Question 1: Define the term 'casting' in manufacturing. Explain one advantage of using casting to produce a product.

Answer: Casting is a process where liquid material such as metal or plastic is poured into a mold and allowed to solidify. An advantage is that casting allows for complex shapes to be produced with minimal waste.

Question 2: Describe the process of welding. What is one common type of welding used in metalwork?

Answer: Welding involves joining two pieces of metal by heating them until they melt and fuse together. A common type of welding is arc welding, which uses an electric arc to generate heat.

Question 3: Identify and explain two different surface finishing techniques used in product manufacturing.

Answer: One technique is polishing, which smooths the surface to improve appearance and feel. Another is electroplating, which coats the product with a thin layer of metal for corrosion resistance and aesthetic appeal.

Question 4: Sketch a simple plan for a wooden box that can be assembled using only nails. Include the main parts and how they are joined.

Answer: A correct sketch would show a rectangular box with four sides, a base, and a lid. The sides are joined at the corners with nails, with dotted lines indicating nail placements. The plan should include labels for each part.

Question 5: Explain the difference between machining and moulding techniques. Provide an example of each.

Answer: Machining involves removing material from a solid block to shape the product, such as using a lathe to turn metal. Moulding involves shaping material into a form by pouring or injecting into a mould, such as plastic injection moulding.

Question 6: Draw a cross-section of a simple injection mould. Label the main parts involved in the moulding process.

Answer: A correct sketch would show a mould cavity, core, injection channel, and ejector pin, with labels indicating each part. The diagram should illustrate how molten material is injected into the cavity.

Question 7: Describe the advantages of using laser cutting over traditional hand cutting methods.

Answer: Laser cutting is more precise, faster, and can produce complex shapes with high accuracy. It also reduces manual effort and waste.

Question 8: Design a simple prototype for a new pen that uses a different mechanism for ink delivery. Briefly outline your idea and the technique you would use to manufacture it.

Answer: A possible design is a pen with a rotating wheel that pushes ink onto the tip. Manufacturing could involve injection moulding for the body and assembly of the internal mechanism with small parts joined by glue or snap-fit.

Question 9: Explain how the technique of soldering is used in electronics and give an example of a product that might be assembled this way.

Answer: Soldering joins electrical components to a circuit board by melting a metal alloy to create a conductive connection. An example is assembling a circuit board for a remote control.

Question 10: Identify two safety precautions that should be taken when using power tools in a workshop.

Answer: Wearing safety goggles to protect eyes from debris and ensuring the tool is properly maintained and switched off when not in use are important safety precautions.