D&T-Resistant Materials-Past Papers

Cambridge International Examinations
Cambridge International General Certificate of Secondary Education

* 1 9 8 7 9 2 7 3 1 4 *
DESIGN AND TECHNOLOGY 0445/31

Paper 3 Resistant Materials May/June 2014
1 hour
Candidates answer on the Question Paper.
No Additional Materials are required.
To be taken together with Paper 1 in one session of 2 hours 15 minutes.
READ THESE INSTRUCTIONS FIRST
Write your Centre number, candidate number and name on all the work you hand in.
Write in dark blue or black pen.
You may use an HB pencil for any diagrams, graphs or rough working.
Do not use staples, paper clips, glue or correction fluid.
DO NOT WRITE IN ANY BARCODES.
Section A
Answer all questions in this section.
Section B
Answer one question in this section.
You may use a calculator.
The total of the marks for this paper is 50.

The number of marks is given in brackets [ ] at the end of each question or part question.
For Examiner’s Use
Section A
Section B
Total
This document consists of 16 printed pages.
DC (LK/SW) 86075/2
© UCLES 2014 [Turn over
2
Section A
1 Fig. 1 shows a step ladder.
Fig. 1
(a) Name a suitable material for the step ladder.
.............................................................................................................................................. [1]
(b) Give one reason for your choice.
.............................................................................................................................................. [1]
2 Fig. 2 shows a coping saw being used to cut a curved shape in wood.
Fig. 2
Describe two checks that would need to be carried out before using the coping saw.
1 .......................................................................................................................................................
2 .................................................................................................................................................. [2]
© UCLES 2014 0445/31/M/J/14

3
3 (a) Complete the drawing below to show a hand file.
[2]
(b) Label the safe edge on the hand file you have drawn. [1]
4 Complete the table below by naming each tool and giving a specific use.
Tool Name Specific use
[4]
© UCLES 2014 0445/31/M/J/14 [Turn over

4
5 Fig. 3 shows a milk container made from a plastic.
fluting
Fig. 3
(a) State a suitable method of manufacture for the milk container.
...............................................................................................................................................[1]
(b) Give one manufacturing reason for the tapered shape of the milk container.
...............................................................................................................................................[1]
(c) Give one reason for the fluting on the milk container.
...............................................................................................................................................[1]
6 Show on Fig. 4 two important anthropometric measurements that would be used to work out the
size of a chair.
Fig. 4
[2]
© UCLES 2014 0445/31/M/J/14

5
7 Fig. 5 shows sheet material with centres for three holes marked out, ready to be drilled.
Fig. 5
Name the tool used to draw the lines on the sheet material when made from:
1 mm thick mild steel .........................................................................................................................
3 mm thick acrylic ..........................................................................................................................[2]
8 Fig. 6 shows folding bars.
Fig. 6
Add to Fig. 6 to show a piece of sheet metal being bent to shape in the folding bars. [3]

6
9 Fig. 7 shows a student soldering electronic components.
Fig. 7
(a) Name the type of solder being used.
...............................................................................................................................................[1]
(b) Give one other example where this type of solder could be used.
...............................................................................................................................................[1]
10 Fig. 8 shows two sun loungers used in a garden.
fabric seat
Ø20 steel tube
moulded polypropylene
A B
Fig. 8
Give two advantages of sun lounger A over sun lounger B.
1 ........................................................................................................................................................
2 ....................................................................................................................................................[2]
© UCLES 2014 0445/31/M/J/14

7
Section B
Answer one question from this section.
11 Fig. 9 shows views of a towel holder made from hardwood and non-ferrous metal.
hardwood frame
40 × 20
150
non-ferrous
metal rod Ø10
500
20°
0
30
Fig. 9
(a) Sketch and name a suitable corner joint at A.
Name of joint..........................................................................................................................[4]
8
(b) The four sides of the hardwood frame will be glued and clamped together.
(i) Name a suitable glue and state the time it will take to set.
Glue ....................................................................................................................................
Time to set .....................................................................................................................[2]
(ii) Name the type of cramps used.
.......................................................................................................................................[1]
(iii) Describe two checks that would be made when clamping the frame.
1 .........................................................................................................................................
2 .....................................................................................................................................[2]
(c) Holes will be drilled into the sides of the frame to take the Ø10 metal rod.
The holes will need to be drilled at an angle of 20°.
Use sketches and notes to show how the holes could be drilled safely and accurately using a
bench-mounted drill.
[3]
(d) Use sketches and notes to show a bending jig that could be used to make sure that the bends
in all three metal rods are the same.
[4]
© UCLES 2014 0445/31/M/J/14

9
(e) Use sketches and notes to show how the towel holder could be fitted against a wall without
screwing through the front of the frame. Include details of sizes and materials used.
[4]
(f) The towel holder could be sold as flat-pack for self-assembly.

Use sketches and notes to show how the design of the hardwood frame and Ø10 metal rods
could be modified so that they would fit into the box shown below and sent to customers.
Include all constructional details.
90
40
ld er
ho
el
tow 0
51
[5]
10
12 Fig. 10 shows details of a bird table.
roof
support
base
B side
Number
Part Length × width × thickness Material
required
Base 1 250 × 250 × 12 Plywood
Side 4 200 × 25 × 12 Pine
Support 1 300 × 30 × 30 Pine
Roof 2 250 × 200 × 9 Plywood
Fig. 10
(a) Give two benefits of making a card model of the bird table before making it from wood.
1 .................................................................................................................................................
2 .............................................................................................................................................[2]
(b) Sketch and name a suitable method of joining the support to the base at B.
Name of method ....................................................................................................................[4]

© UCLES 2014 0445/31/M/J/14
11
(c) The roof is made in two halves that are joined together at A as shown in Fig. 10.
Fig. 11 shows details of one half of the roof marked out ready to be shaped to make the joint.
line C
waste to be removed
Fig. 11
(i) Give two advantages of using a cutting gauge rather than a pencil and try square to
mark out line C.
1 .........................................................................................................................................
2 .....................................................................................................................................[2]
(ii) Use sketches and notes to describe how the waste could be removed.
Name all the tools and equipment used.
[3]

12
(d) Fig. 12 shows the base of the bird table marked out ready to be cut to shape.
waste
Fig. 12
Complete the table below by naming one tool that could be used for each process.
Process Tools/equipment used

Mark out
Saw off waste
Make sawn edges smooth
[3]
(e) The sides will be glued and nailed to the base.
(i) Name a suitable type of nail that could be used.
.......................................................................................................................................[1]
(ii) Name a suitable glue to join the sides to the base.
.......................................................................................................................................[1]
(iii) Give one reason why the sides fitted to the base have gaps in the corners.
.......................................................................................................................................[1]
(f) Describe two problems when designing products for outdoor use and how each problem may
be overcome.
Problem 1 ..................................................................................................................................
Overcome ..................................................................................................................................
Problem 2 ..................................................................................................................................
Overcome ..............................................................................................................................[4]
© UCLES 2014 0445/31/M/J/14

13
(g) Fig. 13 shows a length of pine used to make the support for the roof.
roof
support
Fig. 13
Modifications will need to be made to the support at end D so that it can be joined securely to
the roof.
Use sketches and notes to show how the support and roof could be joined permanently.
Include details of materials and constructions used.
[4]

14
13 Fig. 14 shows a combined photo frame and coat hook made from 4mm thick acrylic.
It will be wall-mounted in a child’s bedroom.
0
20
150
40
20
Ø20 40
Fig. 14
(a) Fig. 15 shows the acrylic sheet from which the photo frame and coat hook will be cut.
230
200
Fig. 15
(i) Draw on Fig. 15 the development (net) of the photo frame and coat hook.
Include the cut out shape for the photo. [5]
© UCLES 2014 0445/31/M/J/14

15
(ii) Give two benefits of using a template to mark out the development (net).
1 .........................................................................................................................................
2 .....................................................................................................................................[2]
(b) When working with acrylic there is a danger that it could crack.
Use sketches and notes to show how this can be prevented when:
(i) sawing in a vice;
[3]
(ii) drilling on a bench-mounted drilling machine.
[3]
(c) When working with acrylic sheet, the surface can become easily scratched.
Describe how scratches can be removed from the surface of acrylic sheet.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

16
(d) Use sketches and notes to show how the coat hook would be heated and bent to shape.
[4]
(e) Use sketches and notes to show how a photograph could be supported behind the photo
frame. Your design must allow the photo to be replaced quickly and easily.
Include details of sizes and constructions.
[6]
Permission to reproduce items where third-party owned material protected by copyright is included has been sought and cleared where possible. Every
reasonable effort has been made by the publisher (UCLES) to trace copyright holders, but if any items requiring clearance have unwittingly been included, the
publisher will be pleased to make amends at the earliest possible opportunity.
Cambridge International Examinations is part of the Cambridge Assessment Group. Cambridge Assessment is the brand name of University of Cambridge Local
Examinations Syndicate (UCLES), which is itself a department of the University of Cambridge.
© UCLES 2014 0445/31/M/J/14

* 1 8 1 4 5 4 3 2 3 2 *

1 hour
Section A
Section B

Section A
Section B
Total
This document consists of 19 printed pages and 1 blank page.
DC (SJF/SW) 86074/2
2
Section A
1 Fig. 1 shows three types of nail.
............................... ............................... ...............................
Fig. 1
Select the correct name for each nail from the list below.
cut tack round wire panel pin oval wire clout [3]
2 Complete the table below by naming the manufacturing process and a specific plastic for each
product.
Product Manufacturing process Specific plastic
sandwich
container
electrical plug
[4]
© UCLES 2014 0445/33/M/J/14

3
3 Complete the drawing below to show a biscuit joint.
[3]
4 Fig. 2 shows a three jaw and a four jaw chuck used with a centre lathe.
three jaw chuck four jaw chuck
Fig. 2
State whether a three jaw or four jaw chuck would be needed to hold each of the sections of metal
labelled A, B and C.
A B C
A .......................................................................................................................................................
B .......................................................................................................................................................
C ...................................................................................................................................................[3]

4
5 A list of metals is given below.
brass iron mild steel aluminium
From the list of metals select:
(a) a ferrous alloy ...........................................................................................................................
(b) a non-ferrous alloy ................................................................................................................[2]
6 Fig. 3 shows a cutting tool.
Fig. 3
(a) Name the cutting tool shown in Fig. 3.
...............................................................................................................................................[1]
(b) Give one benefit of using this type of cutting tool.
...............................................................................................................................................[1]
7 State what is meant by each safety symbol shown below.
(a) ..........................................................................................................................
(b) ..........................................................................................................................
[2]
© UCLES 2014 0445/33/M/J/14

5
8 Fig. 4 shows two types of file.
A B
Fig. 4
Name file A and file B.
File A ................................................................................................................................................
File B .............................................................................................................................................[2]
9 Fig. 5 shows a plan view of the rails and legs of a small table.
Fig. 5
Add sketches and notes to Fig. 5 to show how you would check to see if the construction was
square. [2]
10 Fig. 6 shows a drawer handle.
Fig. 6
Name the manufacturing process used to produce the drawer handle when made from:
polypropylene ...................................................................................................................................
aluminium .....................................................................................................................................[2]

6
Section B
11 Fig. 7 shows a child’s toy breakdown lorry.
drum
winding support
cab handle
cab and base beech
base winding support beech veneers
15
wheels beech
drum beech dowel
13
00
0
2 handle mild steel
Fig. 7
(a) Give two properties of beech that make it suitable for the breakdown lorry.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Fig. 8 shows the handle made from Ø5 mild steel.
Fig. 8
(i) Use sketches and notes to show how the handle could be shaped from a length of Ø5
mild steel.
[3]
© UCLES 2014 0445/33/M/J/14

7
(ii) The end of the handle could be dangerous when held by a child.
Sketch a modification to the end of the handle to make it safe in use.
Include details of materials and construction.
[2]
(iii) Name a suitable adhesive that could be used to join the handle into the drum.
.......................................................................................................................................[1]
(iv) Describe how the adhesive would be prepared and applied.
...........................................................................................................................................
.......................................................................................................................................[2]
(c) The wheels will be produced using a woodturning lathe.

Fig. 9 shows a length of beech set up on a woodturning lathe.
Fig. 9
(i) Name the method of woodturning shown in Fig. 9.
.......................................................................................................................................[1]

8
(ii) Fig. 10 shows a length of beech ready to be set up on the woodturning lathe.
Give a reason why the corners have been removed.
Fig. 10
.......................................................................................................................................[1]
(iii) Name two cutting tools that could be used to produce a round shape on the woodturning
lathe.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(iv) Name a tool that could be used to check the diameter of the beech when it has been
made into a round shape.
.......................................................................................................................................[1]
(d) Fig. 11 shows details of one of the wheels.

Ø60
Ø6
15
Fig. 11
Use sketches and notes to show how one wheel could be screwed to the base of the toy and
allowed to rotate freely. Include details of the fittings used.
[3]
© UCLES 2014 0445/33/M/J/14

9
(e) Fig. 12 shows the winding support made by laminating beech veneers.
Fig. 12
Use sketches and notes to show how the winding support could be made using the process
of lamination.
[4]
(f) (i) Name a suitable finish for the toy.
.......................................................................................................................................[1]
(ii) Give two reasons why the toy needs an applied finish.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]

10
12 Fig. 13 shows a basic design for a child’s musical instrument.
30
dowel rod
bars
12
rail
0
28
mallet
end
Fig. 13
(a) The bars will be cut from a length of hardwood.

Complete the table by naming the tools and/or equipment used to mark out, cut out and finish
the bars.
Process Tools / equipment
Mark to length
Saw to length
Make surfaces clean and smooth

[3]
(b) The hardwood bars could be replaced with bars made from non-ferrous metal.
Complete the table by naming the tools and/or equipment used to mark out, cut out and finish
the bars when made from non-ferrous metal.
Process Tools / equipment
Mark to length
Saw to length
Make surfaces clean and smooth

[3]
© UCLES 2014 0445/33/M/J/14

11
(c) Fig. 14 shows the rails and ends that support the bars.
end
rail 20 wide × 12 thick
rail
end 30 wide × 12 thick
Fig. 14
Sketch and name a suitable joint that could be used to join a rail to an end.
Name of joint .........................................................................................................................[4]

12
(d) Holes are drilled in each rail for dowel rods to support each bar.
Use sketches and notes to show how you would make sure the holes were drilled in identical
positions in both rails.
[2]
(e) Fig. 15 shows a length of Ø9 dowel that will be glued into a hole in the rail.
Also shown is part of a rail with a hole drilled for the dowel.
rail
Fig. 15
Show on Fig. 15 how the dowel could be prepared to make gluing easier and more effective.
[2]
© UCLES 2014 0445/33/M/J/14

13
(f) Each bar will have bevelled edges.

Fig. 16 shows one of the bars with the bevelled edges marked out.
waste
12
20
Fig. 16
(i) Name a suitable plane that could be used to plane off the waste to produce the bevelled
edge.
.......................................................................................................................................[1]
(ii) Use sketches and notes to show how a vice could be used to hold the bar while planing
the bevelled edges.
[3]
(iii) Give one disadvantage of planing off the waste against a bench stop rather than using
a vice.
.......................................................................................................................................[1]

14
(g) Give two reasons why designers often include paint in the design of children’s toys.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(h) Use sketches and notes to show a modification to the design of the musical instrument that
would enable the mallet to be easily stored.
Include details of sizes, materials and constructions used.
[4]
© UCLES 2014 0445/33/M/J/14

15
13 Fig. 17 shows a basic design for a DVD stand.
end
6 mm acrylic
rail
Ø10 stainless
steel tube
800
0
50
25
0
Fig. 17
(a) Fig. 18 shows one end of the DVD stand marked out ready to be cut to shape.
B Ø70
waste
Fig. 18
(i) Name a tool that could be used against a straight edge to mark line A.
.......................................................................................................................................[1]
(ii) Name a tool that could be used to mark out the circle B.
.......................................................................................................................................[1]

16
(b) Use sketches and notes to show how the circular shape could be produced.
[3]
(c) Complete the table below by describing how each of the tools/items of equipment could be
used to finish the edges of the acrylic to a high quality.
Tools/items of equipment How they will be used
Scraper
Wet and dry (silicon carbide)

paper
Polishing mop
Polishing compound
[4]
© UCLES 2014 0445/33/M/J/14

17
(d) Use sketches and notes to show how the stainless steel rails could be attached without drilling
holes in the acrylic ends.
Include details of additional materials, sizes and constructions.
[4]
(e) Describe two ergonomic considerations that a designer would include in the design of a
DVD stand.
1 ................................................................................................................................................
2 ............................................................................................................................................[4]

18
(f) Fig. 19 shows details of a DVD case.
15
190
D
DV
5
13
Fig. 19
The DVD cases can fall over when placed on the stand.
Use sketches and notes to show a device that would overcome this problem.
Your device must:
• prevent the DVD cases from falling over;

• fit onto the stainless steel rails;
• be capable of being moved along the rails.
Include details of additional materials and fittings used.
[6]
© UCLES 2014 0445/33/M/J/14

19
(g) The DVD stand could also be made entirely from wood-based materials.
Give two advantages of making the DVD stand from wood-based materials rather than acrylic
and stainless steel.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2014 0445/33/M/J/14

20
BLANK PAGE
© UCLES 2014 0445/33/M/J/14

* 2 3 5 7 5 9 5 5 0 9 *

Paper 3 Resistant Materials October/November 2014
1 hour
Write in blue or black pen.
Section A
Section B

Section A
Section B
Total
This document consists of 17 printed pages and 3 blank pages.
DC (SJF/SW) 86386/2
2
Section A
1 Fig. 1 shows a chair made from plastic and metal.
moulded plastic seat
metal tube legs
Fig. 1
(a) Name a suitable metal for the legs.
...............................................................................................................................................[1]
(b) Name a suitable plastic for the seat.
...............................................................................................................................................[1]
(c) The metal legs have an applied finish on them. Name a suitable finish for the metal legs.
...............................................................................................................................................[1]
(d) Give one reason for applying a finish to the metal legs.
...............................................................................................................................................[1]
[4]
© UCLES 2014 0445/31/O/N/14
3
3 Fig. 2 shows a cordless electric drill and a bench pillar drill.
cordless electric drill bench pillar drill
Fig. 2
Give one benefit of drilling holes using:
(a) a cordless electric drill
...............................................................................................................................................[1]
(b) a bench pillar drill.
...............................................................................................................................................[1]
4 Fig. 3 shows a piece of wood being sawn.
Fig. 3
(a) Give the specific name of the saw being used.
...............................................................................................................................................[1]
(b) Name the equipment that the wood being sawn is held against.
...............................................................................................................................................[1]
© UCLES 2014 0445/31/O/N/14 [Turn over

4
5 Fig. 4 shows two tools being used to mark the centre of a rod.
Fig. 4
Name tools A and B shown in Fig. 4.
A .......................................................................................................................................................
B ...................................................................................................................................................[2]
6 Fig. 5 shows a split pattern used to make a hacksaw handle.
Fig. 5
Name the process that uses a split pattern to make the hacksaw handle.
......................................................................................................................................................[1]
© UCLES 2014 0445/31/O/N/14

5
7 Fig. 6 shows a triangular shape made from acrylic. Each side of the triangular shape is 60 mm
long.
Fig. 6
Complete the drawing below by showing how three shapes could be marked out on the acrylic
sheet with the minimum of waste.
60
170
[2]
8 Fig. 7 shows part of a woodworker’s bench.
Fig. 7
(a) Name the piece of equipment labelled A in Fig. 7.
...............................................................................................................................................[1]
(b) Give one specific use for this piece of equipment.
...............................................................................................................................................[1]

6
9 Fig. 8 shows two pieces of 15 mm thick hardwood.
A B
Fig. 8
(a) Draw on A in Fig. 8 to show a groove. [2]
(b) Draw on B in Fig. 8 to show a through housing joint. [2]
10 Fig. 9 shows a product that has been blister packaged.
Fig. 9
(a) Name a suitable plastic for the packaging.
...............................................................................................................................................[1]
(b) Give one benefit of blister packaging.
...............................................................................................................................................[1]
© UCLES 2014 0445/31/O/N/14

7
Section B
11 Fig. 10 shows an incomplete design for a coat rack that fits over the top of a door.
The coat rack is made from 1 mm thick metal strip and will be made in a school workshop.
support
positions for
coat hooks
0
40
plate
Fig. 10
(a) State two items of research the designer would consider in the design of the coat rack.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Fig. 11 shows one support marked out, ready to be bent to shape.
30
30
36
0
12
Fig. 11
(i) Name two marking out tools used to mark out the support.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Give one reason why engineers blue is sometimes used when marking out.
.......................................................................................................................................[1]

8
(c) Use sketches and notes to show how you would bend the metal strip to make the support.
[3]
(d) (i) Explain why it could be necessary to anneal metal.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) Describe how you would anneal brass.
...........................................................................................................................................
.......................................................................................................................................[3]
(e) The coat rack in Fig. 10 could be made from brass.
Name an applied finish for the coat rack when made from brass.
...............................................................................................................................................[1]
(f) Describe how you would prepare brass from a sawn finish to a polished surface.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[3]
© UCLES 2014 0445/31/O/N/14

9
(g) (i) The positions for four coat hooks are shown in Fig. 10.
Use sketches and notes to show a design for a coat hook that could be joined to the
plate. Include details of sizes and materials used.
[3]
(ii) Describe in detail the processes involved when joining the coat hook designed in (g)(i)
permanently to the plate. The use of adhesive is not allowed.
[5]

10
12 Fig. 12 shows an incomplete design for a child’s sit-on toy. The wheels have been removed.
The sit-on toy is 700 high × 500 wide and is made from 18 mm thick plywood.
seat
axle Ø10
steel rod
Fig. 12
(a) Give two advantages of using plywood rather than solid wood for the sit-on toy.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) The shape of the sit-on toy will be cut out from a large sheet of plywood.
(i) Name a portable power tool that could be used to cut out the shape.
.......................................................................................................................................[1]
(ii) State two safety precautions you would take when using portable power tools.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
© UCLES 2014 0445/31/O/N/14

11
(c) Fig. 13 shows details of the slot into which the seat will fit.
seat
slot 100 × 18
Fig. 13
(i) Use sketches and notes to show how the slot could be cut out by hand.
[4]
(ii) Use sketches and notes to show how the fixing of the seat could be strengthened.
Include details of materials, sizes and fittings used.
[4]

12
(d) A foot rest is needed for the sit-on toy. The footrest is to be fitted at A in Fig. 12.
Use sketches and notes to design a foot rest that could be adjusted and fixed at three different
heights. Include details of materials, sizes and fittings.
[5]
(e) Explain how the designer has considered anthropometric data in the design of the sit-on toy.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]
© UCLES 2014 0445/31/O/N/14

13
(f) Fig. 14 shows one of the wheels for the sit-on toy. The wheels are made from a plastic.
wheel Ø100 × 30
hole Ø10
Fig. 14
(i) Name a method of manufacture for the wheel.
.......................................................................................................................................[1]
(ii) Use sketches and notes to show how the front wheels could be fitted to the sit-on toy.
The wheels must be allowed to turn freely and must be safe in use.
Include details of materials, sizes and fittings used.
[4]

14
13 Fig. 15 shows a DVD stand made mainly from hardwood.

