Question 1: Explain the process of injection moulding and identify two advantages of using this technique for producing plastic components.

Answer: Injection moulding involves injecting molten plastic into a metal mould cavity, allowing it to cool and solidify into the desired shape. Advantages include high production speed and the ability to produce complex shapes with high precision.

Question 2: Describe the key steps involved in casting a metal object. Include preparation, pouring, and finishing processes.

Answer: The process involves creating a mould, melting the metal and pouring it into the mould, allowing it to cool and solidify, then removing the mould and performing finishing touches such as grinding or polishing.

Question 3: Sketch a simple cross-sectional diagram of a product manufactured using extrusion. Label the key parts of the extrusion process.

Answer: A correct sketch would show a heated metal or plastic material being pushed through a die with a specific profile, resulting in a continuous shape. Labels should include the feedstock, die, and extruded profile.

Question 4: Design Brief: You need to create a lightweight, durable handle for a handheld tool. Which manufacturing technique would you choose and why?

Answer: A suitable technique might be injection moulding because it allows for creating complex, ergonomic shapes with high strength-to-weight ratios, suitable for durable handles.

Question 5: Identify and explain two common finishing techniques used to improve the surface quality of a manufactured product.

Answer: Two finishing techniques are polishing, which smooths the surface and enhances appearance, and grinding, which removes rough edges or excess material to achieve precise dimensions.

Question 6: Draw a simple plan of a product made using CNC machining, showing the main features such as the tool path and cut areas.

Answer: A correct sketch would depict a top-down view of a part with indicated tool paths, cut regions, and annotations showing the machining process, such as drilled holes or cutouts.

Question 7: Explain how welding can be used to join metal parts together. Mention at least two types of welding methods.

Answer: Welding involves melting the edges of metal parts and fusing them together, often with filler material. Two common types are arc welding and MIG welding, both creating strong joints through heat and electrical arc processes.

Question 8: Design Brief: You are tasked with creating a small, decorative metal sculpture. Which technique would be most suitable for shaping the metal, and why?

Answer: Metal forging would be suitable because it allows shaping metal by hammering at high temperatures, enabling detailed and artistic forms suitable for sculptures.

Question 9: Describe the purpose of a jig or fixture in the manufacturing process. How do they improve production quality?

Answer: Jigs and fixtures hold and guide tools or workpieces during manufacturing, ensuring consistent position and accuracy, which improves the quality and repeatability of the outputs.

Question 10: Sketch a plan for a product that requires bending metal components. Indicate the areas where bending should occur and the tools used.

Answer: A correct sketch would show a flat metal sheet with marked bend lines, and annotations indicating the use of a bending brake or press brake to make the bends at specified points.

Question 11: Explain the difference between subtractive and additive manufacturing techniques, providing an example of each.

Answer: Subtractive manufacturing involves removing material from a solid block to create the final shape, such as CNC milling. Additive manufacturing builds objects by adding material layer by layer, such as 3D printing.