Question 1: Describe a common manufacturing technique used to produce plastic objects in large quantities. Include the basic steps involved.

Answer: Injection moulding is a common technique. It involves heating plastic until molten, injecting it into a metal mould under pressure, allowing it to cool and solidify, then ejecting the finished part.

Question 2: Explain the process of using a laser cutter to produce a small metal or acrylic component. Highlight the key stages involved.

Answer: The process involves designing the shape digitally, setting the laser cutter with appropriate parameters, positioning the material, and then using the laser to cut along the design lines with precision. The cut pieces are then removed and finished if needed.

Question 3: Sketch a simple design for a ergonomic handle for a kitchen utensil. Label the main features that improve comfort.

Answer: A correct sketch would show a handle with a contoured shape fitting comfortably in the hand, with textured grip areas, and possibly a finger indentation for better control.

Question 4: Draw a plan for assembling a small wooden box with a lid. Include the main components and how they fit together.

Answer: The plan should include a rectangular base, four sides with joints (e.g., dovetail or butt joints), and a lid that fits over the top. The drawing should show the parts labeled and how they interlock.

Question 5: List and briefly describe two finishing techniques that can improve the appearance and durability of a manufactured product.

Answer: 1. Sanding: smoothing surfaces to remove roughness. 2. Lacquering or painting: applying a protective coating to enhance appearance and prevent damage.

Question 6: Design a plan for creating a prototype of a new type of storage container. Include the materials and making techniques you would use.

Answer: Use lightweight plastic or cardboard for the prototype. Cut and join parts using glue or tape. For a more detailed prototype, consider 3D printing or laser cutting for precise parts.

Question 7: Explain how a computer-aided manufacturing (CAM) process can be used to produce a complex metal part.

Answer: CAM involves creating a digital design using CAD software, then programming CNC machines to follow precise toolpaths that cut or shape the metal according to the design, enabling accurate and repeatable production.

Question 8: Sketch a cross-section of a product made using injection moulding, showing the main stages of the process.

Answer: A correct sketch would show the molten plastic being injected into a closed mould, filling the cavity, cooling, and then ejecting the solidified part. Labels should include the injection point, mould cavity, and cooling channels.

Question 9: Identify a manufacturing technique suitable for producing large quantities of metal fasteners such as bolts or screws. Describe the basic process.

Answer: Cold forging or machining is used. Cold forging involves shaping metal under high pressure using dies, while machining involves cutting the fasteners from metal rods using lathes or CNC machines.

Question 10: Propose a technique to join two different materials, such as metal and plastic, in a product. Describe how this technique works.

Answer: Adhesive bonding can be used, where a strong adhesive is applied to the surfaces, which are then pressed together until the bond cures. Mechanical fastening (like screws or rivets) can also be used for a more secure join.