The bottom of the DVD stand can rotate on the base as shown by the arrows in Fig. 15.
top
350 AF
350 AF
DVD
central column Ø25
bottom
top, bottom and base
base 350 AF (Across Flats) × 19 thick
hardwood
Fig. 15
(a) Use sketches and notes to show how the hardwood top could be made in a school workshop.
Include details of marking out.
[6]
© UCLES 2014 0445/31/O/N/14

15
(b) The top and bottom will be joined by the central column.
Complete the drawing below to show how the top and bottom could be clamped together
while the adhesive sets.
350 AF
top
central column
bottom
[3]
(c) Use sketches and notes to show how the assembled top and bottom of the DVD stand could
be made to rotate on the base. The base must remain level when rotated.
Include details of materials and fittings used.
[4]

16
(d) Fig. 16 shows details of one DVD and the arrangement for storing 12 DVDs.
15
central
column Ø25
190
D
DV DVD
bottom
350 AF × 19 thick
5
13
plan view with top removed
Fig. 16
Use sketches and notes to show:
• how each DVD could be located in its own position;

• details of materials, constructions and fittings used.
[5]
© UCLES 2014 0445/31/O/N/14
17
(e) (i) Name a suitable finish, other than varnish, for the DVD stand.
.......................................................................................................................................[1]
(ii) Describe how the hardwood could be prepared to take your chosen finish.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(f) Describe when the following could be used in the manufacture of the DVD stand:
template ....................................................................................................................................
jig ..........................................................................................................................................[2]
(g) Explain why the hardwood used to make the DVD stand would need to be seasoned.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]
© UCLES 2014 0445/31/O/N/14

18
BLANK PAGE
© UCLES 2014 0445/31/O/N/14

19
BLANK PAGE
© UCLES 2014 0445/31/O/N/14

20
BLANK PAGE
© UCLES 2014 0445/31/O/N/14

* 0 3 8 1 0 1 6 0 9 7 *

1 hour
Section A
Section B

Section A
Section B
Total
DC (NF/CGW) 94729/1
2
Section A
1 Fig. 1 shows waste wood being cut out.
Fig. 1
Name each tool labelled A and B in Fig. 1.
A .......................................................................................................................................................
B .................................................................................................................................................. [2]
2 Fig. 2 shows a butt joint being glued and nailed.
Fig. 2
(a) Name the method of nailing shown in Fig. 2.
.............................................................................................................................................. [1]
(b) Give one reason why the nails are put in at an angle.
.............................................................................................................................................. [1]
(c) Name a suitable adhesive.
.............................................................................................................................................. [1]
© UCLES 2014 0445/32/O/N/14

3
3 Fig. 3 shows a small plastic dish.
Fig. 3
(a) Name a process that could be used to produce the dish.
.............................................................................................................................................. [1]
(b) Name a suitable plastic from which the dish could be made using the process named in (a).
.............................................................................................................................................. [1]
4 A list of metals is given below.
copper cast iron stainless steel duralumin
From the list of metals select:
(a) a ferrous alloy;
.............................................................................................................................................. [1]
(b) a non-ferrous alloy.
.............................................................................................................................................. [1]
5 Fig. 4 shows the end grain of a piece of solid wood being planed.
Fig. 4
Describe how the planing should be completed without splitting the end grain.
..........................................................................................................................................................
..........................................................................................................................................................
..................................................................................................................................................... [2]
4
6 Complete the drawing below to show a tee bridle joint.
[3]
7 Complete the table below by giving a specific name and a specific use for each saw.
Tool Specific name Specific use
[4]
8 Fig. 5 shows a wheelbarrow. The body of the wheelbarrow is made from mild steel.
body
Fig. 5
(a) Give one reason why the body of the wheelbarrow would need a surface finish.
.............................................................................................................................................. [1]
(b) Name a suitable surface finish for the body of the wheelbarrow.
.............................................................................................................................................. [1]
© UCLES 2014 0445/32/O/N/14

5
9 (a) Complete the drawing below to show a back flap hinge.
[2]
(b) Give one advantage of a back flap hinge over a butt hinge.
.............................................................................................................................................. [1]
10 Fig. 6 shows a marking knife.
Fig. 6
(a) Describe one situation where a marking knife would be used to mark out wood rather than a
pencil.
.............................................................................................................................................. [1]
(b) Name one other marking out tool that scores/cuts the surface of the wood.
.............................................................................................................................................. [1]

6
Section B
11 Fig. 7 shows a toy boat made mainly from wood.
mast
hull
Fig. 7
(a) The mast is made from round section wood.
(i) Give the technical term for round section wood.
...................................................................................................................................... [1]
(ii) Name a waterproof adhesive that could be used to fix the mast into the hull.
...................................................................................................................................... [1]
(b) Give two reasons why a template would be useful to mark out the shape of the hull.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2014 0445/32/O/N/14

7
(c) Fig. 8 shows the hull of the toy boat marked out on a block of wood.
position of hole for mast
waste wood
Fig. 8
Complete the table below by naming one tool or item of equipment used for each process.
Stage Process Tool or item of equipment
1 Cut off the waste
2 Make the hole for the mast
3 Make edges smooth
[3]
(d) Fig. 9 shows part of the hull and rudder.
rudder hull
Fig. 9
Add sketches and notes to Fig. 9 to show how the rudder could be fitted to the hull and be
able to move from side to side.
[2]

8
(e) Fig. 10 shows a different design for a toy boat.

The toy boat has a vacuum formed hull and a separate deck made from polystyrene.
deck
hull
Fig. 10
Give two properties of polystyrene that makes it suitable for the toy boat.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(f) Fig. 11 shows the separate parts of the hull and deck.
deck
position for hole

for mast hull
Fig. 11
Use sketches and notes to show how the hull would be vacuum formed.
[8]
© UCLES 2014 0445/32/O/N/14

9
(g) Use sketches and notes to show how the deck would be secured while drilling the hole for
the mast.
[2]
(h) Give two safety precautions you must take when using polystyrene cement to join the deck to
the hull.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(i) Describe two ways by which designers make toys appealing to young children.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

10
12 Fig. 12 shows a tray table.

The tray is made from MDF and the stand could be made from either square section wood or
square metal tube.
tray Ø450 × 20 thick MDF
0
40
Fig. 12
(a) (i) Use sketches and notes to show a method of construction at A if the stand was made
from square section wood.
[3]
(ii) Explain why a sliding bevel would be a useful tool to mark out part of the construction
at A.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
© UCLES 2014 0445/32/O/N/14
11
(b) (i) The stand could be made from square metal tube.
State a suitable standard size of square metal tube.
...................................................................................................................................... [1]
(ii) Use sketches and notes to describe how the construction at A would be brazed if the
stand was made from square metal tube.
[6]
(c) Use sketches and notes to show how the stand could be fixed to the underside of the tray.
You may choose to make the stand in square section wood or square metal tube.
[6]

12
(d) Starting with the MDF block shown below, use sketches and notes to show how the tray could
be produced.
MDF block 450 × 450 × 20
[4]
(e) The surface of the tray is covered with a plastic laminate.
(i) Give two benefits of covering the MDF tray with a plastic laminate.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Name a suitable adhesive to join the plastic laminate to the MDF.
...................................................................................................................................... [1]
© UCLES 2014 0445/32/O/N/14

13
13 Fig. 13 shows a desk tidy made from two parts, tray A and tray B.
Both trays are made from 6 mm thick MDF.
partition
tray A
150
tray B
0
32
24
0
Fig. 13
(a) Give two advantages of MDF compared with other manufactured boards.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Give two items of research a designer would need to consider when designing the desk tidy.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(c) (i) Use sketches and notes to show how a 6 mm thick MDF base could be fitted to tray A.
The edges of the base must not be visible.
[3]

14
(ii) Use sketches and notes to show how the partition in tray A could be fixed to the sides
and base.
[3]
(d) Use sketches and notes to show how tray A could be made to stack on top of tray B safely
and securely. It must be easy to remove tray A from tray B.
Include constructional details and sizes.
[5]
(e) (i) Name a suitable finish for the desk tidy.
...................................................................................................................................... [1]
(ii) Describe how you would prepare the MDF to take your chosen finish.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
© UCLES 2014 0445/32/O/N/14

15
(f) The MDF used for the desk tidy is only 6 mm thick.
Use sketches and notes to show a suitable corner joint at X.
[3]
(g) Describe two functional improvements to the desk tidy shown in Fig. 13.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(h) Many desk tidies are made from plastic.

Give two advantages of making a desk tidy from plastic rather than MDF.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2014 0445/32/O/N/14

16
BLANK PAGE
© UCLES 2014 0445/32/O/N/14

* 2 5 8 7 0 4 1 3 8 8 *

1 hour
Section A
Section B

Section A
Section B
Total
DC (SJF/SW) 86328/2
2
Section A
1 Fig. 1 shows three products made from different metals.
vice nut and bolt saucepan
Fig. 1
Select a metal from the list below that could be used to make each product.
aluminium cast iron brass mild steel lead
vice ...................................................................................................................................................
nut and bolt ......................................................................................................................................
saucepan ......................................................................................................................................[3]
2 Fig. 2 shows a wheel brace and twist drill being used to drill a hole in wood.
Fig. 2
Give two reasons why scrap wood is clamped underneath the wood being drilled.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
© UCLES 2014 0445/33/O/N/14

3
[4]
4 Complete the drawing below to show a sliding bevel.
[2]
5 Name the two methods of filing shown in Fig. 3.
A B
Fig. 3
A .......................................................................................................................................................
B ...................................................................................................................................................[2]

4
6 Fig. 4 shows a cross-pein hammer.
Fig. 4
(a) The hammer handle is made from ash.
State one property of ash that makes it suitable for the hammer handle.
...............................................................................................................................................[1]
(b) Give one reason why one end of the hammer head is wedge shaped.
...............................................................................................................................................[1]
7 Fig. 5 shows a cycle helmet.
outer shell
inner shell
buckle
Fig. 5
Name a specific plastic used to make the:
(a) outer shell;
...............................................................................................................................................[1]
(b) inner shell;
...............................................................................................................................................[1]
(c) buckle.
...............................................................................................................................................[1]
© UCLES 2014 0445/33/O/N/14
5
8 Fig. 6 shows a board made from solid wood.
Fig. 6
(a) Name the fault that has occurred in the board.
...............................................................................................................................................[1]
(b) Give one reason why the fault has occurred.
...............................................................................................................................................[1]
9 Fig. 7 shows part of a table top and a rail.
table top
rail
Fig. 7
(a) Complete Fig. 7 to show how the rail could be fixed to the top using a screw. [2]
(b) Give one benefit of using screws when constructing products made from wood.
...............................................................................................................................................[1]

6
10 Fig. 8 shows sheet metal being cut.
Fig. 8
(a) Name the tool used to cut the sheet metal.
...............................................................................................................................................[1]
(b) Give one benefit of holding the tool in the vice while cutting the sheet metal.
...............................................................................................................................................[1]
© UCLES 2014 0445/33/O/N/14

7
Section B
11 Fig. 9 shows a play table for children.

The play table is made from 18 mm thick MDF and supplied as flat-pack for self-assembly.
75
0
table top
side
480
end
00
10
Fig. 9
(a) Describe two features of the design of the play table that make it suitable for children
3-6 years of age.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) (i) Give two benefits of using a template to mark out the shapes of the sides and ends.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Name one electrically powered saw that could be used to cut out the shapes of the sides
and ends.
.......................................................................................................................................[1]

8
(c) (i) Give two benefits of using MDF for the play table.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) The sides and the ends of the play table will be finished by spray painting.
Give two advantages of spray painting rather than applying the paint with a brush.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(d) The table top will be covered with a plastic laminate.
(i) Give one reason for covering the table top with a plastic laminate.
.......................................................................................................................................[1]
(ii) Name a suitable adhesive that could be used to glue a plastic laminate to the table top.
.......................................................................................................................................[1]
(e) Use sketches and notes to show how one end and one side could be joined using KD (knock-
down) fittings.
[3]
© UCLES 2014 0445/33/O/N/14

9
(f) Use sketches and notes to show how the table top could be supported inside the sides and
ends. Your method must allow for removal.
[3]
(g) Use sketches and notes to show a modification to the play table so that it could be lifted
easily.
Include details describing how the modification would be carried out in a school workshop.
[3]

10
(h) The play table could be made using legs and rails made from solid wood.
Use sketches and notes to show how the play table could be made from solid wood.
Show the sizes of the legs and rails on your sketches.
[5]
© UCLES 2014 0445/33/O/N/14

11
12 Fig. 10 shows a workstation for a laptop computer. The workstation is made from 16 mm thick
melamine faced chipboard and will be wall-mounted.
shelf
B
430
16
0
Fig. 10
(a) Give one advantage and one disadvantage of using melamine faced chipboard for the
workstation.
Advantage .................................................................................................................................
Disadvantage ........................................................................................................................[2]
(b) Sketch and name a corner joint at A.
Name of joint .........................................................................................................................[4]

12
(c) (i) Name two marking out tools, other than a pencil and rule, that could be used to mark out
the joint named in (b).
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Give the specific names of two other tools that could be used to produce the joint named
in (b).
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(d) Sketch and name a permanent joint that could be used to join the upright partition to the
base at B.
Name of joint ........................................................................................................................ [4]
(e) Use sketches and notes to show how each shelf could be adjusted to three different heights.
[3]
© UCLES 2014 0445/33/O/N/14

13
(f) The workstation has a 4 mm thick plywood back.

Use sketches and notes to show how the back of the workstation could be strengthened so
that it could be screwed to a wall.
[3]
(g) The design of the workstation could involve the use of a variety of pre-manufactured fittings.
(i) Describe how three different pre-manufactured fittings could be used in the construction
of the workstation.
1 ........................................................................................................................................
2 ........................................................................................................................................
3 ....................................................................................................................................[3]
(ii) Give two advantages of using pre-manufactured fittings.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]

14
13 Fig. 11 shows an incomplete design for a desk tidy made from acrylic. The base is not shown.
tube 200 high × Ø25
trays 3 thick
Fig. 11
(a) Give two benefits of making the desk tidy from acrylic.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2014 0445/33/O/N/14

15
(b) Fig. 12 shows details of one tray marked out on acrylic sheet.
15
50
waste
15
bend lines
15 70 15
Fig. 12
(i) Use sketches and notes to show how the tray could be cut out and the edges made flat
and smooth. Show how the acrylic would be held securely during the process.
[4]

16
(ii) Use sketches and notes to show how the sides of the tray could be bent to shape.
Include the following details:
• the method of heating the acrylic;
• use of a former;
• the method of holding the acrylic while it cools.
[5]
© UCLES 2014 0445/33/O/N/14

17
(c) Fig. 13 shows a cross-sectional view of an extrusion machine used to produce the tube for
the desk tidy.
plastic granules
heater
extruded tube
die
screw
Fig. 13
Complete the table to show the stages in producing the extruded tube.
Stage Process
4 The extruded tube cools.
[3]
(d) Use sketches and notes to show how one of the trays could be attached to the tube.
Your method must allow the tray to be removed quickly and must include fittings made only
from acrylic.
[5]

18
(e) (i) Use sketches and notes to show a design for a base into which the tube will fit
permanently. Include details of sizes and construction.
[4]
(ii) Use sketches and notes to show how you would check that the tube is upright when
fitted to the base.
[2]
© UCLES 2014 0445/33/O/N/14

19
BLANK PAGE
© UCLES 2014 0445/33/O/N/14

20
BLANK PAGE
© UCLES 2014 0445/33/O/N/14

* 0 8 1 6 1 2 1 7 6 1 *

1 hour
Section A
Section B
At the end of the examination, fasten all your work securely together.
DC (LK/SG) 101379/4
2
Section A
1 Complete the table below by naming each tool.
Tool Name
[3]
2 Fig. 1 shows a jigsaw. The jigsaw has a blade that can be replaced.
Fig. 1
Give two benefits of using a saw that has replaceable blades.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
3 From the list of materials shown below underline two composite materials.
aluminium Kevlar® polystyrene stainless steel glass reinforced plastic
[2]
© UCLES 2015 0445/31/M/J/15

3
4 Fig. 2 shows a rod that will be joined permanently to a base.
rod
base
Fig. 2
State a method of joining the rod to the base permanently when both parts are made from:
(a) mild steel ...................................................................................................................................
(b) acrylic ...................................................................................................................................[2]
5 Fig. 3 shows two wood joints labelled A and B.
A B
Fig. 3
(a) Name each of the wood joints labelled A and B.
A ...............................................................................................................................................
B ...........................................................................................................................................[2]
(b) Give one reason why joint B is stronger than joint A when they are glued.
...............................................................................................................................................[1]

4
6 (a) Name each of the tools labelled A and B shown below.
A B
A ...............................................................................................................................................
B ...........................................................................................................................................[2]
(b) State the purpose of tool A.
...............................................................................................................................................[1]
(c) State the purpose of tool B.
...............................................................................................................................................[1]
7 Complete the drawing below to show a tee halving joint.
[3]
© UCLES 2015 0445/31/M/J/15

5
8 Fig. 4 shows a small table made from hardwood.
Fig. 4
Give two possible reasons why the table top has split.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
9 Fig. 5 shows a palm sander to be used on wood.
Fig. 5
Describe two ways by which the designer has considered ergonomics in the design of the palm
sander.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
10 Fig. 6 shows a symbol found on a product made from a plastic.
2
HDPE
Fig. 6
(a) Name the plastic.
...............................................................................................................................................[1]
(b) State what is meant by the arrowed lines around the number 2.
...............................................................................................................................................[1]
6
Section B
11 Fig. 7 shows details of a variety of wooden shapes and pegs that are part of a child’s construction
kit. The construction kit will be made in a school workshop.
strip 250 × 40 × 10
block 350 × 40 × 40
all centres 50mm

Ø9 holes
Ø9 pegs
Fig. 7
(a) Fig. 8 shows a length of wood from which the strips are made.
10
40
Fig. 8
Use sketches and notes to show the stages in producing a one-off strip 250 mm long
complete with 9 mm diameter holes drilled. Name all the tools and equipment used.
[5]
© UCLES 2015 0445/31/M/J/15

7
(b) A drilling jig would be used to speed up batch production of the strips and blocks.
Use sketches and notes to show a design for a jig used in the drilling of 9 mm holes.
Name the materials used to make the jig.
[7]
(c) The wooden strips and blocks will have a finish applied to them.
(i) Give one advantage of applying a finish to the strips and blocks.
...........................................................................................................................................
(ii) Give one disadvantage of applying a finish to the strips and blocks.
.......................................................................................................................................[2]

8
(d) The construction kit needs a set of six identical wheels.

Use sketches and notes to show how six wheels could be produced.
• specific materials;
• processes used;
• two important sizes.
[8]
(e) The wooden pegs, used to connect the strips and blocks, are made from round section wood.
Give the correct name for round section wood.
...............................................................................................................................................[1]
(f) Many children’s toys are made from plastic.

Give two advantages of making children’s toys from plastic rather than from wood.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2015 0445/31/M/J/15

9
12 Fig. 9 shows a desk tidy made from 4 mm thick acrylic.
80 slot for rule 40 × 6
70
%
70
$
10
0
60
Fig. 9
(a) Complete the development (net) of the desk tidy below to show the bend lines.
Do not include the holes or slot.
80
380
[4]
(b) Complete the table below by giving details of the stages involved in finishing the sawn edges
of the acrylic to a high quality.
Stage Process
1 Draw file edges, holding the acrylic in a vice.
4
[3]

10
(c) (i) Use sketches and notes to show how the slot could be cut out and the edges made
smooth.
[3]
(ii) State two precautions you would take to prevent the acrylic from cracking when drilling
the holes.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(d) Use sketches and notes to show how the bend at A in Fig. 9 could be produced.
Include:
• the method of softening the acrylic;
• the use of a former;
• the method of retaining the shape while the acrylic cools.
[4]
© UCLES 2015 0445/31/M/J/15

11
(e) When the desk tidy shown in Fig. 9 is picked up and moved around, the pens, pencils and
rule fall out.
Use sketches and notes to show a modification to the desk tidy to overcome this problem.
[4]
(f) The desk tidy shown in Fig. 9 could be made from 1 mm thick aluminium sheet.
Use sketches and notes to show how the bend at B could be produced when the desk tidy is
made from 1 mm thick aluminium sheet.
Name the tools and equipment used.
[3]
(g) Both the acrylic and aluminium desk tidies will be self-finished.
Explain what is meant by the term ‘self-finished’.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

12
13 Fig. 10 shows details of a child’s puzzle and the tray in which the puzzle is placed.
The puzzle is made from six pieces of MDF and the tray is made from plywood.
16 20
0 0
12 mm thick MDF
six different colours
puzzle
tray: two layers of 4 mm thick plywood
Fig. 10
(a) Give two advantages of using MDF rather than plywood for the puzzle.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Describe three ways in which the designer has made the puzzle suitable for young children.
1 ................................................................................................................................................
2 . ...............................................................................................................................................
3 ............................................................................................................................................[3]
(c) The tray shown in Fig. 10 is made from two pieces of 4 mm plywood glued together.
(i) Use sketches and notes to explain why the construction of plywood makes it more
suitable for the tray than solid wood.
[3]
© UCLES 2015 0445/31/M/J/15

13
(ii) Use sketches and notes to show how the hole in the top piece of plywood could be cut
out and the sides of the hole made smooth.
[5]
(iii) Use sketches and notes to show how the top and bottom pieces of plywood could be
glued and clamped together.
Name a suitable adhesive and the type of cramps used.
[4]
(iv) The tray could be made from vacuum formed plastic.

Give two advantages of producing the tray from vacuum formed plastic rather than from
plywood.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]

14
(d) The puzzle could be produced using CAD/CAM.

