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

Answer: Metals are strong, durable, and have high tensile strength, making them suitable for structural parts. They are also malleable and ductile, allowing them to be shaped without breaking.

Question 2: Explain why plastics are often chosen for consumer products instead of metals.

Answer: Plastics are lightweight, inexpensive, easy to mould, and resistant to corrosion, making them ideal for consumer products. They can also be produced in a variety of colours and finishes.

Question 3: Identify two environmental impacts associated with the use of non-biodegradable materials in product design.

Answer: Non-biodegradable materials contribute to landfill waste and can cause environmental pollution, harming wildlife and ecosystems.

Question 4: Design Brief: A company needs a lightweight, strong, and environmentally friendly material for a new bicycle frame. Which material would you recommend and why?

Answer: I would recommend using a high-strength aluminium alloy because it is lightweight, strong, and recyclable, making it environmentally friendly.

Question 5: Sketch a cross-sectional diagram of a composite material used in sports equipment. Label the different layers and briefly describe their properties.

Answer: A correct sketch would show a layered structure with a tough outer shell (for impact resistance) and a lightweight core (for strength and weight reduction). Labels should include 'outer layer' (e.g., carbon fibre or resin), 'core' (e.g., foam or honeycomb), and 'adhesive layer'.

Question 6: Draw a simple plan for a product casing made from insulating material. Ensure your sketch includes the shape and any features that improve insulation.

Answer: A plan should show a box-like shape with thick walls, possibly with ribbing or air gaps to improve insulation. The sketch should be clear, with a focus on the thickness and features that enhance thermal insulation.

Question 7: List two properties of ceramics that make them suitable for use in electrical insulators.

Answer: Ceramics are good electrical insulators and can withstand high temperatures without melting or degrading.

Question 8: Explain the difference between thermoplastics and thermosetting plastics in terms of their properties and applications.

Answer: Thermoplastics can be melted and remoulded multiple times, making them suitable for flexible manufacturing and recycling. Thermosetting plastics, once set, cannot be remelted; they are hard, heat-resistant, and used in permanent fixtures like electrical insulators.