Question 1: Describe three common properties of metals that make them suitable for manufacturing structural components.

Answer: Metals are typically strong, durable, and malleable, allowing them to withstand loads and be shaped into various forms while maintaining structural integrity.

Question 2: Explain the main difference between thermoplastics and thermosetting plastics in terms of their properties and usage.

Answer: Thermoplastics can be melted and reshaped multiple times because they soften when heated; thermosetting plastics harden permanently after curing and cannot be remelted. Thermoplastics are used for flexible, recyclable products, while thermosets are used for heat-resistant, durable items.

Question 3: A designer needs to create a lightweight, flexible, and transparent product, such as a face shield. Which material type would you recommend and why?

Answer: A suitable material would be a clear thermoplastic, such as PET or polycarbonate, because they are lightweight, flexible, and transparent, making them ideal for protective visors.

Question 4: Identify two advantages and two disadvantages of using wood as a material in product design.

Answer: Advantages: It is renewable and easy to shape. Disadvantages: It can be affected by moisture and may warp or rot over time.

Question 5: Describe how the property of thermal conductivity affects the choice of material for a cooking pan.

Answer: A good thermal conductor, like aluminum or copper, allows heat to distribute evenly across the pan, making cooking more efficient and preventing hot spots.

Question 6: Sketch a simple cross-section of a composite material used for sports equipment, such as a tennis racket. Label the key layers and their properties.

Answer: A correct sketch would show an outer layer of a durable material like carbon fiber, with an inner core of foam or resin for flexibility and shock absorption. Labels should include 'outer layer: carbon fiber - strong and lightweight' and 'inner core: foam/resin - shock-absorbing and lightweight.'

Question 7: Design a small container that needs to be both waterproof and lightweight. Which material would you choose and why? Include a brief explanation in your answer.

Answer: I would choose a high-density polyethylene (HDPE) plastic because it is waterproof, lightweight, and resistant to impact and chemicals, making it suitable for a waterproof container.

Question 8: Create a plan for testing the strength of a new plastic material intended for use in a load-bearing product. What tests would you include?

Answer: Tests should include tensile testing to measure how much pulling force the material can withstand, impact testing to assess resistance to sudden shocks, and flexural testing to evaluate bending strength.

Question 9: Sketch a concept design for a lightweight, durable handle for a hand tool. Show the shape and suggest a suitable material based on its properties.

Answer: A good sketch would depict an ergonomic, contoured handle with a textured surface for grip. The material could be a reinforced plastic or lightweight metal like aluminum, chosen for strength, weight, and comfort.

Question 10: Explain why the choice of material is critical when designing a product that will be exposed to outdoor weather conditions.

Answer: Materials must resist corrosion, moisture, UV radiation, and temperature changes to ensure durability and safety over time. Examples include stainless steel, treated wood, or UV-resistant plastics.