Complete the abbreviations CAD/CAM below.
Computer Aided D .....................................................
Computer Aided M ..................................................... [2]
(e) Describe two quality control checks that would be carried out during the manufacture of the
puzzle and/or the tray.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(f) Give two reasons why the use of manufactured boards such as MDF and plywood, rather
than plastics, could be considered good for the environment.
1 ................................................................................................................................................
...................................................................................................................................................
2 ................................................................................................................................................
...............................................................................................................................................[2]
© UCLES 2015 0445/31/M/J/15

15
BLANK PAGE
© UCLES 2015 0445/31/M/J/15

16
BLANK PAGE
Permission to reproduce items where third-party owned material protected by copyright is included has been sought and cleared where possible. Every reasonable
effort has been made by the publisher (UCLES) to trace copyright holders, but if any items requiring clearance have unwittingly been included, the publisher will
be pleased to make amends at the earliest possible opportunity.
To avoid the issue of disclosure of answer-related information to candidates, all copyright acknowledgements are reproduced online in the Cambridge International
Examinations Copyright Acknowledgements Booklet. This is produced for each series of examinations and is freely available to download at www.cie.org.uk after
the live examination series.
© UCLES 2015 0445/31/M/J/15

* 7 9 1 4 0 8 0 5 3 4 *

1 hour
Section A
Section B
DC (NF/SG) 108053
2
Section A
1 Complete the table below by naming each tool.
Tool Name
[3]
2 Fig. 1 shows a jigsaw. The jigsaw has a blade that can be replaced.
Fig. 1
Give two benefits of using a saw that has replaceable blades.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
3 From the list of materials shown below underline two composite materials.
aluminium Kevlar® polystyrene stainless steel glass reinforced plastic
[2]
© UCLES 2015 0445/32/M/J/15

3
4 Fig. 2 shows a rod that will be joined permanently to a base.
rod
base
Fig. 2
State a method of joining the rod to the base permanently when both parts are made from:
(a) mild steel ...................................................................................................................................
(b) acrylic ...................................................................................................................................[2]
5 Fig. 3 shows two wood joints labelled A and B.
A B
Fig. 3
(a) Name each of the wood joints labelled A and B.
A ...............................................................................................................................................
B ...........................................................................................................................................[2]
(b) Give one reason why joint B is stronger than joint A when they are glued.
...............................................................................................................................................[1]

4
6 (a) Name each of the tools labelled A and B shown below.
A B
A ...............................................................................................................................................
B ...........................................................................................................................................[2]
(b) State the purpose of tool A.
...............................................................................................................................................[1]
(c) State the purpose of tool B.
...............................................................................................................................................[1]
7 Complete the drawing below to show a tee halving joint.
[3]
© UCLES 2015 0445/32/M/J/15

5
8 Fig. 4 shows a small table made from hardwood.
Fig. 4
Give two possible reasons why the table top has split.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
9 Fig. 5 shows a palm sander to be used on wood.
Fig. 5
Describe two ways by which the designer has considered ergonomics in the design of the palm
sander.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
10 Fig. 6 shows a symbol found on a product made from a plastic.
2
HDPE
Fig. 6
...............................................................................................................................................[1]
(b) State what is meant by the arrowed lines around the number 2.
...............................................................................................................................................[1]
6
Section B
11 Fig. 7 shows details of a variety of wooden shapes and pegs that are part of a child’s construction
kit. The construction kit will be made in a school workshop.
strip 250 × 40 × 10
block 350 × 40 × 40
all centres 50mm

Ø9 holes
Ø9 pegs
Fig. 7
(a) Fig. 8 shows a length of wood from which the strips are made.
10
40
Fig. 8
Use sketches and notes to show the stages in producing a one-off strip 250 mm long
complete with 9 mm diameter holes drilled. Name all the tools and equipment used.
[5]
© UCLES 2015 0445/32/M/J/15

7
(b) A drilling jig would be used to speed up batch production of the strips and blocks.
Use sketches and notes to show a design for a jig used in the drilling of 9 mm holes.
Name the materials used to make the jig.
[7]
(c) The wooden strips and blocks will have a finish applied to them.
(i) Give one advantage of applying a finish to the strips and blocks.
...........................................................................................................................................
(ii) Give one disadvantage of applying a finish to the strips and blocks.
.......................................................................................................................................[2]

8
(d) The construction kit needs a set of six identical wheels.

Use sketches and notes to show how six wheels could be produced.
• specific materials;
• processes used;
[8]
(e) The wooden pegs, used to connect the strips and blocks, are made from round section wood.
Give the correct name for round section wood.
...............................................................................................................................................[1]
(f) Many children’s toys are made from plastic.

Give two advantages of making children’s toys from plastic rather than from wood.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2015 0445/32/M/J/15

9
12 Fig. 9 shows a desk tidy made from 4 mm thick acrylic.
80 slot for rule 40 × 6
70
%
70
$
10
0
60
Fig. 9
(a) Complete the development (net) of the desk tidy below to show the bend lines.
Do not include the holes or slot.
80
380
[4]
(b) Complete the table below by giving details of the stages involved in finishing the sawn edges
of the acrylic to a high quality.
Stage Process
1 Draw file edges, holding the acrylic in a vice.
4
[3]

10
(c) (i) Use sketches and notes to show how the slot could be cut out and the edges made
smooth.
[3]
(ii) State two precautions you would take to prevent the acrylic from cracking when drilling
the holes.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(d) Use sketches and notes to show how the bend at A in Fig. 9 could be produced.
Include:
• the method of softening the acrylic;
• the use of a former;
• the method of retaining the shape while the acrylic cools.
[4]
© UCLES 2015 0445/32/M/J/15

11
(e) When the desk tidy shown in Fig. 9 is picked up and moved around, the pens, pencils and
rule fall out.
Use sketches and notes to show a modification to the desk tidy to overcome this problem.
[4]
(f) The desk tidy shown in Fig. 9 could be made from 1 mm thick aluminium sheet.
Use sketches and notes to show how the bend at B could be produced when the desk tidy is
made from 1 mm thick aluminium sheet.
[3]
(g) Both the acrylic and aluminium desk tidies will be self-finished.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

12
13 Fig. 10 shows details of a child’s puzzle and the tray in which the puzzle is placed.
The puzzle is made from six pieces of MDF and the tray is made from plywood.
16 20
0 0
12 mm thick MDF
six different colours
puzzle
tray: two layers of 4 mm thick plywood
Fig. 10
(a) Give two advantages of using MDF rather than plywood for the puzzle.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Describe three ways in which the designer has made the puzzle suitable for young children.
1 ................................................................................................................................................
2 . ...............................................................................................................................................
3 ............................................................................................................................................[3]
(c) The tray shown in Fig. 10 is made from two pieces of 4 mm plywood glued together.
(i) Use sketches and notes to explain why the construction of plywood makes it more
suitable for the tray than solid wood.
[3]
© UCLES 2015 0445/32/M/J/15

13
(ii) Use sketches and notes to show how the hole in the top piece of plywood could be cut
out and the sides of the hole made smooth.
[5]
(iii) Use sketches and notes to show how the top and bottom pieces of plywood could be
glued and clamped together.
Name a suitable adhesive and the type of cramps used.
[4]
(iv) The tray could be made from vacuum formed plastic.

Give two advantages of producing the tray from vacuum formed plastic rather than from
plywood.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]

14
(d) The puzzle could be produced using CAD/CAM.

Complete the abbreviations CAD/CAM below.
Computer Aided D .....................................................
Computer Aided M ..................................................... [2]
(e) Describe two quality control checks that would be carried out during the manufacture of the
puzzle and/or the tray.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(f) Give two reasons why the use of manufactured boards such as MDF and plywood, rather
than plastics, could be considered good for the environment.
1 ................................................................................................................................................
...................................................................................................................................................
2 ................................................................................................................................................
...............................................................................................................................................[2]
© UCLES 2015 0445/32/M/J/15

15
BLANK PAGE
© UCLES 2015 0445/32/M/J/15

16
BLANK PAGE
© UCLES 2015 0445/32/M/J/15

* 5 3 1 2 6 1 6 5 4 8 *

1 hour
Section A
Section B
DC (AC/FD) 101409/3
2
Section A
1 Fig. 1 shows a student using a drilling machine safely.
Fig. 1
State three safety precautions taken by the student using the drilling machine.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
3 ...................................................................................................................................................[3]
2 Many items of furniture are made from chipboard.

State two advantages of making furniture from chipboard rather than from solid wood.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
3 Complete the table below by naming a suitable adhesive for each of the described uses.
Use Adhesive
gluing plastic laminate to a manufactured
board table top
wooden boat building
gluing metal parts together

[3]
© UCLES 2015 0445/33/M/J/15

3
4 Name a suitable finish for the following products.
aluminium comb ...............................................................................................................................
wooden chopping board ...................................................................................................................
handle of a junior hacksaw ...........................................................................................................[3]
5 Fig. 2 shows a toy car and a machine part. Both are made by the die casting process.
Fig. 2
Give two benefits of using the die casting process to make products.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
6 Name the process that uses the equipment shown in Fig. 3.
Fig. 3
......................................................................................................................................................[1]

4
7 Fig. 4 shows two pieces of wood nailed together.
Fig. 4
(a) Give one reason why the nails are arranged as shown in Fig. 4.
...............................................................................................................................................[1]
(b) Give the specific name of one type of nail that could be used to join wood together.
...............................................................................................................................................[1]
(c) Name a tool that could be used to pull nails out of wood.
...............................................................................................................................................[1]
8 Complete the drawing below to show the marking out for a mortise and tenon joint.
[3]
© UCLES 2015 0445/33/M/J/15

5
9 Fig. 5 shows two centre lathe operations.
ZRUNURWDWHV ZRUNURWDWHV
$ %
Fig. 5
Select the correct centre lathe operation for A and B from the list below.
cutting off parting off shearing off facing off turning off
Operation A ......................................................................................................................................
Operation B ..................................................................................................................................[2]
10 Complete the table below by naming a specific plastic for each product.
3URGXFW 6SHFLILFSODVWLF
IRRGWUD\
SOXPELQJSLSH
FXUWDLQWUDFN
[3]

6
Section B
11 Fig. 6 shows detailed views of a photograph holder made from 4 mm thick clear acrylic.
spacer
130
130 # 10 # 4
200
back front
spacer
stand
Fig. 6
(a) Fig. 7 shows the stand for the photograph holder marked out ready to be cut to shape.
ZDVWH

Fig. 7
Complete the table below by describing what each tool or item of equipment is used for.
Tool / item of
Stage Use
equipment
1 scriber
2 hegner or scroll saw
3 hand file
4 wet and dry paper

[4]
© UCLES 2015 0445/33/M/J/15

7
(b) The front and back are joined to the spacers with acrylic cement.
Give two safety precautions that must be taken when using acrylic cement.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(c) Fig. 8 shows views of a photograph holder made from 1 mm thick aluminium sheet.
KROH
#

Fig. 8
Give two properties of aluminium that make it suitable for the photograph holder.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(d) Use sketches and notes to show how you would cut out the square hole in the 1 mm thick
aluminium sheet shown in Fig. 8.
[5]

8
(e) Describe how the aluminium sheet would be finished to a high quality.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[3]
(f) A batch of twenty identical aluminium photograph holders will be made in a school workshop.
Use sketches and notes to show how the sides of the aluminium photograph holder, shown in
Fig. 8, could be folded accurately.
[5]
© UCLES 2015 0445/33/M/J/15

9
(g) There are benefits of using CAD (Computer Aided Design) and CAM (Computer Aided
Manufacture) when designing and making the photograph holders in Fig. 6 and Fig. 8.
(i) Explain one benefit of using CAD to design the photograph holders.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) Explain one benefit of using CAM to make the photograph holders.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]

10
12 Fig. 9 shows views of a planter in which flowers can be grown.

The planter is made from 15 mm thick solid wood and is sold as flat-pack for self-assembly.

HQG
WRSVLGH
ORZHUVLGH

UDLO
OHJ
EDVH
HQGYLHZ
Fig. 9
(a) Describe one property of solid wood that makes it suitable for use in a planter.
...............................................................................................................................................[1]
(b) Name two solid woods that would be suitable for the planter.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(c) Name two finishes that would be suitable for the planter.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2015 0445/33/M/J/15

11
(d) Use sketches and notes to show a modification to the planter that would make it easier to
carry. Include details of materials and/or methods of construction.
[4]

12
(e) Customers must be able to assemble the planter using only:

• wood screws;
• nuts and bolts;
• dowels and adhesive.
(i) Use sketches and notes to show how these three methods of construction could be
used to join different parts of the planter.
[12]
(ii) List four stages in the order customers should assemble the various parts of the planter.
1 ........................................................................................................................................
2 ........................................................................................................................................
3 ........................................................................................................................................
4 ....................................................................................................................................[4]
© UCLES 2015 0445/33/M/J/15

13
13 Fig. 10 shows a magazine rack made from acrylic.
strips 50 ⫻ 6
400
ends 10 thick
base
5
37
20
0
Fig. 10
(a) Identify three areas of research that would need to be carried out when designing the
magazine rack.
1 ................................................................................................................................................
2 ................................................................................................................................................
3 ............................................................................................................................................[3]
(b) Fig. 11 shows a template of the shape of one end of the magazine rack glued on to acrylic
sheet.
Fig. 11
Give two benefits of using a template when marking out.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]

14
(c) Fig. 12 shows views of the base of the magazine rack.

GHYHORSPHQWQHW
Fig. 12
(i) Use sketches and notes to show how the development (net) of the tray would be heated
and bent to shape.
[3]
(ii) Explain why it would be an advantage to use a strip heater or line bender, rather than an
oven, to heat the acrylic.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
© UCLES 2015 0445/33/M/J/15

15
(d) The strips will be cut from a length of acrylic.

Each of the strips will be fixed to the ends using acrylic cement.
(i) Describe how you would make sure that all the strips were cut and finished to the same
length.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) Use sketches and notes to show how the strips could be equally spaced and held in
position while the acrylic cement sets.
[4]
Question 13(e) is printed on the next page.

16
(e) (i) Many magazine racks are made from wood.

Use sketches and notes to show how the magazine rack shown in Fig. 10 could be
redesigned using wood.
Include the specific names of the wood used and methods of construction.
[6]
(ii) Explain why wooden magazine racks could be considered to be more environmentally
friendly than those made from plastic materials.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[3]
© UCLES 2015 0445/33/M/J/15

* 1 4 6 6 1 7 4 9 0 5 *

1 hour
Section A
Section B
DC (NF/CGW) 101538/3
2
Section A
1 Fig. 1 shows two machine saws.
A B
Fig. 1
Name each machine saw labelled A and B.
A .......................................................................................................................................................
B .................................................................................................................................................. [2]
2 Fig. 2 shows two screws with different slots.
A B
Fig. 2
Name the types of slot shown in screw A and screw B.
A .......................................................................................................................................................
B .................................................................................................................................................. [2]
3 A list of plastics is given below.
acrylic polyester resin epoxy resin polypropylene
Select a plastic from the list that:
(a) can be used with glass fibre;
...................................................................................................................................................
(b) is used as an adhesive.
.............................................................................................................................................. [2]
© UCLES 2015 0445/31/O/N/15
3
4 Fig. 3 shows part of a process used to join pieces of metal permanently.
Fig. 3
(a) Name the process shown in Fig. 3.
...................................................................................................................................................
(b) Name one other method of joining pieces of metal permanently.
.............................................................................................................................................. [2]
5 Name the parts A, B and C of the centre lathe shown below.
A B
A .......................................................................................................................................................
B .......................................................................................................................................................
C .................................................................................................................................................. [3]
6 Complete the drawing below to show a tee hinge.
[2]

4
7 Fig. 4 shows a tennis racquet made from carbon fibre reinforced plastic (CFRP).
Fig. 4
Give two properties of carbon fibre reinforced plastic (CFRP) that make it suitable for a tennis
racquet.
1 ......................................................................................................................................................
2 ................................................................................................................................................. [2]
8 Complete the table below by giving a specific name and a different specific use for each hammer.
Hammer Specific name Specific use
[4]
© UCLES 2015 0445/31/O/N/15

5
9 Fig. 5 shows a cross-sectional view of an injection moulding machine in use.
B
A
Fig. 5
Name the parts A, B and C of the machine shown in Fig. 5.
A .......................................................................................................................................................
B .......................................................................................................................................................
C .................................................................................................................................................. [3]
10 Fig. 6 shows the end of a piece of wood. Two holes will be drilled at the centres shown.
Add to Fig. 6 to show a drilling jig that could be used to make sure that the holes are drilled
accurately.
Fig. 6
[3]

6
Section B
11 Fig. 7 shows a tray made from 6 mm thick acrylic sheet.
60
0
46
30
0
Fig. 7
(a) (i) Fig. 8 shows the acrylic sheet from which the tray will be cut.
420
640
Fig. 8
Draw on Fig. 8 the development (net) of the tray.

Indicate those lines that will be bent and those that will be cut.
Do not include the cut out handholds but do include the shaped ends. [5]
© UCLES 2015 0445/31/O/N/15

7
(ii) Give one advantage of using a marker pen rather than a scriber when marking lines on
acrylic.
...................................................................................................................................... [1]
(iii) Give two reasons why there is a gap at each corner of the tray.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(b) Complete the table below by describing three stages in finishing the cut edges of the acrylic
to a high quality.
Stage Process
[3]
(c) (i) Details of one of the handholds are shown below.

Use sketches and notes to show how the handhold could be cut out and the edges made
smooth. Name all the tools used.
handhold 100 × 25
[4]

8
(ii) Give one reason why a designer would need to consider ergonomics when designing
the handholds.
...........................................................................................................................................
...................................................................................................................................... [1]
(d) Use sketches and notes to show how the development (net) of the tray would be heated and
bent to shape.
[3]
© UCLES 2015 0445/31/O/N/15

9
(e) Fig. 9 shows a different design for a tray made from 6 mm thick acrylic sheet.
60
0
46
30
0
Fig. 9
Use sketches and notes to show a design for a separate handle that would be attached to
each end of the tray.
Your design must show the following:
• details of the material from which the handle is made and sizes;
• how the handle would be made in a school workshop;
• the method of attaching the handle securely to the tray.
[6]

10
12 Fig. 10 shows a bedside table. The height of the bedside table can be adjusted.
The table top is made from veneered manufactured board. The legs and upright are made from
square metal tube.
60
0
40
table top 15 thick

maximum height 800
adjustable minimum height 700
upright
75
0
A
square metal tube 32 × 32

castor
Fig. 10
(a) Name a suitable manufactured board for the table top.
.............................................................................................................................................. [1]
(b) Give one disadvantage of using veneer on a manufactured board rather than solid wood for
the table top.
.............................................................................................................................................. [1]
© UCLES 2015 0445/31/O/N/15

11
(c) Use sketches and notes to show a modification to the table top that would prevent items from
slipping off.
Include:
• names of materials used;

• methods of construction;
• three important sizes.
[5]
(d) Use detailed sketches and notes to show how the upright could be fixed securely to the
underside of the table top. Additional materials may be used.
[5]
12
(e) Use sketches and notes to show how the joint at A could be strengthened.
Include details of materials, sizes and constructions used.
[4]
(f) Use sketches and notes to show how the table top could be adjusted and locked at different
heights between 700 mm – 800 mm.
[6]
© UCLES 2015 0445/31/O/N/15

13
(g) Explain how a designer would use anthropometric data when designing the bedside table.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [3]

14
13 Fig. 11 shows details of a coffee table made from two separate parts.
Each part is made from laminated wood.
350
0
80
35
0
Fig. 11
(a) When designing the coffee table a designer would need to meet a list of specification points.
Give three specification points for the coffee table.
1 ...............................................................................................................................................
2 ...............................................................................................................................................
3 .......................................................................................................................................... [3]
(b) Use detailed notes and sketches to show how one part of the coffee table would be laminated
to a thickness of 15 mm.
[5]
© UCLES 2015 0445/31/O/N/15

15
(c) Fig. 12 shows part of the coffee table with details of a slot marked out ready to be cut out.
15 mm
Fig. 12
(i) Name two marking out tools, other than a pencil and steel rule, used to mark out the slot.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Name two tools that could be used to cut out the slot.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(d) Describe the purpose of the following items used to prepare the surfaces of the laminated
parts to take a finish:
(i) a cork block;
...........................................................................................................................................
(ii) a damp cloth;
...........................................................................................................................................
(iii) glasspaper.
...................................................................................................................................... [3]
(e) The coffee table will have a finish applied with a brush.
(i) Give two reasons why the coffee table requires an applied finish.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
TURN OVER FOR THE REST OF THIS QUESTION

16
(ii) Name one suitable finish for the coffee table.
...................................................................................................................................... [1]
(iii) Give one precaution you would take to ensure a high quality finish when using a brush.
...................................................................................................................................... [1]
(f) Fig. 13 shows a laminated wood coffee table and a traditional coffee table with legs and rails.
Fig. 13
Give two advantages of using a laminated wood construction rather than a traditional legs
and rails construction for a coffee table.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(g) Explain how the use of a computer could help a designer when:
(i) carrying out research;
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) designing the coffee table.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
© UCLES 2015 0445/31/O/N/15

* 0 4 0 4 6 6 6 6 4 2 *

1 hour
Section A
Section B
DC (NF/CGW) 101543/2
2
Section A
1 Give three pieces of information needed when ordering nuts and bolts.
1 ......................................................................................................................................................
2 ......................................................................................................................................................
3 ................................................................................................................................................. [3]
2 Complete the drawing below to show a coping saw.
[2]
3 Fig. 1 shows a wooden frame construction glued and clamped.
scrap wood
scrap wood
Fig. 1
(a) Name the type of cramp used.
...................................................................................................................................................
(b) Give one reason why pieces of scrap wood are used.
.............................................................................................................................................. [2]
© UCLES 2015 0445/32/O/N/15
3
4 Underline the two ‘smart’ materials in the list below.
aluminium polymorph nitinol fibreglass nylon [2]
Tool Specific name Specific use
[4]
6 Fig. 2 shows a veneer being cut from a log.
Fig. 2
(a) Give one advantage of using veneers when making furniture.
...................................................................................................................................................
(b) Give one disadvantage of using veneers when making furniture.
.............................................................................................................................................. [2]

4
7 Fig. 3 shows part of a wooden frame.

