Question 1: Describe a process you could use to join two pieces of wood securely for a small furniture project. Include the steps involved.

Answer: A common process is using dowel joints or screws. Steps include marking the positions, drilling holes, applying glue (if using dowels), inserting the dowels or screws, and clamping or tightening until secure.

Question 2: Explain how a laser cutter can be used to make precise cuts in acrylic sheets for a product design project.

Answer: A laser cutter uses a focused laser beam to melt or vaporize material along a programmed path. It allows precise, clean cuts in acrylic by following digital designs with high accuracy.

Question 3: Identify and describe a suitable technique for shaping a metal rod into a curved form. Include safety considerations.

Answer: Bending with a metal jig or using a vice and heat (hot bending) can shape a metal rod into a curve. Safety includes wearing gloves, eye protection, and ensuring the metal is heated evenly if hot bending.

Question 4: Sketch a design for a ergonomic handle for a handheld tool. Show how the handle would fit comfortably in the hand.

Answer: A correct sketch would illustrate a handle with a contoured shape that supports the palm and fingers, with a smooth surface and appropriate length to grip comfortably.

Question 5: Describe the process of vacuum forming and identify what types of products it is suitable for making.

Answer: Vacuum forming involves heating a plastic sheet until soft, then stretching it over a mold and using a vacuum to suck the plastic tightly onto the shape. It is suitable for making packaging, prototypes, and small product shells.

Question 6: List three different methods for finishing a wooden surface to improve its appearance and durability.

Answer: Methods include sanding to smooth the surface, applying varnish or lacquer for protection and shine, and staining to change the colour.

Question 7: Explain how a 3D printer creates a product. Include the key steps involved.

Answer: A 3D printer builds objects layer by layer from a digital model, typically using materials like plastic filament. The steps include designing the model, slicing it into layers, and the printer depositing material precisely to form the shape.

Question 8: Describe a manufacturing technique suitable for creating a large number of identical plastic components quickly. Explain why it is effective.

Answer: Injection moulding is suitable. It involves injecting heated plastic into a mould cavity, allowing rapid production of identical parts with high precision and repeatability.

Question 9: Sketch a simple plan for a folding metal stand that can be easily stored when not in use. Indicate the main components and hinges.

Answer: A correct plan would show a basic frame with two or three main parts connected by hinges, allowing the stand to fold flat. The sketch should include the base, support arms, and hinge points clearly labeled.

Question 10: Identify a suitable finishing technique to protect a metal product from corrosion and explain how it works.

Answer: Galvanizing is suitable; it involves coating the metal with a layer of zinc, which prevents rusting by acting as a barrier and providing sacrificial protection.