditions. Sketch a handle design, indicating the choice of material and its properties.

Answer: A sketch of an ergonomic handle with a grip pattern. The material could be rubber-coated aluminium or a polymer composite, justified by its strength, lightweight nature, and resistance to water and corrosion.