Add to Fig. 3 to show how the corner joint could be strengthened.
Fig. 3 [2]
8 Fig. 4 shows a handle made from aluminium alloy.
Fig. 4
(a) Name the process used to make the handle.
...................................................................................................................................................
(b) Give one suitable finish for the handle.
.............................................................................................................................................. [2]
© UCLES 2015 0445/32/O/N/15

5
9 Fig. 5 shows a block of wood with a shape marked out ready to be removed.
12 waste to be removed
Fig. 5
Describe three main stages in removing the waste wood and producing clean, smooth edges.
1 ......................................................................................................................................................
2 ......................................................................................................................................................
3 ................................................................................................................................................. [3]
10 Fig. 6 shows two different wooden chairs.
rail
leg
A B
Fig. 6
(a) Name the process used to produce the legs in chair A.
...................................................................................................................................................
(b) Name one construction that could be used to join the legs and rails in chair B.
...................................................................................................................................................
(c) Give one advantage of the construction of chair A over chair B.
.............................................................................................................................................. [3]
6
Section B
11 Fig. 7 shows views of a computer desk made from 15 mm thick manufactured board.
The computer desk will be sold as flat-pack furniture for self-assembly.
A
end
top
keyboard
shelf
780
63
0
0
48
Fig. 7
(a) Give two benefits of flat-pack furniture for:
(i) the consumer;
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) the manufacturer.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
© UCLES 2015 0445/32/O/N/15

7
(b) Use sketches and notes to show how knock-down (KD) fittings could be used to join the top to
one end at A.
[4]
(c) Use sketches and notes to show how the keyboard shelf could be made to move in and out
as shown in Fig. 7. Include details of materials and constructions used.
[4]

8
(d) The ends and shelves will be spray painted.
(i) Give two advantages of spray painting rather than applying paint with a brush.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Describe two safety precautions you would take when spray painting.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(e) Evaluate the design of the computer desk shown in Fig. 7 in terms of:
(i) safety;
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) appearance;
...........................................................................................................................................
...................................................................................................................................... [2]
(iii) costs.
...........................................................................................................................................
...................................................................................................................................... [2]
(f) Explain why the computer desk could be considered to have a limited lifetime.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [3]
© UCLES 2015 0445/32/O/N/15

9
BLANK PAGE
Question 12 is printed on the next page.

10
12 Fig. 8 shows an incomplete design for a freestanding barbecue.

The barbecue body is made from 1 mm thick mild steel sheet.
350
500
body
Fig. 8
(a) Give two reasons why mild steel is suitable for the barbecue body.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Give one reason why the mild steel sheet would need an applied finish.
.............................................................................................................................................. [1]
(c) Fig. 9 shows one end of the barbecue body marked out, ready to be cut to shape.
350
flaps 10 mm wide
250
1 mm thick mild steel sheet
Fig. 9
© UCLES 2015 0445/32/O/N/15

11
Use sketches and notes to show how the shape could be cut out.
Name all the tools and equipment.
[4]
(d) Fig. 10 shows one end of the barbecue body with flaps bent to 90°.
flaps bent to 90°
Fig. 10
Use sketches and notes to show how the flaps could be bent to 90°.
[3]
12
(e) Sketch one permanent method of joining the ends to the sides of the barbecue body.
[2]
(f) Use sketches and notes to show how the barbecue body could be supported at a height of
500 mm above the ground.
Your design must include:

• named materials;
• two important sizes;
• a temporary method of joining the support to the barbecue body.
[8]
© UCLES 2015 0445/32/O/N/15
13
(g) Fig. 11 shows three tools commonly used with the barbecue.
Fig. 11
Use sketches and notes to design a rack for the three tools that could be fixed to the
barbecue body.
[5]

14
13 Fig. 12 shows a palette used to mix paints. The palette is vacuum formed.
25
150
0
0
2
Fig. 12
(a) (i) Name a suitable plastic for the palette.
...................................................................................................................................... [1]
(ii) A former made from MDF is used to vacuum form the palette.
Give two advantages of using MDF rather than solid wood for the former.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(iii) Describe two considerations you would take into account when making a former used to
vacuum form the palette.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(b) Use detailed sketches and notes to show how the palette would be vacuum formed.
[8]
© UCLES 2015 0445/32/O/N/15

15
(c) Fig. 13 shows a holder used when mixing paints.
plastic paint pot
manufactured board 6 mm thick

holes Ø40
softwood 12 mm thick
40
0
25
15
0
Fig. 13
(i) Name a manufacturing process, other than vacuum forming, used to produce the plastic
paint pots.
...................................................................................................................................... [1]
(ii) Use sketches and notes to show how the manufactured board top would be held securely
while the holes for the paint pots are drilled.
[3]
Question 13 continues on the following page.

16
(iii) Use sketches and notes to show how the manufactured board top could be joined
permanently to the softwood sides.
[3]
(d) Fig. 14 shows three paintbrushes that will be stored with the holder shown in Fig. 13.
minimum Ø maximum Ø length

6 12
240
5 9
200
3 5
150
Fig. 14
Use sketches and notes to show a modification to the holder so that the three paintbrushes
could be stored safely. Include details of materials, constructions and sizes.
[5]
© UCLES 2015 0445/32/O/N/15

* 8 6 2 2 4 0 8 0 6 1 *

1 hour
Section A
Section B
DC (NF/CGW) 101540/4
2
Section A
1 Fig. 1 shows a countersunk head woodscrew and a round head woodscrew.
countersunk round
Fig. 1
(a) Show clearly on Fig. 1:
(i) the length of the countersunk head woodscrew;
(ii) the length of the round head woodscrew. [2]
(b) State what is meant by the term ‘gauge’ when choosing a woodscrew.
.............................................................................................................................................. [1]
2 Fig. 2 shows part of a car rear light unit.
Fig. 2
(a) Name a suitable plastic for the rear light unit.
.............................................................................................................................................. [1]
(b) Give two properties of the plastic that make it suitable for the rear light unit.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2015 0445/33/O/N/15

3
3 Complete the drawing below to show a G cramp.
[2]
4 Fig. 3 shows two lengths of wood, A and B. Each piece is 100 mm long.
25 × 25
A B
Fig. 3
Describe how you would produce the shape shown in length B from the square section shape A.
..........................................................................................................................................................
..........................................................................................................................................................
..................................................................................................................................................... [2]
5 Fig. 4 shows food packaging made from plastic.
rib
Fig. 4
(a) Name the process used to make the food packaging.
.............................................................................................................................................. [1]
(b) Give one reason why ribs are used in the design of the food packaging.
.............................................................................................................................................. [1]

4
6 Fig. 5 shows a metalworking process.
Fig. 5
.............................................................................................................................................. [1]
(b) Name a metal commonly used for the process shown in Fig. 5.
.............................................................................................................................................. [1]
7 Fig. 6 shows views of a student making a model of a tool handle.
mark out cut out shape finished model
Fig. 6
(a) Name a suitable plastic that could be used to make the model of the tool handle shown in
Fig. 6.
............................................................................................................................................. [1]
(b) The model of the tool handle could also be made from the ‘smart’ material, polymorph.
Give two advantages of using polymorph for the tool handle rather than a plastic material.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2015 0445/33/O/N/15

5
8 Fig. 7 shows an incomplete drawing of the side view of the jaws of a machine vice used to hold
metal while it is drilled.
Fig. 7
Complete the drawing to show details of the machine vice jaws. [2]
9 Fig. 8 shows a bending jig and metal rod that has been bent to shape.
metal rod Ø6
Ø10 holes
1st peg in position
Fig. 8
Draw on the base in Fig. 8 to show the positions of three additional ∅10 metal pegs that would
enable the ∅6 metal rod to be bent to the shape shown in Fig. 8. [3]
10 Fig. 9 shows metal being hard (silver) soldered.

Name the items of equipment A, B and C in Fig. 9.
B
A
C
Fig. 9
A .......................................................................................................................................................
B .......................................................................................................................................................
C .................................................................................................................................................. [3]
6
Section B
11 Fig. 10 shows a basic design for a wall-mounted letter and key rack made from 4 mm thick acrylic
sheet.
100
70
hook
0
24
Fig. 10
(a) Fig. 11 shows the development (net) of the letter and key rack marked out on a sheet of acrylic.
100
70
50
Fig. 11
Name two tools used to mark out the development (net).
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2015 0445/33/O/N/15
7
(b) When drilling holes in acrylic sheet there is a danger that the acrylic could crack.
State two precautions that you could take to reduce the risk of this happening.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(c) Use sketches and notes to show how the development (net) of the letter and key rack would
be heated and bent to shape.
[3]
(d) The basic shape of the letter and key rack could be produced by the extrusion process.
Fig. 12 shows an extrusion moulding machine.
Add notes to Fig. 12 to describe the process of extrusion. [4]
basic shape of letter and key rack
Fig. 12

8
(e) Use sketches and notes to show how a partition could be added along the length of the base
of the letter and key rack so that letters could be kept separate.
Include all constructional details and sizes.
[5]
(f) Fig. 13 shows a length of ∅5 acrylic rod from which the five hooks will be made.
Fig. 13
Use sketches and notes to show how:
• the hooks would be sawn to length;

• the sawn ends would be made smooth;
• the hooks would be fixed permanently in the ∅5 holes.
[5]
© UCLES 2015 0445/33/O/N/15
9
(g) The letter and key rack will be wall-mounted.

Use sketches and notes to show a modification to the design so that it could be positioned
against a wall. Include all constructional details and sizes.
Holes must not be visible when viewed from the front.
[4]

10
12 Fig. 14 shows a coffee table. A cutting list gives details of sizes of each of its parts.
glass top 600 × 450
Number Length × Width

Part required × Thickness Material
Manufactured
A Top 1 1000 × 600 × 20 board
Legs 4 450 × 50 × 50 Hardwood
Long rails 2 800 × 80 × 20 Hardwood
End rails 2 500 × 80 × 20 Hardwood
Fig. 14
(a) Give two characteristics that you would expect to find in hardwoods used to make high quality
furniture.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Give one reason why the hardwood used to make the coffee table must be seasoned.
.............................................................................................................................................. [1]
(c) (i) Give one reason why the edges of the manufactured board table top would need to be
covered with a lipping.
...................................................................................................................................... [1]
(ii) Describe one type of lipping that could be applied to the edge of the manufactured board.
...................................................................................................................................... [1]
© UCLES 2015 0445/33/O/N/15

11
(d) Sketch and name a suitable joint at A in Fig. 14
[4]
(e) Fig. 15 shows one leg marked out ready to be shaped.
waste
45
0
Fig. 15
(i) Name a plane that could be used to remove the waste.
...................................................................................................................................... [1]
(ii) Use sketches and notes to show how the leg would be held in a vice so that the waste
could be planed off.
[2]

12
(f) Fig. 16 shows one corner of the coffee table with details of a leg, rails and table top.
table top 20 thick
rail 80 × 20
leg 50 × 50
Fig. 16
Use sketches and notes to show how the table top could be secured to the rails.
[4]
© UCLES 2015 0445/33/O/N/15
13
(g) Fig. 17 shows the area of the table top to be removed to allow for the 6 mm thick glass insert.
glass 600 × 450
table top 1000 × 600
Fig. 17
(i) Use sketches and notes to show how the waste could be removed and the edges made
flat and smooth.
[4]
(ii) Use sketches and notes to show how the 6 mm thick glass could be supported inside the
table top. Include details of constructions and sizes.
[3]

14
(h) Explain how the coffee table shown in Fig. 14 could be considered to be a product that is
environmentally friendly.
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [2]
© UCLES 2015 0445/33/O/N/15

15
13 Fig. 18 shows a DVD rack made from 1 mm thick sheet metal.
5
24
10
0
Fig. 18
(a) (i) Name two tools used to mark out the slots on the sheet metal shown below.
275
290 slots 15 mm wide
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Use sketches and notes to show how one slot could be cut out and the edges made flat
and smooth. Name all the tools and equipment used.
[6]
16
(b) The DVD rack could be made from mild steel or aluminium.
(i) Name a suitable applied finish for a DVD rack made from mild steel.
...................................................................................................................................... [1]
(ii) Describe how you could finish the DVD rack when made from aluminium without applying
an additional finish.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [3]
(c) Use sketches and notes to show how the sheet metal could be bent to shape.
[4]
© UCLES 2015 0445/33/O/N/15

17
(d) As the user’s collection of DVDs increases an additional DVD rack is needed.
Use sketches and notes to show how the DVD rack in Fig. 18 could be modified so that an
identical DVD rack could be connected to either end of it quickly and easily.
Include details of materials used and sizes.
[4]
(e) There is a danger that the edges of the DVD rack could cause scratches when placed on a
polished surface.
Use sketches and notes to show a design modification to the DVD rack to prevent this.
[4]
(f) Give one reason why the DVD rack could be considered to be a product with a limited lifetime.
...................................................................................................................................................
.............................................................................................................................................. [1]
© UCLES 2015 0445/33/O/N/15
18
BLANK PAGE
© UCLES 2015 0445/33/O/N/15

19
BLANK PAGE
© UCLES 2015 0445/33/O/N/15

20
BLANK PAGE
© UCLES 2015 0445/33/O/N/15

* 0 7 5 6 3 9 4 9 5 1 *

1 hour
Section A
Section B
DC (KN/FD) 116911/1
2
Section A
1 Fig. 1 shows the edge of a piece of wood being planed.
Fig. 1
(a) Name the type of plane in Fig. 1.
...............................................................................................................................................[1]
(b) Draw on the wood in Fig. 1 to show the correct grain direction. [1]
2 Fig. 2 shows a desk tidy made from a plastic.
Fig. 2
Give three specification points for the desk tidy.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
3 ...................................................................................................................................................[3]
3 Complete the statement by adding the correct material from the list below.
‘Hardening and tempering is a process that is carried out on
.............................................................................................’
thermosetting plastic manufactured board carbon steel composite material [1]
© UCLES 2016 0445/31/M/J/16

3
4 Complete the drawing below to show a through housing joint.
[3]
5 Fig. 3 shows a container used in a fast food outlet.
Fig. 3
(a) Name a suitable plastic that could be used to make the container.
...............................................................................................................................................[1]
(b) (i) Give one advantage of using a plastic for this type of container.
...........................................................................................................................................
(ii) Give one disadvantage of using a plastic for this type of container.
.......................................................................................................................................[2]

4
6 Fig. 4 shows a chisel.
Fig. 4
(a) Name the type of chisel shown in Fig. 4.
...............................................................................................................................................[1]
(b) Describe two features of the chisel shown in Fig. 4 that makes it suitable for its purpose.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
7 Fig. 5 shows a remote control.
Fig. 5
Give three ergonomic features in the design of the remote control.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
3 ...................................................................................................................................................[3]
8 Complete the drawing below to show a flat file.
[2]
© UCLES 2016 0445/31/M/J/16

5
9 Fig. 6 shows a chair made from wood.
Fig. 6
(a) Name the process by which the parts of the chair are shaped.
...............................................................................................................................................[1]
(b) Give one benefit of this type of process when making the chair.
...............................................................................................................................................[1]
10 Show clearly on the drawing of the centre lathe below where each of the parts labelled A, B and C
would be fitted.
$ % &
[3]

6
Section B
11 Fig. 7 shows views of an incomplete design for a wall-mounted cabinet.
A
softwood sides 15 thick
0
50
400
15
0
Fig. 7
(a) (i) Name a suitable softwood for the sides of the cabinet.
.......................................................................................................................................[1]
(ii) Name a manufactured board for the back of the cabinet and suggest a suitable standard
thickness.
Manufactured board ......................................................................................................[1]
Suitable thickness .........................................................................................................[1]
(b) Fig. 8 shows four pre-manufactured components that could be used in the construction of the
cabinet.
handle butt hinge magnetic catch wall plate
Fig. 8
© UCLES 2016 0445/31/M/J/16

7
(i) Give two benefits of using pre-manufactured fittings when constructing the cabinet.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Describe where each of the pre-manufactured components could be used in the cabinet
and how they would be fitted.
Handle ...............................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
Butt hinge ..........................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
Magnetic catch ..................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
Wall plate ...........................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(c) Sketch and name a permanent joint that could be used at corner A in Fig. 7.
[4]
8
(d) Use sketches and notes to show how one of the glass shelves could be supported at three
different positions inside the cabinet.
[3]
(e) Fig. 9 shows details of one corner of the door frame.
40
12 thick
Fig. 9
(i) Name a suitable corner joint for the door frame.
.......................................................................................................................................[1]
(ii) Use sketches and notes to show how a 4 thick glass panel could be fitted to the door
frame.
[3]
(f) Many cabinets have solid doors.

Give one advantage of a framed door with a glass panel rather than a solid door.
...............................................................................................................................................[1]
© UCLES 2016 0445/31/M/J/16
9
12 Fig. 10 shows details of a table football game.
cabinet
18 thick
metal rod
100
12
00
600
Fig. 10
(a) (i) The metal rods could be made from Ø10 mild steel or aluminium.
Choose either mild steel or aluminium and give a reason for your choice.
Chosen metal ............................................................
Reason ..........................................................................................................................[1]
(ii) When pulled and pushed, the rods cause the holes in the side of the cabinet to become
worn and enlarged.
Use sketches and notes to show how this problem could be overcome.
Name any materials used.
[3]

10
(b) (i) Fig. 11 shows a metal rod that will be attached to a wooden handle by means of an
epoxy resin adhesive.
handle
metal rod
Fig. 11
Describe how an epoxy resin adhesive would be prepared and applied.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) The handles could be produced using a smart material such as polymorph.
Describe how polymorph could be used to produce the handles.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[3]
(c) (i) Fig. 12 shows one of the players and the metal rod to which it is attached.
The players are made from injection moulded plastic.
Add sketches and notes to Fig. 12 to show how the player could be fixed to the metal rod
without the use of adhesive.
[3]
Fig. 12
© UCLES 2016 0445/31/M/J/16
11
(ii) Fig. 13 shows a cross-sectional view of an injection moulding machine.

Complete the table to give the stages in the injection moulding process.
multi-part hopper
mould
injector
heater screw or ram
Fig. 13
Stage Process
1
2
3
4
5 The mould is cooled and the moulding ejected
[4]
(iii) Explain why the injection moulding process is only suitable when manufacturing in large
quantities.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(d) The players could be made from aluminium.

Name a process that could be carried out in a school workshop to produce the players using
aluminium.
...............................................................................................................................................[1]

12
(e) Use sketches and notes to design a scoring system that could be used during a game of
table football.
The scoring system must:

• be fixed to the cabinet;
• record a maximum of five goals scored at each end.
[6]
© UCLES 2016 0445/31/M/J/16

13
13 Fig. 14 shows a hardwood shelf supported by two end brackets.

The brackets could be made from acrylic or aluminium.
hardwood shelf 15 thick
0
60
20
0
Fig. 14
(a) (i) Give two benefits of using a template to mark out the shape of a bracket.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Explain why a template would need to be made from wood or metal rather than card or
paper when marking out large quantities of brackets.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(b) (i) Acrylic and aluminium are materials that can be self-finished.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]

14
(ii) Fig. 15 shows the shape of one bracket marked out on sheet material.
Fig. 15
You may choose to make the bracket in either 4 thick acrylic or 1.5 thick aluminium.
Use sketches and notes to show how one bracket could be cut out by hand and the
edges made smooth in the material of your choice.
Chosen material ...............................................................
[5]
© UCLES 2016 0445/31/M/J/16

15
(c) Use sketches and notes to show how one of the bends could be produced when the bracket
is made from:
(i) 4 thick acrylic;
[3]
(ii) 1.5 thick aluminium.
[3]
(d) Explain why round head screws rather than countersink head screws would be used to screw
the brackets to the wall when the brackets are made from 1.5 thick aluminium.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]
(e) Explain why the hardwood shelf would not be glued permanently to the brackets.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

16
(f) Fig. 16 shows details of the right hand bracket.
50
60
60
Fig. 16
Use sketches and notes to show how the shelf and bracket could be modified so that the shelf
could be secured to the bracket without the use of fittings, fixings or adhesive.
[4]
© UCLES 2016 0445/31/M/J/16

* 2 1 7 8 9 0 0 3 4 6 *

1 hour
Section A
Section B
DC (RW) 124565
2
Section A
1 Fig. 1 shows the edge of a piece of wood being planed.
Fig. 1
(a) Name the type of plane in Fig. 1.
...............................................................................................................................................[1]
(b) Draw on the wood in Fig. 1 to show the correct grain direction. [1]
2 Fig. 2 shows a desk tidy made from a plastic.
Fig. 2
Give three specification points for the desk tidy.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
3 ...................................................................................................................................................[3]
3 Complete the statement by adding the correct material from the list below.
‘Hardening and tempering is a process that is carried out on
.............................................................................................’
thermosetting plastic manufactured board carbon steel composite material [1]
© UCLES 2016 0445/33/M/J/16

3
4 Complete the drawing below to show a through housing joint.
[3]
5 Fig. 3 shows a container used in a fast food outlet.
Fig. 3
(a) Name a suitable plastic that could be used to make the container.
...............................................................................................................................................[1]
(b) (i) Give one advantage of using a plastic for this type of container.
...........................................................................................................................................
(ii) Give one disadvantage of using a plastic for this type of container.
.......................................................................................................................................[2]

4
6 Fig. 4 shows a chisel.
Fig. 4
(a) Name the type of chisel shown in Fig. 4.
...............................................................................................................................................[1]
(b) Describe two features of the chisel shown in Fig. 4 that makes it suitable for its purpose.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
7 Fig. 5 shows a remote control.
Fig. 5
Give three ergonomic features in the design of the remote control.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
3 ...................................................................................................................................................[3]
8 Complete the drawing below to show a flat file.
[2]
© UCLES 2016 0445/33/M/J/16

5
9 Fig. 6 shows a chair made from wood.
Fig. 6
(a) Name the process by which the parts of the chair are shaped.
...............................................................................................................................................[1]
(b) Give one benefit of this type of process when making the chair.
...............................................................................................................................................[1]
10 Show clearly on the drawing of the centre lathe below where each of the parts labelled A, B and C
would be fitted.
$ % &
[3]

6
Section B
11 Fig. 7 shows views of an incomplete design for a wall-mounted cabinet.
A
softwood sides 15 thick
0
50
400
15
0
Fig. 7
(a) (i) Name a suitable softwood for the sides of the cabinet.
.......................................................................................................................................[1]
(ii) Name a manufactured board for the back of the cabinet and suggest a suitable standard
thickness.
Suitable thickness .........................................................................................................[1]
(b) Fig. 8 shows four pre-manufactured components that could be used in the construction of the
cabinet.
handle butt hinge magnetic catch wall plate
Fig. 8
© UCLES 2016 0445/33/M/J/16

7
(i) Give two benefits of using pre-manufactured fittings when constructing the cabinet.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Describe where each of the pre-manufactured components could be used in the cabinet
and how they would be fitted.
Handle ...............................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
Butt hinge ..........................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
Magnetic catch ..................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
Wall plate ...........................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(c) Sketch and name a permanent joint that could be used at corner A in Fig. 7.
[4]
8
(d) Use sketches and notes to show how one of the glass shelves could be supported at three
different positions inside the cabinet.
[3]
(e) Fig. 9 shows details of one corner of the door frame.
40
12 thick
Fig. 9
(i) Name a suitable corner joint for the door frame.
.......................................................................................................................................[1]
(ii) Use sketches and notes to show how a 4 thick glass panel could be fitted to the door
frame.
[3]
(f) Many cabinets have solid doors.

