Question 1: Describe the process of creating a product using a moulding technique. Include the key steps involved.

Answer: The process involves designing a mould, preparing the material (such as plastic or metal), pouring or injecting the material into the mould, allowing it to cool or set, and then removing the finished part. Finishing touches may include trimming excess material and surface finishing.

Question 2: Explain how a CNC (Computer Numerical Control) machine is used in manufacturing products. Mention at least two advantages of using CNC machining.

Answer: A CNC machine is controlled by computer software to precisely cut, carve, or shape materials based on digital designs. Advantages include high precision and repeatability, and the ability to produce complex shapes efficiently.

Question 3: Identify and describe a suitable manufacturing technique for creating a lightweight, intricate metal component.

Answer: Electroforming or investment casting could be suitable, as they allow for detailed and lightweight metal parts with complex shapes.

Question 4: Draw a simple plan of a product that would be best manufactured using the lamination technique. Label the main layers involved.

Answer: A correct sketch would show multiple thin layers stacked or bonded together, such as plywood or laminated glass, with clear labels indicating each layer.

Question 5: Design a brief plan for making a plastic container with a handle. Include the manufacturing technique you would use and justify your choice.

Answer: Use blow moulding to produce the container, as it allows for hollow, seamless shapes suitable for bottles and similar containers. The handle can be added during the mould design or attached afterward.

Question 6: Sketch a cross-sectional view of a product made using injection moulding. Show the main features of the mould and the final product.

Answer: A correct sketch would display a mould cavity, the injection point, and the final plastic part with detailed features, such as ribs or textures, in a cross-sectional view.

Question 7: Explain the key differences between casting and forging as manufacturing techniques.

Answer: Casting involves pouring liquid material into a mould to solidify into a shape, suitable for complex parts. Forging involves shaping metal by applying compressive forces, resulting in stronger parts due to grain alignment, but with less complex shapes.

Question 8: Identify a suitable technique for creating a large, flat sheet of material with a smooth surface finish, and explain why.

Answer: Rolling is suitable for producing large, flat sheets with a smooth surface, as it involves passing material through rollers to achieve uniform thickness and surface quality.

Question 9: Design a sketch of a product that combines two different manufacturing techniques. Label each part with its respective technique.

Answer: A correct sketch might show a wooden frame (cut and assembled via carpentry) with a plastic cover (formed by vacuum forming) attached, with labels indicating 'Carpentry' and 'Vacuum Forming'.

Question 10: Describe the advantages of using laser cutting over traditional hand cutting in manufacturing products.

Answer: Laser cutting offers high precision, faster production times, and clean, accurate cuts with minimal material waste compared to manual cutting methods.

Question 11: Explain how 3D printing can be used in the prototype development stage of product design.

Answer: 3D printing allows rapid creation of prototypes directly from digital models, enabling quick testing of form, fit, and function before mass production, saving time and costs.