A-Level Design and Technology: Product Design – Paper 1 (Technical Principles) | Exam Questions & Detailed Answers | 2025 Updated Edition

A-level DESIGN AND TECHNOLOGY: PRODUCT DESIGN Paper 1 Technical Principles Friday 7 June 2019 Morning Time allowed: 2 hours 30 minutes Materials For this paper you must have: • normal writing and drawing instruments • a scientific calculator. Instructions • Use black ink or black ball-point pen. Use pencil only for drawing. • Fill in the boxes at the top of this page. • Answer all questions. • You must answer the questions in the spaces provided. • Do not write outside the box around each page or on blank pages. • Do all rough work in this book. Cross through any work you do not want to be marked. Information • The marks for questions are shown in brackets. • The maximum mark for this paper is 120. *Jun* IB/G/Jun19/E16 7552/1 Answer all questions in the spaces provided. box Explain why ‘potatopak’ is a suitable material for the manufacture of disposable cutlery. [3 marks] Explain how BSI certification impacts on the purchase of a child’s car seat by a consumer. [6 marks] Give three benefits of using stock forms of material for a manufacturer. [3 marks] box 1 2 3 PAR is a stock form of timber. What does PAR stand for? [1 mark] Turn over for the next question Turn over ► Figure 1 shows a children’s climbing frame. Figure 1 Explain why powder coating is an appropriate finish for the climbing frame shown in Figure 1. box [6 marks] Define each of the following terms: • copyright • trademark • patent. [3 marks] box Copyright Trademark Patent Turn over for the next question Turn over ► Figures 2 and 3 show rolls of adhesive tape. Figure 2 Figure 3 A roll with an ABS core A roll with a cardboard core Compare the environmental impact of the materials used to manufacture the cores of the adhesive tapes shown. box [6 marks] Figure 4 shows the dimensions of a component to be made using 3D printing. Figure 4 All dimensions in mm Not drawn to scale Front view Side view Completed component Material costs Material Printed density (grams per mm3) Cost per 500 g ABS 0.000 448 g £18 Calculate the material cost of manufacturing 50 units. box Show your working out. [5 marks] Turn over ► box Name a specific application for each of the following compliant materials: • bleed proof paper • duplex card • moulded paper pulp. [3 marks] Bleed proof paper Duplex card Moulded paper pulp Evaluate the following techniques for rendering a design: • using computer aided design (CAD) • hand generated. [6 marks] box Turn over for the next question Turn over ► Figure 5 shows an aluminium seat clamp. Figure 6 shows the dimensions of a block of aluminium. Figure 5 Figure 6 All dimensions in mm Not drawn to scale The seat clamp is currently manufactured by wastage from the aluminium block shown in Figure 6. The manufacturer wants to produce the clamp using a redistribution process. Compare the cost of each manufacturing process if 5000 units are to be produced. Show your working out. Volume of the seat clamp 7280 mm3 Cost of aluminium £4 per 100 000 mm3 Cost of manufacturing a mould for the redistribution process £3000 [6 marks] box box Explain the safe work practices necessary to protect workers when using solvent adhesives. [6 marks] Turn over ► Explain why neoprene is a suitable material to manufacture a case to carry a laptop. [8 marks] box Figure 7 shows a lift interface. box Figure 7 All dimensions in mm Not drawn to scale Evaluate how well the lift interface has been designed to be inclusive to all users. [6 marks] Turn over ► A manufacturer is producing a glass reinforced plastic (GRP) moulding. Calculate the volume of hardener needed. Show all of your working. Size of GRP mat needed for moulding 2 metres × 5 metres Ratio of resin to hardener 3 : 2 Total volume of liquid (resin and hardener) needed per m2 of GRP matting 3 litres per m2 [4 marks] Explain why industrial tests are more accurate than workshop tests when testing material properties. [2 marks] Describe how a specific industrial test is undertaken to measure material hardness. [4 marks] Turn over ► Figure 8 and Figure 9 show two bicycle frames. Figure 8 Figure 9 Aluminium TIG welded bicycle frame