Give one advantage of a framed door with a glass panel rather than a solid door.
...............................................................................................................................................[1]
© UCLES 2016 0445/33/M/J/16
9
12 Fig. 10 shows details of a table football game.
cabinet
18 thick
metal rod
100
12
00
600
Fig. 10
(a) (i) The metal rods could be made from Ø10 mild steel or aluminium.
Choose either mild steel or aluminium and give a reason for your choice.
Chosen metal ............................................................
Reason ..........................................................................................................................[1]
(ii) When pulled and pushed, the rods cause the holes in the side of the cabinet to become
worn and enlarged.
Use sketches and notes to show how this problem could be overcome.
Name any materials used.
[3]

10
(b) (i) Fig. 11 shows a metal rod that will be attached to a wooden handle by means of an
epoxy resin adhesive.
handle
metal rod
Fig. 11
Describe how an epoxy resin adhesive would be prepared and applied.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) The handles could be produced using a smart material such as polymorph.
Describe how polymorph could be used to produce the handles.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[3]
(c) (i) Fig. 12 shows one of the players and the metal rod to which it is attached.
The players are made from injection moulded plastic.
Add sketches and notes to Fig. 12 to show how the player could be fixed to the metal rod
without the use of adhesive.
[3]
Fig. 12
© UCLES 2016 0445/33/M/J/16
11
(ii) Fig. 13 shows a cross-sectional view of an injection moulding machine.

Complete the table to give the stages in the injection moulding process.
multi-part hopper
mould
injector
heater screw or ram
Fig. 13
Stage Process
1
2
3
4
5 The mould is cooled and the moulding ejected
[4]
(iii) Explain why the injection moulding process is only suitable when manufacturing in large
quantities.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(d) The players could be made from aluminium.

Name a process that could be carried out in a school workshop to produce the players using
aluminium.
...............................................................................................................................................[1]

12
(e) Use sketches and notes to design a scoring system that could be used during a game of
table football.
The scoring system must:

• be fixed to the cabinet;
• record a maximum of five goals scored at each end.
[6]
© UCLES 2016 0445/33/M/J/16

13
13 Fig. 14 shows a hardwood shelf supported by two end brackets.

The brackets could be made from acrylic or aluminium.
hardwood shelf 15 thick
0
60
20
0
Fig. 14
(a) (i) Give two benefits of using a template to mark out the shape of a bracket.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Explain why a template would need to be made from wood or metal rather than card or
paper when marking out large quantities of brackets.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(b) (i) Acrylic and aluminium are materials that can be self-finished.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]

14
(ii) Fig. 15 shows the shape of one bracket marked out on sheet material.
Fig. 15
You may choose to make the bracket in either 4 thick acrylic or 1.5 thick aluminium.
Use sketches and notes to show how one bracket could be cut out by hand and the
edges made smooth in the material of your choice.
Chosen material ...............................................................
[5]
© UCLES 2016 0445/33/M/J/16

15
(c) Use sketches and notes to show how one of the bends could be produced when the bracket
is made from:
(i) 4 thick acrylic;
[3]
(ii) 1.5 thick aluminium.
[3]
(d) Explain why round head screws rather than countersink head screws would be used to screw
the brackets to the wall when the brackets are made from 1.5 thick aluminium.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]
(e) Explain why the hardwood shelf would not be glued permanently to the brackets.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

16
(f) Fig. 16 shows details of the right hand bracket.
50
60
60
Fig. 16
Use sketches and notes to show how the shelf and bracket could be modified so that the shelf
could be secured to the bracket without the use of fittings, fixings or adhesive.
[4]
© UCLES 2016 0445/33/M/J/16

* 9 8 2 3 0 4 8 4 5 9 *

1 hour
Section A
Section B
DC (ST/FD) 128120
2
Section A
1 Complete the table below by naming a specific material for each product.
3URGXFW 6SHFLILFPDWHULDO
PHWDOFDQ
SODVWLFJHDUV
PHWDOKLQJHIRUDQRXWVLGHGRRU
[3]
2 Add to the drawing below to show dovetail nailing.
[2]
© UCLES 2016 0445/31/O/N/16

3
3 Fig. 1 shows an item of equipment used in a workshop.
Fig. 1
(a) Name the item of equipment.
.............................................................................................................................................. [1]
(b) Add a sketch to Fig. 1 to show how the item of equipment would be used. [2]
4 Complete the drawing below to show a tongue and groove joint.
[2]

4
5 Fig. 2 shows a commercially produced shelving system made from aluminium.
upright
bracket
Fig. 2
(a) Name a process used to make the upright part of the shelving system.
.............................................................................................................................................. [1]
(b) Name two finishes that could be applied to the aluminium shelving system.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
6 Complete the table below by describing a specific use for each of the saws shown.
Saw Specific use
[3]
© UCLES 2016 0445/31/O/N/16

5
7 Fig. 3 shows a joint marked out on wood and a mortise gauge that will be used to mark it out.
OLQHVWREHPDUNHGRXW
Fig. 3
Give two stages in setting the mortise gauge before the joint can be marked out.
Stage 1 .............................................................................................................................................
Stage 2 ........................................................................................................................................ [2]
8 Fig. 4 shows a handset that has been moulded to shape.
Fig. 4
Name a process that could be used to make the handset when made from:
(a) plastic ........................................................................................................................................
(b) metal .................................................................................................................................... [2]
9 Fig. 5 shows a piece of hardwood that will be used as a table top.
19 thick hardwood
Fig. 5
Add to Fig. 5 to show two faults that could occur to the table top due to poor seasoning. [2]

6
10 Fig. 6 shows a woodworking process.
Fig. 6
.............................................................................................................................................. [1]
(b) Name the items of equipment labelled A and B.
A ...............................................................................................................................................
B .......................................................................................................................................... [2]
© UCLES 2016 0445/31/O/N/16

7
Section B
11 Fig. 7 shows views of a small table that includes a magazine rack.

The product is designed as flat-pack for self-assembly.
35
0 0
45
plywood table top
hardwood leg
hardwood rack
plywood stand
Fig. 7
(a) Give two benefits to the user of buying self-assembly products.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

8
(b) Fig. 8 shows part of the table top with a slot marked out ready to be cut out.
40 280
20 thick
Fig. 8
Use sketches and notes to show how the slot could be cut out and the edges made flat and
smooth.
[4]
(c) Use sketches and notes to show how the stand could be joined permanently to the table top
as shown in Fig. 7.
Additional materials may be used.
[4]
© UCLES 2016 0445/31/O/N/16
9
(d) Fig. 9 shows details of the end of the leg.

The leg will be joined to the underside of the table top by means of a glued dowel joint.

Fig. 9
(i) State an appropriate diameter of dowel to be used.
...................................................................................................................................... [1]
(ii) Draw on Fig. 9 to show the marking out with measurements for two holes to take the
dowels. [2]

10
(e) Fig. 10 shows details of the stand and the rack.
rack 15 thick
rack 275 long

stand 15 thick
Fig. 10
Use sketches and notes to show how the rack could be screwed to the stand.
Give four details about the type of screw used to include:
• material;
• length;
• type of head;
• the number required.
[6]
© UCLES 2016 0445/31/O/N/16

11
(f) Fig. 11 shows two different designs of rack that could be used with the table.
A B
Fig. 11
(i) Decide which of the two designs, A or B, is stronger. Explain why.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) Explain why design A could be considered wasteful in terms of materials used.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(g) Give two properties of a finish that would be applied to the table and magazine rack.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

12
12 Fig. 12 shows a desk tidy made from acrylic with a hardwood base.
DFU\OLFGHVNWLG\WKLFN
KDUGZRRGEDVHWKLFN
Fig. 12
(a) Give two properties of acrylic that make it suitable for the desk tidy.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(c) Give two reasons why the holes in the desk tidy would be drilled before the acrylic was bent
to shape.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2016 0445/31/O/N/16

13
(d) Fig. 13 shows the development (net) of the desk tidy.
Ø50 centres for holes bend lines
70
A
120 100 60
Fig. 13
Use sketches and notes to show how the shape at A could be cut out and the edges made
smooth.
[3]
(e) Use sketches and notes to show how one of the bends shown in the development (net) could
be produced.
Include the following details.
• the method of softening the acrylic
• the use of a former
• the method of retaining the shape while the acrylic cools
[4]
14
(f) Use sketches and notes to show modifications to the design of the desk tidy so that:
• the pencils do not slide about;

• a quantity of paper clips can be stored.
[4]
(g) Fig. 14 shows the hardwood used to make the base for the desk tidy.
The base will have bevelled edges. Two bevelled edges are shown marked out.
bevelled edge
13
0
80
Fig. 14
(i) Give one benefit of using hardwood for the base of the desk tidy.
...................................................................................................................................... [1]
(ii) Suggest a suitable thickness for the hardwood base.
...................................................................................................................................... [1]
© UCLES 2016 0445/31/O/N/16

15
(iii) Use sketches and notes to show how the two bevelled edges shown in Fig. 14 could be
produced.
[3]
(iv) Use sketches and notes to show how the acrylic desk tidy could be joined to the
hardwood base without the use of an adhesive.
[3]

16
13 Fig. 15 shows an incomplete design for a bird feeder made from 1.5 thick aluminium sheet.
URRI
125
;
125
0
15 25
0
Fig. 15
(a) Give two reasons why aluminium is a good choice of material for the bird feeder.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Fig. 16 shows part of the bird feeder, without the roof, marked out on a sheet of aluminium.
waste
bend lines
150
flap 20
250
Fig. 16
© UCLES 2016 0445/31/O/N/16

17
(i) Name two marking out tools used to mark out the shape.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Use sketches and notes to show how the shape could be cut out from the sheet.
[3]
(iii) Use sketches and notes to show how the aluminium would be bent to shape along the
bend lines. Name all the tools and equipment used.
[4]

18
(c) Fig. 17 shows the back of the roof of the bird feeder.
The flaps will be pop riveted to the main part of the bird feeder.
IODSVZLGH
Fig. 17
(i) Describe how the roof could be attached using pop rivets.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [3]
(ii) Give one advantage of using pop riveting rather than the traditional riveting process.
...................................................................................................................................... [1]
(d) A container to hold water is required. The position for the container is shown at X in Fig. 15.
The container will be made from vacuum formed plastic.
(i) Use sketches and notes to show a design for a vacuum formed plastic container to hold
water. Show how the container will be attached to the bird feeder.
[3]
© UCLES 2016 0445/31/O/N/16

19
(ii) Use sketches and notes to show the mould that will be used to vacuum form the container.
[3]
(iii) Name a suitable plastic for the vacuum formed container.
...................................................................................................................................... [1]
(e) Use sketches and notes to show a modification to the design of the bird feeder so that it could
be suspended from the branch of a tree.
Name all the materials and fittings used.
[3]
© UCLES 2016 0445/31/O/N/16

20
BLANK PAGE
© UCLES 2016 0445/31/O/N/16

* 3 3 3 4 6 4 8 9 1 4 *

1 hour
Section A
Section B
DC (NF/FD) 117567/1
2
Section A
1 Fig. 1 shows three saws used to cut wood.
Fig. 1
Name each of the saws A, B and C.
A .......................................................................................................................................................
B .......................................................................................................................................................
C .................................................................................................................................................. [3]
© UCLES 2016 0445/32/O/N/16

3
Product Specific material
metal spoon
metal wire
plastic bowl
[3]
3 Complete the drawing below to show a half lap joint.
[2]

4
4 Complete the table below by naming each of the marking out tools.
Marking out tool Name
[3]
5 Fig. 2 shows a length of wood with three slots marked out.
Fig. 2
(a) Give one reason why the lines would be marked out using a marking knife rather than a
pencil.
.............................................................................................................................................. [1]
(b) Name a tool that could be used with a marking knife to mark all the lines at the same angle
across the grain of the wood.
.............................................................................................................................................. [1]
© UCLES 2016 0445/32/O/N/16

5
6 Fig. 3 shows two products made from plastic.
channel container
Fig. 3
Name the moulding process used to make each product.
channel ........................................................................................................................................ [1]
container ..................................................................................................................................... [1]
7 Fig. 4 shows a mortise with a square haunch.
square haunch
Fig. 4
(a) Draw a square haunch tenon that would fit into the square haunch mortise shown in Fig. 4.
[2]
(b) Describe the purpose of the square haunch.
.............................................................................................................................................. [1]
6
8 Fig. 5 shows two different types of drill bit.
A B
Fig. 5
Name the drill bits A and B shown in Fig. 5.
A .......................................................................................................................................................
B .................................................................................................................................................. [2]
9 Complete the table by naming each tool or item of equipment used to cut sheet metal.
Tool or item of equipment Name
[3]
© UCLES 2016 0445/32/O/N/16

7
10 Fig. 6 shows two pieces of resistant material.
Fig. 6
Name a suitable adhesive that could be used to join the two pieces of material shown above when
made from:
(a) pine ...........................................................................................................................................
(b) steel ..................................................................................................................................... [2]

8
Section B
11 Fig. 7 shows views of a clock used to teach children how to tell the time.
The clock face is made from plywood and the clock hands are made from acrylic.
The clock hands will be moved by the teacher.
Ø 250 12
Fig. 7
(a) Give two specification points for the clock.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) (i) Fig. 8 shows the clock face marked out on a sheet of 12 thick plywood.
The shape will be cut out using a jigsaw.
Fig. 8
Give two safety precautions that must be taken when using a jigsaw.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
© UCLES 2016 0445/32/O/N/16

9
(ii) Describe how the shape could be made round and the edges made smooth after it has
been cut out with a jigsaw.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(c) Fig. 9 shows one clock hand marked out on 5 thick acrylic.
30
80
Fig. 9
Use sketches and notes to show how the clock hand could be cut out and the edges finished
to a high quality.
[4]
(d) Give one benefit of using acrylic for the clock hands.
.............................................................................................................................................. [1]
10
(e) Add sketches and notes to the drawing below to show how the clock hands could be fitted to
the clock face.
The teacher must be able to move the clock hands.
clock hands: 5 thick acrylic
clock face: 12 thick plywood
[3]
(f) The numbers on the clock face could be designed by CAD (Computer Aided Design) and
made using CAM (Computer Aided Manufacture).
Give one benefit of using:
CAD to design the numbers;
.............................................................................................................................................. [1]
CAM to make the numbers.
.............................................................................................................................................. [1]
© UCLES 2016 0445/32/O/N/16

11
(g) Use sketches and notes to show how the clock could be made to stand on its own. Include
details of materials, constructions and fittings used.
[5]
(h) Use sketches and notes to show how the clock could be made to fit to a wall instead of
standing on its own. Include details of materials, constructions and fittings used.
[4]
12
12 Fig. 10 shows a wall-mounted shelf unit.
14
500 0
0
50
shelves: veneered chipboard 15 thick

end frames: mild steel rod Ø8
Fig. 10
(a) Give two advantages of using veneered chipboard rather than solid wood for the shelves of
the wall-mounted shelf unit.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Fig. 11 shows a wooden former around which the mild steel rod will be bent to the shape of
the end frame.
baseboard:
25 thick MDF
Fig. 11
(i) Add sketches and notes to Fig. 11 to show how the mild steel rod could be held against
the former while it is bent to shape. [3]
© UCLES 2016 0445/32/O/N/16

13
(ii) When shaping the mild steel rod it can become work hardened.
Explain what is meant by the term ‘work hardened’.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(c) Fig. 12 shows the two ends of a length of Ø8 mild steel rod. The mild steel rod has been bent
to the shape of the end frame. The ends will be brazed together.
joint to be brazed
Fig. 12
Use sketches and notes to show how the ends of the mild steel rod could be brazed together.
Include details of how the ends would be prepared before they are brazed.
[8]
14
(d) Use sketches and notes to show how the veneered chipboard shelves could be fixed to the
end frames made from mild steel rod. Additional materials, fittings and fixings may be used.
[6]
(e) Give one reason why each of the materials used to make the wall-mounted shelf unit shown
in Fig. 10 could be considered to be environmentally friendly.
Mild steel .............................................................................................................................. [1]
Veneered chipboard ............................................................................................................. [1]
© UCLES 2016 0445/32/O/N/16

15
(f) Fig. 13 shows a wall-mounted shelf unit with veneered chipboard sides rather than mild steel
end frames.
Fig. 13
Give two reasons why the designer has decided to use veneered chipboard sides rather than
mild steel end frames.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

16
13 Fig. 14 shows views of an incomplete design for a towel holder made mainly from oak.
30
45
195
Fig. 14
(a) Give two properties of oak that make it suitable for the towel holder.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Fig. 15 shows details of one rail marked out, ready to be shaped.
ZDVWH

Fig. 15
Use sketches and notes to show how the waste wood could be removed and the surfaces
made flat and smooth. Include details of how the rail would be supported while it is shaped.
[5]
© UCLES 2016 0445/32/O/N/16

17
(c) Use sketches and notes to show how all the rails could be:
• connected to the back of the towel holder;
• allowed to swing as shown in Fig. 14;
• spaced apart.
Include details of materials, constructions and fittings used.
[8]
(d) Use sketches and notes to show how the towel holder could be fitted to a wall.
Holes must not be drilled in the front of the towel holder.
[5]

18
(e) (i) Give two reasons why a clear polyurethane varnish would be a suitable finish for the
towel holder.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Describe three stages to prepare the parts of the towel holder to take a clear polyurethane
varnish finish.
1 .......................................................................................................................................
2 .......................................................................................................................................
3 .................................................................................................................................. [3]
© UCLES 2016 0445/32/O/N/16

19
BLANK PAGE
© UCLES 2016 0445/32/O/N/16

20
BLANK PAGE
© UCLES 2016 0445/32/O/N/16

* 8 1 2 2 2 0 9 5 0 1 *

1 hour
Section A
Section B
DC (NF/FD) 117569/2
2
Section A
3URGXFW 6SHFLILFPDWHULDO
PHWDOFDQ
SODVWLFJHDUV
PHWDOKLQJHIRUDQRXWVLGHGRRU
[3]
2 Add to the drawing below to show dovetail nailing.
[2]
© UCLES 2016 0445/33/O/N/16

3
3 Fig. 1 shows an item of equipment used in a workshop.
Fig. 1
(a) Name the item of equipment.
.............................................................................................................................................. [1]
(b) Add a sketch to Fig. 1 to show how the item of equipment would be used. [2]
[2]

4
5 Fig. 2 shows a commercially produced shelving system made from aluminium.
upright
bracket
Fig. 2
(a) Name a process used to make the upright part of the shelving system.
.............................................................................................................................................. [1]
(b) Name two finishes that could be applied to the aluminium shelving system.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
6 Complete the table below by describing a specific use for each of the saws shown.
Saw Specific use
[3]
© UCLES 2016 0445/33/O/N/16

5
7 Fig. 3 shows a joint marked out on wood and a mortise gauge that will be used to mark it out.
OLQHVWREHPDUNHGRXW
Fig. 3
Give two stages in setting the mortise gauge before the joint can be marked out.
Stage 1 .............................................................................................................................................
Stage 2 ........................................................................................................................................ [2]
8 Fig. 4 shows a handset that has been moulded to shape.
Fig. 4
Name a process that could be used to make the handset when made from:
(a) plastic ........................................................................................................................................
(b) metal .................................................................................................................................... [2]
9 Fig. 5 shows a piece of hardwood that will be used as a table top.
19 thick hardwood
Fig. 5
Add to Fig. 5 to show two faults that could occur to the table top due to poor seasoning. [2]

6
10 Fig. 6 shows a woodworking process.
Fig. 6
.............................................................................................................................................. [1]
(b) Name the items of equipment labelled A and B.
A ...............................................................................................................................................
B .......................................................................................................................................... [2]
© UCLES 2016 0445/33/O/N/16

7
Section B
11 Fig. 7 shows views of a small table that includes a magazine rack.

The product is designed as flat-pack for self-assembly.
35
0 0
45
plywood table top
hardwood leg
hardwood rack
plywood stand
Fig. 7
(a) Give two benefits to the user of buying self-assembly products.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

8
(b) Fig. 8 shows part of the table top with a slot marked out ready to be cut out.
40 280
20 thick
Fig. 8
Use sketches and notes to show how the slot could be cut out and the edges made flat and
smooth.
[4]
(c) Use sketches and notes to show how the stand could be joined permanently to the table top
as shown in Fig. 7.
Additional materials may be used.
[4]
© UCLES 2016 0445/33/O/N/16
9
(d) Fig. 9 shows details of the end of the leg.

The leg will be joined to the underside of the table top by means of a glued dowel joint.

Fig. 9
(i) State an appropriate diameter of dowel to be used.
...................................................................................................................................... [1]
(ii) Draw on Fig. 9 to show the marking out with measurements for two holes to take the
dowels. [2]

10
(e) Fig. 10 shows details of the stand and the rack.
rack 15 thick
rack 275 long

stand 15 thick
Fig. 10
Use sketches and notes to show how the rack could be screwed to the stand.
Give four details about the type of screw used to include:
• material;
• length;
• type of head;
• the number required.
[6]
© UCLES 2016 0445/33/O/N/16

11
(f) Fig. 11 shows two different designs of rack that could be used with the table.
A B
Fig. 11
(i) Decide which of the two designs, A or B, is stronger. Explain why.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) Explain why design A could be considered wasteful in terms of materials used.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(g) Give two properties of a finish that would be applied to the table and magazine rack.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

12
12 Fig. 12 shows a desk tidy made from acrylic with a hardwood base.
DFU\OLFGHVNWLG\WKLFN
KDUGZRRGEDVHWKLFN
Fig. 12
(a) Give two properties of acrylic that make it suitable for the desk tidy.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(c) Give two reasons why the holes in the desk tidy would be drilled before the acrylic was bent
to shape.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2016 0445/33/O/N/16

13
(d) Fig. 13 shows the development (net) of the desk tidy.
Ø50 centres for holes bend lines
70
A
120 100 60
Fig. 13
Use sketches and notes to show how the shape at A could be cut out and the edges made
smooth.
[3]
(e) Use sketches and notes to show how one of the bends shown in the development (net) could
be produced.
Include the following details.
• the use of a former
• the method of retaining the shape while the acrylic cools
[4]
14
(f) Use sketches and notes to show modifications to the design of the desk tidy so that:
• the pencils do not slide about;

• a quantity of paper clips can be stored.
[4]
(g) Fig. 14 shows the hardwood used to make the base for the desk tidy.
The base will have bevelled edges. Two bevelled edges are shown marked out.
bevelled edge
13
0
80
Fig. 14
(i) Give one benefit of using hardwood for the base of the desk tidy.
...................................................................................................................................... [1]
(ii) Suggest a suitable thickness for the hardwood base.
...................................................................................................................................... [1]
© UCLES 2016 0445/33/O/N/16

15
(iii) Use sketches and notes to show how the two bevelled edges shown in Fig. 14 could be
produced.
[3]
(iv) Use sketches and notes to show how the acrylic desk tidy could be joined to the
hardwood base without the use of an adhesive.
[3]

16
13 Fig. 15 shows an incomplete design for a bird feeder made from 1.5 thick aluminium sheet.
URRI
125
;
125
0
15 25
0
Fig. 15
(a) Give two reasons why aluminium is a good choice of material for the bird feeder.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Fig. 16 shows part of the bird feeder, without the roof, marked out on a sheet of aluminium.
waste
bend lines
150
flap 20
250
Fig. 16
© UCLES 2016 0445/33/O/N/16

17
(i) Name two marking out tools used to mark out the shape.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(ii) Use sketches and notes to show how the shape could be cut out from the sheet.
[3]
(iii) Use sketches and notes to show how the aluminium would be bent to shape along the
bend lines. Name all the tools and equipment used.
[4]

18
(c) Fig. 17 shows the back of the roof of the bird feeder.
The flaps will be pop riveted to the main part of the bird feeder.
IODSVZLGH
Fig. 17
(i) Describe how the roof could be attached using pop rivets.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [3]
(ii) Give one advantage of using pop riveting rather than the traditional riveting process.
...................................................................................................................................... [1]
(d) A container to hold water is required. The position for the container is shown at X in Fig. 15.
The container will be made from vacuum formed plastic.
(i) Use sketches and notes to show a design for a vacuum formed plastic container to hold
water. Show how the container will be attached to the bird feeder.
[3]
© UCLES 2016 0445/33/O/N/16

19
(ii) Use sketches and notes to show the mould that will be used to vacuum form the container.
[3]
(iii) Name a suitable plastic for the vacuum formed container.
...................................................................................................................................... [1]
(e) Use sketches and notes to show a modification to the design of the bird feeder so that it could
be suspended from the branch of a tree.
Name all the materials and fittings used.
[3]
© UCLES 2016 0445/33/O/N/16

20
BLANK PAGE
© UCLES 2016 0445/33/O/N/16

* 4 6 7 3 6 3 0 8 7 3 *

1 hour
Section A
Section B
DC (NH/CGW) 136197/1
2
Section A
1 Fig. 1 shows two pieces of hardwood that have been glued together.
Fig. 1
From the list below circle the type of glue that would provide the strongest joint.
contact adhesive hot melt glue gun PVA [1]
2 Complete the drawing below to show odd leg calipers.
[2]
3 Complete the statement by adding the correct term from the list below.
lightweight recycled smart dense
A thermochromic material changes colour with changes in temperature.
This is an example of a .................................................. material. [1]
© UCLES 2017 0445/32/M/J/17

3
4 Fig. 2 shows the end of a length of wood.

