Question 1: A company wants to design a lightweight bicycle frame that is strong and resistant to corrosion. Which material would be most suitable, and why? Provide at least two reasons for your choice.

Answer: A suitable material could be aluminium alloy because it is lightweight and corrosion-resistant. Reasons include its high strength-to-weight ratio and good resistance to rust, making it ideal for outdoor use.

Question 2: Identify a material suitable for making a handle that needs to be both comfortable to hold and durable. Explain your reasoning.

Answer: Plastic, such as polypropylene, could be suitable because it can be molded into ergonomic shapes and provides a comfortable grip. It is also durable and resistant to impact.

Question 3: A designer needs to create a decorative jewelry box that is visually appealing and easy to manufacture. Which material would you recommend and why?

Answer: Wood, such as oak or cherry, could be recommended because it has an attractive natural appearance and is easy to carve or finish, making it suitable for decorative purposes.

Question 4: Describe a scenario where a composite material would be preferred over a pure metal or plastic. Explain the benefits.

Answer: A scenario could be designing a lightweight, high-strength sports helmet. A composite material like carbon fibre reinforced plastic would be preferred because it offers high strength and stiffness while remaining lightweight, providing better protection without adding bulk.

Question 5: Sketch a simple design for a reusable coffee cup, indicating the materials you would use for the outer shell, inner lining, and handle. Make sure your sketch shows the overall shape and the different parts.

Answer: A correct sketch would show a cylindrical cup shape with a separate handle attached to the side. The outer shell could be drawn with a label indicating plastic or metal, the inner lining with a label for thermal-resistant plastic or silicone, and the handle with a material that provides insulation, such as rubber or silicone.

Question 6: Design a small, portable storage container for electronic components that needs to be lightweight, sturdy, and resistant to moisture. Draw your plan and label the materials you would choose for each part.

Answer: The drawing should depict a rectangular container with a lid. Labels should specify plastic for the main body, rubber or silicone for seals to prevent moisture ingress, and possibly metal clasps for secure closure.

Question 7: A manufacturer wants to produce a set of outdoor garden furniture that is weatherproof and requires minimal maintenance. Which material would you suggest and why?

Answer: Recycled plastic or treated wood (such as teak) would be suitable because they are weatherproof and require minimal maintenance due to their resistance to rot and moisture.

Question 8: Explain the advantages of using biodegradable materials in product design. Provide an example of a product that could benefit from this choice.

Answer: Biodegradable materials decompose naturally, reducing environmental impact and waste. An example could be packaging materials or disposable cutlery, which would benefit from being environmentally friendly and reducing landfill waste.