Question 1: Describe the process of how a vacuum forming technique is used to create a plastic product. Include the main steps involved.

Answer: A sheet of thermoplastic is heated until malleable, then stretched over a mould in a vacuum chamber. The vacuum pulls the plastic tightly around the mould, and once cooled, the formed product is trimmed and finished.

Question 2: Explain the advantages of using CNC machining over manual carving when producing complex components.

Answer: CNC machining offers higher precision, consistency, faster production times, and the ability to produce complex geometries that are difficult to achieve manually.

Question 3: Identify three different methods of joining two metal parts together and briefly describe each.

Answer: Welding - melting and fusing metal parts together; Riveting - using metal fasteners to hold parts; Bolting - joining with threaded fasteners allowing disassembly.

Question 4: Sketch a simple ergonomic handle for a handheld tool. Include the shape and any features that improve grip comfort.

Answer: A sketch showing a handle with a contoured, rounded shape that fits comfortably in the palm, with textured areas on the grip for slip resistance. The handle should taper towards the end for better control.

Question 5: List and briefly explain three finishing techniques used to improve the surface quality of manufactured plastic products.

Answer: Sanding - smoothing surfaces using abrasive materials; Polishing - buffing to achieve a glossy finish; Painting or coating - applying a protective or decorative layer.

Question 6: What are the key considerations when selecting materials for a product that will undergo repeated mechanical stress?

Answer: Material strength, durability, fatigue resistance, and suitability for the specific load conditions are crucial factors.

Question 7: Draw a plan for a small prototype container made from cardboard that demonstrates a folding lid. Show the main components and how they connect.

Answer: A plan sketch showing a rectangular base with fold lines for the sides and lid. The lid should be attached with a fold or hinge line, indicating where it opens and closes.

Question 8: Describe how a soldering iron is used in the making process of electronic products. Include safety precautions that should be taken.

Answer: A soldering iron heats up to melt solder, which is used to connect electronic components on a circuit board. Safety precautions include wearing eye protection, working in a ventilated area, and handling the hot iron carefully.

Question 9: Identify three different waste minimisation strategies during the manufacturing process and explain how they benefit the environment.

Answer: Using material efficiently to reduce scrap; Recycling scrap materials; Designing products for easy disassembly and recycling, all reducing waste and environmental impact.