Draw on Fig. 2 to show a groove and a rebate.
Fig. 2 [2]
5 Fig. 3 shows four items used to fasten materials together.
A B C D
Fig. 3
Name each of the items A, B, C and D shown in Fig. 3.
A .......................................................................................................................................................
B .......................................................................................................................................................
C .......................................................................................................................................................
D ...................................................................................................................................................[4]
6 Fig. 4 shows three layers of a sheet of plywood.
Fig. 4
Complete Fig. 4 by drawing the grain direction on layers 2 and 3 to show how plywood is
constructed. [1]

4
7 The table below shows products made mainly from plastic.

Complete the table by naming a suitable plastic for each product.
Product Name of plastic
electric plug body

BATTERY
plastic blister packaging
knife handle
[3]
8 Fig. 5 shows a manufactured board.
Fig. 5
(a) Name the manufactured board.
...............................................................................................................................................[1]
(b) Describe briefly how the manufactured board shown in Fig. 5 is made.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]
(c) The manufactured board shown in Fig. 5 is widely used in the production of mass-produced
furniture.
From the list below circle the most important benefit of using this manufactured board.
weight appearance cost strength [1]
© UCLES 2017 0445/32/M/J/17

5
9 Fig. 6 shows a mild steel bracket for a hanging basket.
0
20
300
brace
Fig. 6
(a) State a suitable thickness of mild steel strip for the bracket.
...............................................................................................................................................[1]
(b) Give two methods of joining the brace to the bracket permanently.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
10 Fig. 7 shows a toast rack made from metal.
base
Fig. 7
(a) (i) Name a suitable ferrous metal for the toast rack.
...........................................................................................................................................
(ii) Name a suitable non-ferrous metal for the toast rack.
.......................................................................................................................................[2]
(b) Give two reasons why a base has been fitted to the toast rack.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
6
Section B
11 Fig. 8 shows views of an artist’s drawing board.
storage unit: 1.5 thick plastic
ledge: 10×10 hardwood

support: Ø8 metal rod
board: 15 thick manufactured board
Fig. 8
(a) Describe two good design features of the artist’s drawing board.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Complete the parts list below by naming a specific material for each of the parts of the drawing
board.
Number
Part Length × Width × Thickness Specific material
Required
board 1 650 × 450 × 15
storage unit 1 300 × 100 × 1.5
ledge 1 400 × 10 × 10
support 1 750 × Ø8
[4]
(c) (i) Name a portable power saw that could be used to cut out the shape of the drawing board
from a large sheet of manufactured board.
.......................................................................................................................................[1]
(ii) Give one safety precaution, other than wearing eye protection, that must be taken when
using portable power tools.
.......................................................................................................................................[1]
© UCLES 2017 0445/32/M/J/17

7
(d) The storage unit that will fit into the drawing board is produced by vacuum forming.
(i) Describe two important features of the design of the former used to vacuum form the
storage unit.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Explain why it is important to heat the plastic to the correct temperature when vacuum
forming.
...........................................................................................................................................
.......................................................................................................................................[2]
(e) Fig. 9 shows the ends of the support fixed into hardwood blocks.
hardwood blocks glued to

underside of board
Fig. 9
(i) Explain why the designer has used hardwood blocks for the ends of the support to fit into
rather than drilling holes directly into the drawing board.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) The support will be made by bending one length of Ø8 metal rod to shape.
Use sketches and notes to show how the Ø8 metal rod could be bent to shape.
[3]

8
(f) Use sketches and notes to show a different method of supporting the drawing board to that
shown in Fig. 8.
Include details of all materials and constructions used.
[6]
(g) Give two benefits of using a portable power sander to prepare the surface of the drawing
board before a finish is applied.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2017 0445/32/M/J/17

9
12 Fig. 10 shows a bird feeder made from wood and plastic.
roof: 4 thick clear acrylic
end: 12 thick plywood

200
base: 12 thick plywood
0
12 20
0
Fig. 10
(a) Give two reasons why acrylic is a good choice of material for the roof of the bird feeder.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Fig. 11 shows a tool that could be used to produce the Ø50 holes in the base of the bird
feeder.
Fig. 11
Name the tool shown in Fig. 11.
...............................................................................................................................................[1]

10
(c) Fig. 12 shows one end of the bird feeder marked out ready to be cut to shape.
outside curve
inside curve
Fig. 12
(i) Name a machine saw that could be used to cut out the shape.
.......................................................................................................................................[1]
(ii) Name a tool that could be used to finish the inside curve.
.......................................................................................................................................[1]
(iii) Give one safety precaution you would take when using a disc sander to finish the outside
curve.
.......................................................................................................................................[1]
(d) Use sketches and notes to show how the base and ends could be joined together permanently.
[3]
© UCLES 2017 0445/32/M/J/17

11
(e) Fig. 13 shows the roof of the bird feeder marked out on a sheet of acrylic.
roof shape
0
40
50
0 Fig. 13
(i) Name two ways of marking lines on the surface of acrylic.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) When sawing acrylic there is a possibility that it could crack.

Describe how this could be prevented.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(f) Use sketches and notes to show how the curved shape of the roof could be produced.
[4]

12
(g) Two plastic bowls are needed to fit into the holes in the base of the bird feeder.
Fig. 14 shows the former that will be used to vacuum form the plastic bowls.
Fig. 14
(i) Describe two features of the design of the former that will allow the plastic bowls to be
released from the former when vacuum formed.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Use sketches and notes to show how one plastic bowl could be produced by vacuum
forming.
[6]
© UCLES 2017 0445/32/M/J/17

13
13 Fig. 15 shows views of a computer desk manufactured as flat-pack for self-assembly.

The end frames, back rail and supports are made from hardwood.
750
drawer
support
back rail 25×25
75×20
end frame
25×25
00
10
50
0
Fig. 15
(a) The computer desk top will be made from manufactured board.
(i) Name a suitable manufactured board for the desk top.
.......................................................................................................................................[1]
(ii) Give a reason for your choice of manufactured board.
.......................................................................................................................................[1]
(b) (i) Sketch and name a permanent joint that could be used at corner A in Fig. 15.
[4]

14
(ii) Fig. 16 shows an exploded view of a support and an end frame.

Use sketches and notes to show how the support could be joined to the end frame using
a temporary fixing in the space below.
support 25×25
end frame
Fig. 16
[3]
(c) The hardwood parts of the computer desk will be finished with polyurethane varnish.
(i) Describe how each of the items listed below could be used to prepare the surfaces of the
hardwood parts before a polyurethane varnish finish is applied.
Medium grade glasspaper
...........................................................................................................................................
Fine grade glasspaper
...........................................................................................................................................
Damp cloth
...........................................................................................................................................
Cork block
.......................................................................................................................................[4]
(ii) Give two reasons why polyurethane varnish is a suitable finish for the computer desk.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
© UCLES 2017 0445/32/M/J/17

15
(d) Explain how the designer has decided on the measurements of:
(i) the length and width of the computer desktop;
...........................................................................................................................................
(ii) the height of the computer desk top above the ground.
.......................................................................................................................................[2]
(e) Fig. 17 shows details of a drawer that will be supported below the computer desk top.
sides 15 thick
50
0
60
25
0
Fig. 17
Use sketches and notes to show how the drawer could be supported below the computer
desk top and made to slide in and out as shown in Fig. 15.
Include details of materials, constructions and two important sizes.
[6]
(f) Many items of furniture are designed for self-assembly.

Give two drawbacks of self-assembly furniture.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2017 0445/32/M/J/17
16
BLANK PAGE
© UCLES 2017 0445/32/M/J/17

* 1 6 3 8 2 2 4 9 8 1 *

1 hour
Section A
Section B
DC (KN/SW) 136196/1
2
Section A
1 Complete the table below by naming each of the tools or items of equipment used to hold wood.
Name Name
Name Name
[4]
2 Fig. 1 shows two safety clothing [PPE] signs.
Wear mask Wear gloves
Fig. 1
Describe a workshop process where:
(a) a mask must be worn;
...................................................................................................................................................
(b) gloves must be worn.
...............................................................................................................................................[2]
© UCLES 2017 0445/33/M/J/17

3
3 Shape Memory Alloy [SMA] is an example of a ‘smart’ material.

Complete the statement by adding the correct term from the list below.
heated quenched in water polished
SMA will return to its original shape when it is .............................................................................[1]
4 Fig. 2 shows three boards that will be glued together to make a solid wood table top.
15
0
15
0
15
1 0
Fig. 2
(a) Give one reason why it would be necessary to join three boards together to make a solid
wood table top.
...............................................................................................................................................[1]
(b) Complete Fig. 2 by drawing the end grain on boards 2 and 3 so that the table top would
remain stable. [2]
(c) Name the type of cramps that would be used when gluing the boards together.
...............................................................................................................................................[1]
5 Complete the table by naming the correct metal from the list below to match each description.
mild steel cast iron copper stainless steel brass aluminium
Metal Description
hard, tough, used to make sink units
hard, brittle, used to make metalwork vices
lightweight, resists corrosion, used to make aircraft bodies
[3]

4
6 Fig. 3 shows the end of a length of wood.

Draw on Fig. 3 to show a chamfered edge and a bevelled edge.
chamfered edge bevelled edge
Fig. 3
[2]
7 Fig. 4 shows a tee square made from two pieces of acrylic.
joint
Fig. 4
Name a suitable method of joining the two pieces of acrylic together:
(a) temporarily;
...................................................................................................................................................
(b) permanently.
...............................................................................................................................................[2]
8 Fig. 5 shows a method of joining two wooden boards.
Fig. 5
Name the method of joining.
......................................................................................................................................................[1]
© UCLES 2017 0445/33/M/J/17

5
9 Fig. 6 shows a modelling knife.

The metal body of the knife is made in two parts that are screwed together.
body
Fig. 6
(a) Name a process that could be used to produce the two parts for the body of the knife.
...............................................................................................................................................[1]
(b) Name a metal that could be used to make the body of the knife.
...............................................................................................................................................[1]
10 Complete the drawing of each tool shown below and describe its use.
Scriber Use
Chuck key Use
[4]

6
Section B
11 Fig. 7 shows views of a child’s table and a parts list.
A
B
A
B
A
table shown with top removed
Number
Part Length × Width × Thickness Material
Required
leg 4 450 × 60 × 15 softwood
end rail A 4 470 × 60 × 15 softwood
long rail B 3 740 × 60 × 15 softwood
table top 1 840 × 540 × 19 manufactured board
Fig. 7
(a) (i) Name a suitable softwood and manufactured board for parts of the table shown in the
parts list.
Softwood ...........................................................................................................................
(ii) The legs and rails are all 60 wide × 15 thick.

Give one benefit to a manufacturer of using materials that are the same width and
thickness.
.......................................................................................................................................[1]
(b) Give two ways in which the table top could be made more hardwearing for use by children.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
© UCLES 2017 0445/33/M/J/17
7
(c) The table top will be attached to the rails by means of screws.
Fig. 8 shows part of the table with the positions for two screw holes marked out.
centre for screw hole
Fig. 8
(i) Use a sketch and notes to show how the holes could be drilled so that the screw head
would be hidden.
[3]
(ii) Use sketches and notes to show how a knock-down (KD) fitting could be used to attach
the table top to the rails.
[3]
8
(d) The rails and the legs will be joined using dowel joints.
A drilling jig is needed when drilling the holes for the dowel.
(i) Give two benefits of using a drilling jig when drilling the holes for the dowel.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(ii) Fig. 9 shows an exploded view of a dowel joint between a rail and a leg.
rail
leg
Fig. 9
Use sketches and notes to show a drilling jig that could be used when drilling holes in the
ends of the rails.
[4]
© UCLES 2017 0445/33/M/J/17
9
(e) A container is required to store pens, pencils and other small items of equipment.
Fig. 10 shows the area where the container will fit into the table top.
area to be removed 250 × 120
Fig. 10
(i) Use sketches and notes to show how the area could be removed and the edges made
smooth.
[4]
(ii) Use sketches and notes to show a design for a container that could fit into the area cut
out. Include details of materials and constructions used.
[4]
10
12 Fig. 11 shows views of a cycle rack that could be fixed to the wall of a garage or shed.
wooden back 200 × 40 × 15
pivot
sheet metal support

280 × 75 × 1.5
Fig. 11
(a) Give two items of research a designer would need to consider when designing a cycle rack.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) Sketch and name a suitable method of joining parts A to the back shown in Fig. 11.
[4]
© UCLES 2017 0445/33/M/J/17

11
(c) Fig. 12 shows details of the sheet metal support.
28
0
20
27 35
0
75
Fig. 12
An outline of the sheet of metal used to make the support is shown below.
(i) Draw on the outline the development (net) for the support.
not to scale [4]
(ii) Give two advantages of making the support for the cycle rack from non-ferrous metal
rather than ferrous metal.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]

12
(d) To make the support, the slot will be cut out and the metal will be bent to shape.
(i) Use sketches and notes to show how the slot could be cut out and the edges made
smooth.
[4]
(ii) Use sketches and notes to show how the sheet metal could be bent to shape.
[3]
© UCLES 2017 0445/33/M/J/17

13
(e) Fig. 13 shows views of the back and support.

The support will be pivoted between parts A and will fold down when not in use.
wall
A
folds down
Fig. 13
Use sketches and notes to show how the support could be locked in a horizontal position as
shown in Fig. 13.
[3]

14
(f) Fig. 14 shows a cycle helmet that is to be stored on the cycle rack.
Use sketches and notes to show a modification to any part of the cycle rack so that the
helmet could be stored.
Fig. 14
[3]
© UCLES 2017 0445/33/M/J/17

15
BLANK PAGE

16
13 Fig. 15 shows an incomplete design for a toy lorry. The hopper is designed to tip.
20
hopper
0
30
200
wheels Ø70 × 20
Fig. 15
(a) Give three specification points for the toy lorry.
1 ................................................................................................................................................
2 ................................................................................................................................................
3 ............................................................................................................................................[3]
(b) The wheels could be made from a hardwood using a woodturning lathe.
The wheels could also be made from thermoplastic and injection moulded.
Fig. 16 shows both methods of manufacture.
woodturning injection moulding
Fig. 16
(i) Describe four stages when making a set of wheels by means of either woodturning or
injection moulding.
Chosen method .................................................................................................................
1 ........................................................................................................................................
2 ........................................................................................................................................
3 ........................................................................................................................................
4 ....................................................................................................................................[4]
© UCLES 2017 0445/33/M/J/17
17
(ii) Use sketches and notes to show how one of the wheels could be attached to the base of
the lorry and allowed to turn freely.
[3]
(c) The hopper shown in Fig. 15 will be made from plastic by means of vacuum forming.
Use sketches and notes to show a design for a former that could be used to produce the
hopper.
[4]

18
(d) Use sketches and notes to show how the hopper could be made to tip as shown in Fig. 15.
Include details of materials, fittings and constructions used.
[6]
(e) Wooden toys can be painted or varnished to protect the wood.
Give one additional benefit of using:
(i) paint; .................................................................................................................................
...........................................................................................................................................
(ii) varnish. ..............................................................................................................................
.......................................................................................................................................[2]
(f) Explain the benefits to a manufacturer of producing children’s toys made from plastic rather
than wood-based materials.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[3]
© UCLES 2017 0445/33/M/J/17

19
BLANK PAGE
© UCLES 2017 0445/33/M/J/17

20
BLANK PAGE
© UCLES 2017 0445/33/M/J/17

* 1 3 5 1 8 4 3 1 7 4 *

1 hour
Section A
Section B
DC (SC) 151812
2
Section A
1 Fig. 1 shows a child’s scooter.
Fig. 1
Describe three ways in which the designer has considered the child’s safety in the design of a

scooter.
1 ......................................................................................................................................................
2 ......................................................................................................................................................
3 ..................................................................................................................................................[3]
2 Describe a specific use for each of the chisels shown in Fig. 2.
cold chisel bevel-edge chisel
Fig. 2
Cold chisel
..........................................................................................................................................................
Bevel-edge chisel
......................................................................................................................................................[2]
© UCLES 2017 0445/31/O/N/17
3
3 Complete the drawing below to show a tenon saw.
[2]
4 SMA is a smart material that, when bent out of shape, will return to its original shape when
heated.
SMA stands for: Shape Memory A................................ [1]
5 Fig. 3 shows a variety of tools used in a school workshop.
A B C D
E F G H
Fig. 3
Complete the table below to show which tool from Fig. 3 would be used for each of the processes
listed.
Process Tool A–H
cutting through Ø12 mild steel bar
starting off a hole on a centre lathe
cutting a screw thread on a round bar
cutting shapes out of 1 thick copper sheet

[4]

4
6 Fig. 4 shows a washing-up liquid bottle made from plastic and a symbol that can be seen on the
bottle.
1
PET
Fig. 4
...............................................................................................................................................[1]
(b) Describe one problem for the environment when using products made from plastic.
...............................................................................................................................................[1]
7 Complete the drawing below to show a stopped housing joint.
[3]
© UCLES 2017 0445/31/O/N/17

5
8 Fig. 5 shows a house number plate made from brass, a non-ferrous alloy.
Fig. 5
Explain the term ‘non-ferrous alloy’.
..........................................................................................................................................................
......................................................................................................................................................[2]
9 Fig. 6 shows a hot melt glue gun.
Fig. 6
Give one benefit and one drawback of using a hot melt glue gun.
Benefit ..............................................................................................................................................
..........................................................................................................................................................
Drawback .........................................................................................................................................
......................................................................................................................................................[2]
10 The table below shows two fastening devices.

Complete the table by naming each fastening device and stating how each would be tightened.
Fastening device Name Method of tightening
[4]

6
Section B
11 Fig. 7 shows two bookends. The bookends could be made from plastic or metal.
One bookend has two storage strips where pens and pencils could be stored.
150
storage strips
10
0 90
Fig. 7
(a) Complete the table below by naming a suitable specific material and appropriate thickness of
material for the bookends.
Material Specific name Appropriate thickness

thermoplastic
ferrous metal
[4]
(b) Fig. 8 shows one bookend marked out ready to be bent to shape.
bend line
Fig. 8
Name one appropriate way of marking a line on the surface of:
(i) thermoplastic;
.......................................................................................................................................[1]
(ii) ferrous metal.
.......................................................................................................................................[1]
© UCLES 2017 0445/31/O/N/17
7
(c) Use sketches and notes to show how the bookends could be bent to shape when made from:
(i) thermoplastic;
[3]
(ii) ferrous metal.
[3]

8
(d) Fig. 9 shows the storage strips that will be joined to the bookend of the same material.
20
thermoplastic ferrous metal
Fig. 9
(i) Describe three main stages when joining a storage strip to the bookend permanently
when made from either thermoplastic or ferrous metal.
Chosen material ...........................................................
1 .......................................................................................................................................
2 .......................................................................................................................................
3 ...................................................................................................................................[3]
(ii) Use sketches and notes to show a modification to the thermoplastic bookend and
storage strips so that the storage strips could be attached to the bookend without using a
permanent method of joining.
[3]
© UCLES 2017 0445/31/O/N/17

9
(e) (i) The thermoplastic bookend will be self-finished.

...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) The ferrous metal bookend will be finished by dip coating with plastic.
Describe three main stages in the process of dip coating with plastic.
1 .......................................................................................................................................
2 .......................................................................................................................................
3 ...................................................................................................................................[3]
(f) The bookends are to be manufactured in large quantities.

