Question 1: Describe the process of making a hole in a piece of wood using a drill. Include safety precautions and tools required.

Answer: Use a drill with an appropriate drill bit for wood. Secure the wood piece with clamps. Wear safety goggles. Mark the spot for the hole, align the drill perpendicular to the surface, and apply steady pressure while drilling. Release the trigger once the hole is complete and turn off the drill. Remove any debris and check the hole for accuracy.

Question 2: Explain how the process of laminating can be used to create a strong, layered wooden panel. Include the key steps involved.

Answer: Laminating involves bonding thin layers of wood or other materials with adhesive. First, prepare the surface by sanding. Apply a suitable adhesive evenly on each layer. Stack the layers carefully, ensuring alignment. Use clamps or a press to apply pressure uniformly. Leave to cure for the recommended time before trimming or finishing.

Question 3: Design Brief: You need to create a lightweight, durable storage box for school supplies. Which manufacturing technique would you choose and why?

Answer: A suitable technique would be injection moulding if using plastic, as it allows for mass production of lightweight, durable parts with complex shapes. Alternatively, if using wood, CNC routing could be used for precise, consistent parts. I would choose injection moulding for its efficiency and uniformity.

Question 4: Sketch a simple design for a handle made from metal that can be attached to a toolbox. Include labels for key features.

Answer: The sketch should show a curved or straight metal handle with a grip area, holes for screws or bolts at each end, and possibly a reinforcement section. Labels should include 'Grip area', 'Attachment holes', and 'Reinforcement'.

Question 5: Explain the process of welding two metal parts together. Identify common types of welding and their typical applications.

Answer: Welding involves joining two metal pieces by melting their edges and fusing them together using heat, often with a filler material. Common types include MIG welding (good for thin metals and quick work), TIG welding (more precise, used for high-quality finishes), and arc welding. The process requires safety gear and proper ventilation.

Question 6: Draw a plan for a simple, foldable paper prototype of a phone stand. Include labels for the main parts.

Answer: The plan should show a flat base with a back support that folds out, and a slot or groove for holding the phone. Labels should include 'Base', 'Back support', and 'Folding joint'.

Question 7: Describe the process of creating a smooth finish on a metal surface after welding. Include techniques and materials used.

Answer: The process involves grinding the weld with a file or grinder to remove excess material. Follow with sanding using fine abrasive papers to smooth the surface. Use polishing compounds and a cloth or buffing wheel for a shiny finish. Safety precautions include wearing protective glasses and gloves.

Question 8: Design Brief: You need to produce a set of ergonomic kitchen utensils that are comfortable to hold. Which technique would you use for shaping the handles and why?

Answer: I would use injection moulding with a plastic material for the handles, as it allows for ergonomic shapes and a comfortable grip. The process is suitable for mass production and can incorporate textured surfaces for better grip.

Question 9: Explain how a CNC machine can be used in the production of a wooden chair. Include advantages of using CNC technology.

Answer: A CNC machine can be programmed to cut and carve wooden components with high precision according to a digital design. It can produce complex joint details and consistent parts. Advantages include high accuracy, repeatability, reduced waste, and faster production times.

Question 10: Sketch a cross-section of a layered composite material used in sports equipment. Label the layers and their functions.

Answer: The sketch should show multiple layers, such as an outer protective layer, a core layer for shock absorption, and an inner layer for structure. Labels should include 'Outer layer (protective)', 'Core (shock absorption)', and 'Inner layer (structural support)'.