Give two benefits to a manufacturer to produce the bookends without the storage strips.
1 ...............................................................................................................................................
2 ...........................................................................................................................................[2]

10
12 Fig. 10 shows a sign that will be located in a school corridor to give directions to a Design and
Technology display.
The sign is made from 15 thick hardwood and can be made to be wall-mounted or freestanding.
lo gy
no
ch
Te y
i g n &spla
s Di
De
Fig. 10
(a) Fig. 11 shows the sign marked out ready to be cut to shape.
600
waste
C
140
A B
Fig. 11
(i) Name an attractive hardwood for the sign.
.......................................................................................................................................[1]
(ii) For each of the areas A, B and C, name a different tool that could be used to remove the
waste.
A .......................................................................................................................................
B .......................................................................................................................................
C ...................................................................................................................................[3]
© UCLES 2017 0445/31/O/N/17

11
(iii) Describe how the surfaces of the sign could be prepared to take an applied finish.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(iv) Name a suitable finish and describe how it could be applied to achieve a high quality
finished surface.
Suitable finish .................................................................................................................[1]
How to achieve a high quality finished surface.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(b) Use sketches and notes to show how the sign could be fixed to a wall.
Your method of fixing must not be seen on the front of the sign.
Include all named materials and methods of construction.
[5]

12
(c) Use sketches and notes to show how the sign could be freestanding and supported at a
height of 1.5 metres above the ground.
• a stable base;
• a method of joining the sign to the support;
[8]
(d) The sign and lettering could be produced using Computer-Aided-Design, [CAD].
Describe how CAD could be used to design the words ‘Design & Technology Display’.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[3]
© UCLES 2017 0445/31/O/N/17

13
13 Fig. 12 shows a wooden stool and a parts list. The stool is designed for a person to stand on.
platform
Number
end Part Length × width × thickness
Required
platform 1 350 × 250 × 20
end 2 250 × 250 × 20
rail
rail 1 300 × 50 × 20
Fig. 12
(a) From the list of materials below, circle a hardwood that would be suitable for making the
stool.
plywood ash pine cedar [1]
(b) The platform for the stool is 250 wide. The widest available hardwood board is only 150 wide.
Fig. 13 shows two boards, each 150 wide.
uneven sawn edges
Fig. 13
Use sketches and notes to show how the two boards, each 150 wide, could be prepared and
joined to make the platform for the stool.
[6]
14
(c) Sketch and name a method of permanently joining the rail to one end.
[4]
(d) Fig. 14 shows the shaping to be carried out to one end.
waste
Fig. 14
Use sketches and notes to show how the waste wood could be removed and the sawn edges
made flat and smooth.
[3]
© UCLES 2017 0445/31/O/N/17

15
(e) Fig. 15 shows a bit that could be used to drill the hole in the stool platform.
Fig. 15
(i) Name the bit shown in Fig. 15.
.......................................................................................................................................[1]
(ii) When drilling the wood there is a danger that the wood can split as the drill passes
through the wood. Use sketches and notes to show how this could be prevented.
[3]
(f) Describe how more grip could be applied to the surface of the platform so that a person
standing on it would be less likely to slip.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

16
(g) Fig. 16 shows a stool made from plastic that has the same purpose as the stool made from
wood.
Fig. 16
(i) Name a suitable plastic for the stool.
.......................................................................................................................................[1]
(ii) Name a process that could be used to produce the stool.
.......................................................................................................................................[1]
(iii) Explain why the wooden stool would be more expensive to manufacture in large
quantities than the plastic stool.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[3]
© UCLES 2017 0445/31/O/N/17

* 3 3 7 7 7 7 2 5 4 4 *

1 hour
Section A
Section B
DC (AL/FC) 136179/2
2
Section A
1 Complete the drawing below to show the construction of blockboard.
[2]
2 Fig. 1 shows a metalwork vice A and a woodwork vice B.
body
jaws
A B
Fig. 1
(a) Name the metal from which the body of the metalwork vice is made.
...............................................................................................................................................[1]
(b) Give one property of beech that makes it suitable for the jaws of the woodwork vice.
...............................................................................................................................................[1]
3 Thermochromic materials are an example of ‘smart’ materials.

Complete the statement by adding the correct term from the list below.
weight temperature hardness light
Thermochromic materials change colour with changes in ................................................................

[1]
© UCLES 2017 0445/32/O/N/17
3
4 Fig. 2 shows two watering cans.
watering can A watering can B

polypropylene mild steel
Fig. 2
(a) Name a process used to manufacture the body of watering can A.
...............................................................................................................................................[1]
(b) Explain why watering can B would be galvanised.
...................................................................................................................................................
...............................................................................................................................................[2]
(c) (i) State which of the two watering cans, A or B, would be cheaper to mass produce.
......................................... [1]
(ii) Give one reason for your choice.
.......................................................................................................................................[1]
5 Complete the drawing below to show outside calipers.
[2]
4
6 Two workshop processes that could be dangerous are listed in the table below.
Complete the table by describing each danger and how it can be prevented.
Process Danger How it can be prevented
Joining pieces of acrylic

with acrylic cement
Pouring molten
aluminium when casting
[4]
7 Fig. 3 shows a label on a box of screws.
A 4.0 × 50 mm
40
×5
20
0 0
200
Fig. 3
State what each item of information means.
A........................................................................................................................................................
B........................................................................................................................................................
C....................................................................................................................................................[3]
[2]
© UCLES 2017 0445/32/O/N/17

5
9 Fig. 4 shows solid wood boards being seasoned outdoors in the open air.
roof to shield from rain

and direct sun
boards
sticks
piers
flat, dry, wood-free site
Fig. 4
(a) Give one reason why solid wood has to be seasoned.
...............................................................................................................................................[1]
(b) Name a different method of seasoning solid wood boards.
...............................................................................................................................................[1]
10 Complete the table by naming the correct plastic from the list below to match each description.
nylon phenol formaldehyde ABS polypropylene melamine formaldehyde
Plastic Description
hard, durable, used to make saucepan handles and dark
electrical fittings
self-lubricating, used to make gear wheels, clothing, combs,
curtain rails
[2]

6
Section B
11 Fig. 5 shows a picnic table that can be folded flat to fit in the back of a car.
50
0
0
90
table top: manufactured board 15 thick
500
rail
legs: 20 metal tube
Fig. 5
(a) Give three items of research the designer would need to consider when designing the picnic
table.
1 .................................................................................................................................................
2 .................................................................................................................................................
3 .............................................................................................................................................[3]
(b) (i) Name a suitable metal for the legs and rails.
.......................................................................................................................................[1]
(ii) Name two heat processes that could be used to join the legs and rails.
1 .........................................................................................................................................
2 .....................................................................................................................................[2]
© UCLES 2017 0445/32/O/N/17

7
(c) Give two benefits of covering the table top with a plastic laminate.
1 .................................................................................................................................................
2 .............................................................................................................................................[2]
(d) Fig. 6 shows the underside of the table top and the two end frames.
end frame A
folds flat
Fig. 6
Include details of materials, fittings and constructions when answering parts (i), (ii) and (iii).
(i) Use sketches and notes to show how end frame A could be made to fold against the
underside of the table top.
[4]

8
(ii) Use sketches and notes to show how both end frames could be held flat against the
underside of the table top when carried.
[4]
(iii) Use sketches and notes to show how both end frames could be locked against the table
top to prevent them from folding inwards when in use.
[4]
(e) Use sketches and notes to show a modification to the end frames so that the picnic table
could remain level when positioned on uneven ground.
Include details of materials, fittings and constructions.
[5]
© UCLES 2017 0445/32/O/N/17
9
12 Fig. 7 shows a bird feeder and a parts list.
top rail
roof
window
end
front rail
base
Number
Part Length × Width × Thickness Material
Required
end 2 200 × 150 × 12 Pine
roof 2 300 × 140 × 12 Pine
base 1 225 × 200 × 12 Pine
top rail 1 225 × 50 × 12 Pine
front rail 2 225 × 50 × 12 Pine
window 2 235 × 120 × 4 Clear acrylic
Fig. 7
(a) Fig. 8 shows one end of the bird feeder marked out, ready to be cut to shape.
Fig. 8
(i) Use sketches and notes to show how a sliding bevel could be used to mark out the
shape.
[2]
10
(ii) Name a saw that could be used to cut out the shape.
.......................................................................................................................................[1]
(iii) Name a plane that could be used to make the sawn edges flat and smooth.
.......................................................................................................................................[1]
(b) The ends will be glued and nailed to the base.
(i) Name a specific type of nail that could be used to join the ends to the base.
.......................................................................................................................................[1]
(ii) Name an adhesive suitable for outdoor use and state approximately how long it takes to
set.
Suitable adhesive ...........................................................................................................[1]
Time to set......................................................................................................................[1]
(c) The roof is made in two parts. Each part is hinged to the top rail as shown in Fig. 7.
Sketch and name a suitable hinge.
[3]
Name of hinge .......................................................................................................................[1]
© UCLES 2017 0445/32/O/N/17

11
(d) Fig. 9 shows details of the 4 thick clear acrylic window.
15
5
17
Fig. 9
(i) Use sketches and notes to show how the shaded area could be removed and the edges
[3]
(ii) Use sketches and notes to show how the 4 thick clear acrylic window could be fitted
securely inside the bird feeder.
Include all constructional details.
[4]
12
(e) Fig. 10 shows a sectional view of part of the bird feeder with a Ø5 aluminium rod that will
hook over the branch of a tree.
Ø5 aluminium rod
top rail
roof
Fig. 10
Add sketches to Fig. 10 to show how the Ø5 aluminium rod could be attached to the top rail of
the bird feeder. [3]
(f) Describe two problems that designers face when designing products for outdoor use and
how they may be solved.
Problem 1 ..................................................................................................................................
...............................................................................................................................................[1]
Solution ......................................................................................................................................
...............................................................................................................................................[1]
Problem 2 ..................................................................................................................................
...............................................................................................................................................[1]
Solution ......................................................................................................................................
...............................................................................................................................................[1]
© UCLES 2017 0445/32/O/N/17

13
13 Fig. 11 shows views of a shelf unit made from 15 thick MDF in a school workshop.
The shelf unit will be made as flat-pack for self-assembly.
180
0
60
18
0
Fig. 11
(a) Give two advantages of making the shelf unit from MDF rather than solid wood.
1 .................................................................................................................................................
2 .............................................................................................................................................[2]
(b) Fig. 12 shows one end of the shelf unit with a template that will be used when drawing the
shape onto the MDF.
template
Fig. 12
(i) Give one advantage of using a template rather than marking out the shape by hand.
.......................................................................................................................................[1]
(ii) Name one saw that could be used to cut out the shape.
.......................................................................................................................................[1]
(iii) Name a tool that could be used to finish the inside curve.
.......................................................................................................................................[1]

14
(c) The ends are joined to the shelf and back with dowels.
Fig. 13 shows one end of the shelf unit ready for the positions of dowels to be marked out.
A
5
16
15
Fig. 13
(i) Draw accurately on end A shown in Fig. 13 the positions for two dowels.
Show clearly all dimensions. [3]
(ii) Circle the most appropriate diameter of dowel that could be used.
Ø4 Ø6 Ø9 Ø12
[1]
(iii) State the purpose of the chamfer and the grooves on the dowel peg shown below.
grooves
chamfer
chamfer ..............................................................................................................................
grooves ..........................................................................................................................[2]
© UCLES 2017 0445/32/O/N/17

15
(iv) A batch of twenty identical shelf units will be made in a school workshop.
Use sketches and notes to show a design for a drilling jig that could be used when
drilling the holes for the dowels in the ends of the shelf unit shown in Fig. 13.
[4]
(v) Explain how the drilling jig you have designed in part (iv) would be used.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]

16
(d) Fig. 14 shows the back of the shelf unit.

Two brass plates 1.5 thick are set into the back so that the shelf unit can be fitted to a wall.
Fig. 14
Fig. 15 shows details of the brass plates.
Ø5
slot
30
Ø10
1.5 thick
30
Fig. 15
Use sketches and notes to show how the slot could be cut out in the brass plate.
Name all the tools used. Do not include details of marking out.
[4]
© UCLES 2017 0445/32/O/N/17
17
(e) Give two reasons why the shelf unit would be given a painted finish rather than a clear
varnished finish.
1 .................................................................................................................................................
2 .............................................................................................................................................[2]
(f) Give two reasons why self-assembly products are popular with consumers.
1 .................................................................................................................................................
2 .............................................................................................................................................[2]
© UCLES 2017 0445/32/O/N/17

18
BLANK PAGE
© UCLES 2017 0445/32/O/N/17

19
BLANK PAGE
© UCLES 2017 0445/32/O/N/17

20
BLANK PAGE
© UCLES 2017 0445/32/O/N/17

* 0 2 5 8 9 0 3 0 0 8 *

1 hour
Section A
Section B
DC (SLM/SW) 136199/1
2
Section A
1 Fig. 1 shows a child’s scooter.
Fig. 1
Describe three ways in which the designer has considered the child’s safety in the design of a

scooter.
1 ......................................................................................................................................................
2 ......................................................................................................................................................
3 ..................................................................................................................................................[3]
2 Describe a specific use for each of the chisels shown in Fig. 2.
cold chisel bevel-edge chisel
Fig. 2
Cold chisel
..........................................................................................................................................................
Bevel-edge chisel
......................................................................................................................................................[2]
© UCLES 2017 0445/33/O/N/17
3
3 Complete the drawing below to show a tenon saw.
[2]
4 SMA is a smart material that, when bent out of shape, will return to its original shape when
heated.
SMA stands for: Shape Memory A................................ [1]
5 Fig. 3 shows a variety of tools used in a school workshop.
A B C D
E F G H
Fig. 3
Complete the table below to show which tool from Fig. 3 would be used for each of the processes
listed.
Process Tool A–H
cutting through Ø12 mild steel bar
starting off a hole on a centre lathe
cutting a screw thread on a round bar
cutting shapes out of 1 thick copper sheet

[4]

4
6 Fig. 4 shows a washing-up liquid bottle made from plastic and a symbol that can be seen on the
bottle.
1
PET
Fig. 4
...............................................................................................................................................[1]
(b) Describe one problem for the environment when using products made from plastic.
...............................................................................................................................................[1]
7 Complete the drawing below to show a stopped housing joint.
[3]
© UCLES 2017 0445/33/O/N/17

5
8 Fig. 5 shows a house number plate made from brass, a non-ferrous alloy.
Fig. 5
Explain the term ‘non-ferrous alloy’.
..........................................................................................................................................................
......................................................................................................................................................[2]
9 Fig. 6 shows a hot melt glue gun.
Fig. 6
Give one benefit and one drawback of using a hot melt glue gun.
Benefit ..............................................................................................................................................
..........................................................................................................................................................
Drawback .........................................................................................................................................
......................................................................................................................................................[2]
10 The table below shows two fastening devices.

Complete the table by naming each fastening device and stating how each would be tightened.
Fastening device Name Method of tightening
[4]

6
Section B
11 Fig. 7 shows two bookends. The bookends could be made from plastic or metal.
One bookend has two storage strips where pens and pencils could be stored.
150
storage strips
10
0 90
Fig. 7
(a) Complete the table below by naming a suitable specific material and appropriate thickness of
material for the bookends.
Material Specific name Appropriate thickness

thermoplastic
ferrous metal
[4]
(b) Fig. 8 shows one bookend marked out ready to be bent to shape.
bend line
Fig. 8
Name one appropriate way of marking a line on the surface of:
(i) thermoplastic;
.......................................................................................................................................[1]
(ii) ferrous metal.
.......................................................................................................................................[1]
© UCLES 2017 0445/33/O/N/17
7
(c) Use sketches and notes to show how the bookends could be bent to shape when made from:
(i) thermoplastic;
[3]
(ii) ferrous metal.
[3]

8
(d) Fig. 9 shows the storage strips that will be joined to the bookend of the same material.
20
thermoplastic ferrous metal
Fig. 9
(i) Describe three main stages when joining a storage strip to the bookend permanently
when made from either thermoplastic or ferrous metal.
Chosen material ...........................................................
1 .......................................................................................................................................
2 .......................................................................................................................................
3 ...................................................................................................................................[3]
(ii) Use sketches and notes to show a modification to the thermoplastic bookend and
storage strips so that the storage strips could be attached to the bookend without using a
permanent method of joining.
[3]
© UCLES 2017 0445/33/O/N/17

9
(e) (i) The thermoplastic bookend will be self-finished.

...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(ii) The ferrous metal bookend will be finished by dip coating with plastic.
Describe three main stages in the process of dip coating with plastic.
1 .......................................................................................................................................
2 .......................................................................................................................................
3 ...................................................................................................................................[3]
(f) The bookends are to be manufactured in large quantities.

Give two benefits to a manufacturer to produce the bookends without the storage strips.
1 ...............................................................................................................................................
2 ...........................................................................................................................................[2]

10
12 Fig. 10 shows a sign that will be located in a school corridor to give directions to a Design and
Technology display.
The sign is made from 15 thick hardwood and can be made to be wall-mounted or freestanding.
lo gy
no
ch
Te y
i g n &spla
s Di
De
Fig. 10
(a) Fig. 11 shows the sign marked out ready to be cut to shape.
600
waste
C
140
A B
Fig. 11
(i) Name an attractive hardwood for the sign.
.......................................................................................................................................[1]
(ii) For each of the areas A, B and C, name a different tool that could be used to remove the
waste.
A .......................................................................................................................................
B .......................................................................................................................................
C ...................................................................................................................................[3]
© UCLES 2017 0445/33/O/N/17

11
(iii) Describe how the surfaces of the sign could be prepared to take an applied finish.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(iv) Name a suitable finish and describe how it could be applied to achieve a high quality
finished surface.
Suitable finish .................................................................................................................[1]
How to achieve a high quality finished surface.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(b) Use sketches and notes to show how the sign could be fixed to a wall.
Your method of fixing must not be seen on the front of the sign.
[5]

12
(c) Use sketches and notes to show how the sign could be freestanding and supported at a
height of 1.5 metres above the ground.
• a stable base;
• a method of joining the sign to the support;
[8]
(d) The sign and lettering could be produced using Computer-Aided-Design, [CAD].
Describe how CAD could be used to design the words ‘Design & Technology Display’.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[3]
© UCLES 2017 0445/33/O/N/17

13
13 Fig. 12 shows a wooden stool and a parts list. The stool is designed for a person to stand on.
platform
Number
end Part Length × width × thickness
Required
platform 1 350 × 250 × 20
end 2 250 × 250 × 20
rail
rail 1 300 × 50 × 20
Fig. 12
(a) From the list of materials below, circle a hardwood that would be suitable for making the
stool.
plywood ash pine cedar [1]
(b) The platform for the stool is 250 wide. The widest available hardwood board is only 150 wide.
Fig. 13 shows two boards, each 150 wide.
uneven sawn edges
Fig. 13
Use sketches and notes to show how the two boards, each 150 wide, could be prepared and
joined to make the platform for the stool.
[6]
14
(c) Sketch and name a method of permanently joining the rail to one end.
[4]
(d) Fig. 14 shows the shaping to be carried out to one end.
waste
Fig. 14
Use sketches and notes to show how the waste wood could be removed and the sawn edges
[3]
© UCLES 2017 0445/33/O/N/17

15
(e) Fig. 15 shows a bit that could be used to drill the hole in the stool platform.
Fig. 15
(i) Name the bit shown in Fig. 15.
.......................................................................................................................................[1]
(ii) When drilling the wood there is a danger that the wood can split as the drill passes
through the wood. Use sketches and notes to show how this could be prevented.
[3]
(f) Describe how more grip could be applied to the surface of the platform so that a person
standing on it would be less likely to slip.
...................................................................................................................................................
...................................................................................................................................................
...............................................................................................................................................[2]

16
(g) Fig. 16 shows a stool made from plastic that has the same purpose as the stool made from
wood.
Fig. 16
(i) Name a suitable plastic for the stool.
.......................................................................................................................................[1]
(ii) Name a process that could be used to produce the stool.
.......................................................................................................................................[1]
(iii) Explain why the wooden stool would be more expensive to manufacture in large
quantities than the plastic stool.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[3]
© UCLES 2017 0445/33/O/N/17

* 2 4 1 0 2 5 0 6 9 1 *

1 hour
Section A
Section B
DC (LK/SW) 152392/1
2
Section A
1 Fig. 1 shows a door bolt made from steel for use in a bathroom. The bolt has a chrome finish.
Fig. 1
Give two benefits of a chrome finish for the door bolt.
1 .......................................................................................................................................................
2 ................................................................................................................................................... [2]
2 Fig. 2 shows an incomplete leg fastening used to join a leg to the rails of a table.
Fig. 2
Add to Fig. 2 to show how the leg fastening could be fixed to the leg and the rails. [3]
© UCLES 2018 0445/32/M/J/18

3
3 Complete the table below by adding the correct name from the list.
forstner countersink flat twist centre
Drill Name
[3]
4 Fig. 3 shows a skateboard. The deck is made by gluing thin layers of wood together.
Fig. 3
(a) Give the correct term for ‘thin layers of wood’.
...............................................................................................................................................[1]
(b) Complete the statement below by adding the correct term from the list.
casting machining shaping laminating
Gluing thin layers of wood together is known as ..................................................................[1]

4
5 Fig. 4 shows a handle made from metal.
Fig. 4
Add sketches and notes to Fig. 4 to show a modification to the handle that would make it easier to
grip and turn. [2]
6 Fig. 5 shows a canoe.
Fig. 5
Name two composite materials that could be used to make the canoe.
1 .......................................................................................................................................................
2 ...................................................................................................................................................[2]
© UCLES 2018 0445/32/M/J/18

5
7 Fig. 6 shows a piece of steel that has cracked due to work hardening during bending.
Fig. 6
Explain what is meant by the term ‘work hardening’.
..........................................................................................................................................................
..........................................................................................................................................................
......................................................................................................................................................[2]
8 Fig. 7 shows views of a cabinet and a 6 mm thick sliding glass door to be fitted inside the cabinet.
Add sketches and notes to Fig. 7 to show how two sliding glass doors could be fitted inside the
cabinet.
top of cabinet
15 thick
glass door 6 thick
bottom of cabinet
15 thick
Fig. 7
[3]

6
9 Complete the table by naming the correct plastic from the list below to match each description.
nylon melamine PVC polythene polystyrene
Material Description of material

hard, tough, weather resistant, used for pipes,
guttering, window frames
hard-wearing, strong, range of colours, used for
decorative laminates
lightweight plastic, absorbs shock, good heat and
sound insulator
[3]
10 Fig. 8 shows a person sitting at a desk, using a computer. Three areas, where consideration of
ergonomics is required, are labelled A, B and C.
C
B
Fig. 8
Describe briefly the ergonomic consideration for each of the areas A, B and C shown.
A .......................................................................................................................................................
B .......................................................................................................................................................
C ...................................................................................................................................................[3]
© UCLES 2018 0445/32/M/J/18

7
Section B
11 Fig. 9 shows a child’s desk organiser made from 4 mm thick acrylic. The desk organiser will store
paints, brushes, marker pens, crayons and similar equipment.
Ø60 tube
partition
30
base
0
12
120
Fig. 9
(a) Fig. 10 shows the development (net) of the base of the desk organiser as a card template
that will be glued to the acrylic.
bend lines
Fig. 10
(i) Give one advantage of using a template rather than marking the development (net)
directly onto the acrylic.
.......................................................................................................................................[1]

8
(ii) Use sketches and notes to show how the acrylic development (net) could be cut out by
hand.
• the method of holding the acrylic

• the name of a suitable saw
• one precaution that would be taken to prevent damage when sawing
[4]
(b) Fig. 11 shows a basic former around which the acrylic will be moulded to shape.
Fig. 11
Describe how the acrylic could be:

• made soft enough to be moulded to shape
• held securely while it cools
[4]
© UCLES 2018 0445/32/M/J/18

9
(c) The base of the desk organiser could also be produced by the vacuum forming process.
(i) Name a suitable plastic, other than acrylic, that could be vacuum formed.
.......................................................................................................................................[1]
(ii) Describe two modifications that would need to be made to the former shown in Fig. 11
so that it could be used to vacuum form the base of the desk organiser.
1 ........................................................................................................................................
2 ....................................................................................................................................[2]
(iii) Explain why vacuum forming would be a better method of producing the base of the
desk organiser if it were to be batch produced.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(d) The partitions will be joined permanently to the base and the Ø60 tube using acrylic cement.
Describe two safety precautions that must be taken when using acrylic cement.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(e) Many of the edges of the acrylic will need to be made smooth and highly polished.
List three tools or items of equipment that could be used to make the edges smooth and
highly polished.
1 ................................................................................................................................................
2 ................................................................................................................................................
3 ............................................................................................................................................[3]

10
(f) To make it easier for children to access the equipment in the desk organiser an additional
base is required that will allow the desk organiser to rotate.
Children will then be able to turn the desk organiser to select the equipment they need.
Use sketches and notes to show how the desk organiser could be made to rotate freely on a
base.
• specific materials
• two important sizes
[6]
© UCLES 2018 0445/32/M/J/18

11
12 Fig. 12 shows a guitar stand made from hardwood. The stand can store up to four guitars.
top rail
support
upright
bottom rail
700
end rail
0
85
45
0
Fig. 12
(a) A parts list for the guitar stand is shown below.
Number
Part Length × Width × Thickness Hardwood
reqd.
Upright 2 700 × 40 × 15
Top rail 1 × 40 × 15
Bottom rail 2 × 40 × 12
End rail 2 450 × 60 × 15
Support 4 120 × 50 × 12
Complete the parts list by stating the two missing dimensions and naming one suitable
hardwood for the guitar stand. [3]
(b) Give three items of research a designer would need to consider when designing the guitar
stand.
1 ................................................................................................................................................
2 ................................................................................................................................................
3 ............................................................................................................................................[3]

12
(c) Fig. 13 shows one support marked out ready to be cut to shape.
12
50
waste
0
12
Fig. 13
Complete the table below by naming specific tools or items of equipment used to produce
the final shape.
Stage Process Specific tool or item of equipment
1 Remove the waste
2 Produce an accurately shaped curve
3 Smooth the surfaces
[3]
(d) Fig. 14 shows views of a bottom rail showing rounded edges.
marked out after planing
Fig. 14
(i) Name a suitable plane that could be used to produce the rounded edges.
.......................................................................................................................................[1]
(ii) Give one reason why the bottom rails are covered with fabric.
.......................................................................................................................................[1]
© UCLES 2018 0445/32/M/J/18

13
(e) The end rails will be joined to the uprights by means of 25 mm long screws.
Complete the drawing of the screw shown below by:
• naming the type of head

• showing accurately the length of the screw
• naming a suitable material
not to scale
[3]
(f) Fig. 15 shows one end of the top rail. The top rail is joined to the upright by means of dowels.
10
20
centres for dowel holes
15
Fig. 15
Use sketches and notes to show a design for a drilling jig that could be used to ensure that
holes are drilled accurately in the ends of the top rails.
Name the material/s from which the drilling jig is made.
[5]

14
(g) Use sketches and notes to show how a set of ‘feet’ could be added to the guitar stand.
Name the material used to make the ‘feet’.
[3]
(h) A wax finish will be applied to the guitar stand.
(i) Give one reason why two different grades of abrasive paper would be used to prepare
the surfaces before the wax finish is applied.
...........................................................................................................................................
.......................................................................................................................................[1]
(ii) Give one reason why the guitar stand would be waxed rather than painted.
...........................................................................................................................................
.......................................................................................................................................[1]
(iii) Give one advantage of applying a wax finish rather than a polyurethane varnish finish to
the guitar stand.
...........................................................................................................................................
.......................................................................................................................................[1]
© UCLES 2018 0445/32/M/J/18

15
13 Fig. 16 shows a card model for a safety glasses holder. The holder could be made from wood or
metal. The safety glasses holder will be wall-mounted in a school workshop.
100
0
17
60
Fig. 16
(a) Give two benefits of making a card model of the holder before making it from wood or metal.
1 ................................................................................................................................................
2 ............................................................................................................................................[2]
(b) The development (net) of the safety glasses holder will be marked out on a sheet of metal.
(i) Name a suitable ferrous metal for the holder.
.......................................................................................................................................[1]
(ii) Name a suitable non-ferrous metal for the holder.
.......................................................................................................................................[1]
(iii) The table below shows three marking out tools that could be used to mark out sheet
metal.
Complete the table by giving the specific name for each tool.
Tool Name
[3]
16
(iv) Explain why tinsnips would be a more effective tool to cut out the shape of the holder
rather than a hacksaw.
...........................................................................................................................................
...........................................................................................................................................
.......................................................................................................................................[2]
(c) Fig. 17 shows a safety glasses holder made from plywood.
back, front and sides 9 mm thick

base 4 mm thick plywood
Fig. 17
(i) Plywood is a very stable manufactured board that is unlikely to twist or warp.
Use sketches and notes to show the construction of plywood.
[3]
(ii) Name a different manufactured board that could be used to make the safety glasses
holder.
.......................................................................................................................................[1]
© UCLES 2018 0445/32/M/J/18

17
(iii) The parts of the safety glasses holder shown in Fig. 17 will be nailed and glued together.
Name a specific type of nail that could be used to join the parts of the holder together.
.......................................................................................................................................[1]
(iv) State a suitable length for the nail that could be used to join the front to the sides.
.......................................................................................................................................[1]
(v) Name a suitable adhesive that could be used to glue the parts together.
.......................................................................................................................................[1]
(vi) State approximately how long the adhesive named in part (v) would take to set.
.......................................................................................................................................[1]
(d) Choose whether to make the safety glasses holder from metal or plywood.
(i) Use sketches and notes to show a modification to the safety glasses holder so that it
could be fixed to a wall and easily removed for cleaning.
[3]

18
(ii) Use sketches and notes to show how a ‘lid’ could be fitted to the holder so that the safety
glasses could be kept clean.
[5]
© UCLES 2018 0445/32/M/J/18

19
BLANK PAGE
© UCLES 2018 0445/32/M/J/18

20
BLANK PAGE
© UCLES 2018 0445/32/M/J/18

* 0 8 4 0 0 4 6 0 3 2 *

1 hour
Section A
Section B
DC (KS) 157240
2
Section A
1 Name the two standard metal sections shown below.
......................................... ............................................... [2]
2 (a) Name the type of tools shown in Fig. 1.
Fig. 1
.............................................................................................................................................. [1]
(b) Give one reason why the tools in Fig. 1 can remove wood quickly and efficiently.
.............................................................................................................................................. [1]
3 Fig. 2 shows three different holes drilled before woodscrews can be used to join the two pieces of
wood. Each hole has a different purpose.
woodscrew
Fig. 2
Name each type of hole, A, B and C.
A .......................................................................................................................................................
B .......................................................................................................................................................
C .................................................................................................................................................. [3]
© UCLES 2018 0445/31/O/N/18
3
4 Complete the table below by naming a different material that matches each of the descriptions.
Material Description
hard plastic, wide range of colours, used to make
car rear light clusters
manufactured board made by gluing layers together
at 90° to each other
close-grained hardwood used to make mallet heads
and children’s toys
an alloy of copper and zinc, metal with corrosion
resistance, electrical conductivity
[4]
5 Fig. 3 shows an incomplete drawing of a marking gauge.
Fig. 3
Complete the drawing of the marking gauge by adding:
(a) the thumbscrew;
(b) the pin or spur. [2]
6 Fig. 4 shows equipment used in a moulding process.
pegs
finished moulding
Fig. 4
(a) Name the moulding process shown in Fig. 4.
.............................................................................................................................................. [1]
(b) State the purpose of the pegs in the moulding process.
.............................................................................................................................................. [1]
4
7 Fig. 5 shows two sit-on toys used by children.

Toy A is made from wood and toy B from plastic.
A B
Fig. 5
Describe one benefit to the user of making a sit-on toy from:
wood .................................................................................................................................................
plastic ...............................................................................................................................................
[2]
8 Fig. 6 shows a wooden frame construction, a hardboard corner plate and a corrugated fastener.
A
80
B 80
hardboard corner plate
15
25
corrugated fastener
Fig. 6
Draw on Fig. 6 to show how the frame construction could be strengthened by means of:
(a) the hardboard corner plate at A; [1]
(b) the corrugated fastener at B. [1]
© UCLES 2018 0445/31/O/N/18

5
9 Fig. 7 shows a metric micrometer and a close-up view of the sleeve and thimble.
sleeve
30
0 5
thimble 25
20
sleeve
thimble
Fig. 7
State the exact reading to one hundredth of a mm (0.01).
..................................................................................................................................................... [3]
10 Fig. 8 shows an item of workshop equipment.
Fig. 8
(a) State one specific use for the item of equipment shown in Fig. 8.
.............................................................................................................................................. [1]
(b) Give two safety precautions, other than wearing safety glasses, that must be taken when
using the item of equipment.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

6
Section B
11 Fig. 9 shows a storage unit. A printer will be placed on top of the unit, which will be positioned
under a desk. The unit has shelves that will be used to store printer paper.
0
35 45
0
top
500
end
shelf
not all dimensions are given
Fig. 9
(a) An incomplete parts list for the storage unit is shown below.
Complete the parts list.
Number
required
Top 1 450 × ................ × 19 Veneered chipboard
Shelf 2 ................ × ................ × 19 Veneered chipboard
End 2 ................ × 350 × 19 Veneered chipboard
[4]
(b) Give two advantages of using veneered chipboard rather than solid wood for the storage
unit.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2018 0445/31/O/N/18
7
(c) Sketch and name a pre-manufactured component that would enable the storage unit to be
moved about easily.
[3]
(d) Use sketches and notes to show how one shelf could be joined to one end using knock-down
(KD) fittings.
[4]

8
(e) Fig. 10 shows part of the top of the storage unit.
veneered surface
Fig. 10
Use sketches and notes to show how a solid wood lipping could be applied to one edge.
[3]
(f) Use sketches and notes to show a modification to the storage unit so that a quantity of paper
clips, pens, pencils and a 300 mm plastic rule could be stored safely.
[5]
© UCLES 2018 0445/31/O/N/18
9
(g) There is a possibility that the paper stored on the shelves could fall through the back of
the unit.
Use sketches and notes to show how this could be prevented.
[4]

10
12 Fig. 11 shows a headphone stand made from 5 thick acrylic.

The headphone stand has two main parts: a base and a support.
support
headphones
base
10 overall height 230

0
Fig. 11
(a) Give two items of research that would need to be considered when designing the headphone
stand.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Give two reasons why you would make a model of the headphone stand before making it
from acrylic.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2018 0445/31/O/N/18

11
(c) Fig. 12 shows the base of the headphone stand made from acrylic.
Fig. 12
(i) Use sketches and notes to show how the bend at A could be formed.
[4]
(ii) Explain why acrylic can be considered to be a ‘smart’ material.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]

12
(d) (i) Describe how the support could be joined permanently to the base of the headphone
stand using acrylic cement.
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) Give two safety precautions that must be taken when using acrylic cement.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(e) Fig. 13 shows a different design of headphone stand made from hardwood.
support 200 high × 15 thick
base 100 × 100 × 15
Fig. 13
(i) Sketch and name a suitable joint used to join the support to the base at A in Fig. 13.
[4]
© UCLES 2018 0445/31/O/N/18

13
(ii) Fig. 14 shows the shape of the support drawn on paper and glued onto a block of
hardwood.
Fig. 14
Give the correct term for the paper shape.
...................................................................................................................................... [1]
(iii) Name two types of saw that could be used to cut out the shape.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(f) Use sketches and notes to show a modification to either the acrylic headphone stand or the
hardwood headphone stand that would allow the cable to be stored neatly.
[4]
14
13 Fig. 15 shows two designs of shelf units.

Both designs are manufactured and sold as self-assembly products.
Design A Design B
hardwood shelf and brackets veneered manufactured board
and stainless steel brackets
Fig. 15
(a) Give one reason why the parts of Design A would have a finish applied before they are
assembled.
.............................................................................................................................................. [1]
(b) Give one benefit of using stainless steel for the brackets in Design B.
.............................................................................................................................................. [1]
(c) (i) Explain why there is a possibility that the hardwood shelf could split if it was fixed
permanently to the bracket in Design A.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) Use sketches and notes to show a method of fixing the shelf to the bracket in Design A
that would prevent it from splitting.
[2]
© UCLES 2018 0445/31/O/N/18

15
(d) Fig. 16 shows details of one bracket used with Design A.

The bracket is made by joining three strips of wood together.
200
hardwood 25 × 25
Fig. 16
(i) Use sketches and notes to show a design for a sawing jig that could be used when
sawing 200-long strips from a length of hardwood.
The sawing jig must:

• hold the hardwood securely;
• allow the hardwood to be cut accurately to length.
[6]

16
(ii) Sketch and name a suitable joint at X in Fig. 16.
[4]
(iii) Name three tools used to produce the joint named in (ii).
Do not include marking-out tools.
1 .......................................................................................................................................
2 .......................................................................................................................................
3 .................................................................................................................................. [3]
(e) Use sketches and notes to show details of one functional improvement that could be made to
shelf unit Design A shown in Fig. 15.
[2]
© UCLES 2018 0445/31/O/N/18

17
(f) Explain which of the shelf brackets, Design A or Design B, could be more expensive to
mass-produce.
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [2]
(g) (i) Give one benefit to the consumer of buying self-assembly products.
...................................................................................................................................... [1]
(ii) Give one benefit to the manufacturer of making self-assembly products.
...................................................................................................................................... [1]
© UCLES 2018 0445/31/O/N/18

18
BLANK PAGE
© UCLES 2018 0445/31/O/N/18

19
BLANK PAGE
© UCLES 2018 0445/31/O/N/18

20
BLANK PAGE
© UCLES 2018 0445/31/O/N/18

* 4 1 0 5 6 0 5 7 3 9 *

1 hour
Section A
Section B
DC (NF/SG) 152520/1
2
Section A
1 Fig. 1 shows a length of wood marked to the required width.
waste
edge
A
side
0
30
12
Fig. 1
(a) Name a tool, other than a pencil and steel rule, that could be used to mark the line A.
.............................................................................................................................................. [1]
(b) Name a plane that could be used to remove the waste.
.............................................................................................................................................. [1]
2 Fig. 2 shows a variety of different plastic tubes.
Fig. 2
Name the process used to make the plastic tubes.
..................................................................................................................................................... [1]
© UCLES 2018 0445/32/O/N/18

3
3 Complete the table below by naming each tool and describing a specific use for each.
Tool Name Use
[4]
4 Fig. 3 shows two pieces of wood that will be joined together using a biscuit joint.
Fig. 3
Draw on Fig. 3 to show how two biscuits could be used to join A to B. [3]

4
5 Fig. 4 shows three products made from different thermosetting plastics.
A B C
Fig. 4
Name a different thermosetting plastic that could be used to make each of the products.
A Electrical fitting .........................................................................................................................
B Plastic laminate ........................................................................................................................
C Two-part adhesive ............................................................................................................... [3]
6 Fig. 5 shows a three jaw and a four jaw chuck that are used with a centre lathe.
Fig. 5
(a) Describe a specific use for a three jaw chuck.
...................................................................................................................................................
.............................................................................................................................................. [1]
(b) Describe a specific use for a four jaw chuck.
...................................................................................................................................................
.............................................................................................................................................. [1]
© UCLES 2018 0445/32/O/N/18

5
7 Fig. 6 shows a pair of shin pads used by hockey players. The shin pads are made from a composite
material.
Fig. 6
(a) Name one composite material that could be used to make the shin pads.
.............................................................................................................................................. [1]
(b) Describe two properties of a composite material that makes it suitable for the shin pads.
1 .................................................................................................................................................
2 ............................................................................................................................................ [2]
8 Name the type of soldering that could be used when joining:
(a) electronic components to a circuit board;
.............................................................................................................................................. [1]
(b) nickel silver jewellery.
.............................................................................................................................................. [1]

6
9 Fig. 7 shows part of a leg and rail of a table and a knock-down (KD) fitting.
rail
rail
leg
leg
Fig. 7
Draw on Fig. 7 to show how the knock-down (KD) fitting could be fitted to the leg and rail to make
a strong joint. [3]
10 Fig. 8 shows a process used to make a plastic bowl.
metal ring
plastic sheet after heating
clamp
plastic sheet before heating

seal air
Fig. 8
.............................................................................................................................................. [1]
(b) Add to Fig. 8 to show how the bowl could be produced with a flat bottom. [1]
© UCLES 2018 0445/32/O/N/18

7
Section B
11 Fig. 9 shows views of a toothbrush holder made from 4 mm thick acrylic.
20
support
A
100
130
20
0
18
90
70
end
view with end removed
Fig. 9
(a) Fig. 10 shows a sheet of acrylic on which the development (net) of the support will be marked
out. Corner A is shown in Figs. 9 and 10.
A
not to scale
Fig. 10
(i) Draw on Fig. 10 to show all the bend lines. [4]

(ii) From the list below circle one item of equipment used to mark the bend lines on the
surface of the acrylic.
lead pencil biro scriber felt marker marking knife [1]

8
(b) Use sketches and notes to show how the development (net) could be bent to shape.

• the method of producing an accurate shape
[5]
(c) Fig. 11 shows one end marked out, ready to be cut to shape.
waste
130
90
Fig. 11
Use sketches and notes to show how the waste could be removed and the rounded corners
produced. Name all the tools and equipment used.
[4]
© UCLES 2018 0445/32/O/N/18
9
(d) The edges of the ends and support will be self-finished to a high quality before the parts are
joined together.
(i) Name the method of filing used to make the edges smooth.
...................................................................................................................................... [1]
(ii) Explain why two different grades of wet and dry (silicon carbide) paper would be used
when self-finishing the edges.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(e) The support will be joined to the ends by using acrylic cement.
(i) Describe how the acrylic cement would be applied and how the parts would be held
together while the acrylic cement sets.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) State why it is important to work in a well-ventilated area when using acrylic cement.
...................................................................................................................................... [1]
(f) Use sketches and notes to show how the toothbrush holder could be modified so that a tube
of toothpaste could be stored.
Describe how the modification could be made in a school workshop.
Name all tools and equipment used.
[5]

10
12 Fig. 12 shows an incomplete design of a desk. The desk top is made from manufactured board
and the legs and rails from hardwood.
end frame 60 × 20
A
desk top height 700

1000
00
60 10
0
Fig. 12
(a) (i) Name a suitable manufactured board for the desk top.
...................................................................................................................................... [1]
(ii) Suggest an appropriate thickness of manufactured board for the desk top.
...................................................................................................................................... [1]
(iii) Name a suitable hardwood for the legs and rails.
...................................................................................................................................... [1]
(iv) Complete the statement below by adding the correct term from the list.
mechanisms seasoning anthropometrics sustainability
The designer decided to make the desk 700 mm high after studying ...............................
�� [1]
© UCLES 2018 0445/32/O/N/18

11
(b) The corner bridle joint shown below could be used to join the leg and rail at corner A in
Fig. 12.
(i) Name two marking out tools, other than a pencil, that could be used to mark out the
corner bridle joint.
1 .........................................................................................................................................
2 .................................................................................................................................... [2]
(ii) Name two tools that could be used to cut out the corner bridle joint.
1 .........................................................................................................................................
2 .................................................................................................................................... [2]
(c) Use sketches and notes to show how the desk top could be fixed to the end frames.
Include details of constructions and fittings used.
[5]

12
(d) Fig. 13 shows the legs and rails of one frame ready to be glued and clamped.
position for cramp
position for cramp
Fig. 13
(i) Name the cramps that would be used to secure the joints.
...................................................................................................................................... [1]
(ii) Name a suitable adhesive that could be used to glue the joint together.
...................................................................................................................................... [1]
(iii) Describe two checks that would need to be carried out when the legs and rails are glued
and clamped together.
1 .........................................................................................................................................
2 .................................................................................................................................... [2]
© UCLES 2018 0445/32/O/N/18

13
(e) Fig. 14 shows the shape of one end frame marked out on a sheet of manufactured board.
The end frame will be cut out of the sheet of manufactured board rather than using separate
legs and rails.
1000 waste
600
Fig. 14
(i) Give one advantage and one disadvantage of making the end frame from one piece of
manufactured board rather than separate legs and rails.
Advantage .........................................................................................................................
...........................................................................................................................................
Disadvantage ....................................................................................................................
...................................................................................................................................... [2]
(ii) Name a portable power tool that could be used to cut out the shape of the end frame.
...................................................................................................................................... [1]
(iii) Describe two safety precautions, other than personal protection equipment, that must be
taken when using portable power tools.
1 .........................................................................................................................................
2 .................................................................................................................................... [2]

14
(f) Fig. 15 shows two desks. Desk A is a modern desk and desk B is a traditional design.
A B
Fig. 15
Explain why the design of the desk has changed.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [3]
© UCLES 2018 0445/32/O/N/18

15
13 Fig. 16 shows a wall-mounted adjustable shelving system.
metal support rods Ø8
shelves 700 × 300 × 15
uprights 1200 × 50 × 25
Fig. 16
(a) Name suitable specific materials for the parts of the shelving system:
• hardwood uprights .............................................................................................................
• metal support rods ............................................................................................................
• manufactured board shelves ........................................................................................ [3]
(b) The manufactured board used for the shelves is veneered.
(i) Give one benefit of covering the manufactured board with veneer.
...................................................................................................................................... [1]
(ii) Give one drawback of covering the manufactured board with veneer.
...................................................................................................................................... [1]

16
(c) Fig. 17 shows part of one upright with the centres for Ø8 holes marked out.
50
25
50
40 centres for Ø8 drilled holes
Fig. 17
Use sketches and notes to show a design for a jig to allow three holes to be drilled accurately.
Include details of materials used.
[5]
© UCLES 2018 0445/32/O/N/18

17
(d) Fig. 18 shows details of one metal support rod.
60
0
35
60
Fig. 18
Use sketches and notes to show how the two bends in the support could be produced.
[4]
(e) The metal support rods will have a clear lacquer finish.
Describe how the metal could be prepared before applying clear lacquer.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [3]
18
(f) Fig. 19 shows one corner of a shelf marked out ready to be cut out to take the upright.
25
25
Fig. 19
(i) Name one marking out tool, other than a pencil and a steel rule, that could be used to
mark out the shape.
...................................................................................................................................... [1]
(ii) Name a back saw that could be used to cut out the shape.
...................................................................................................................................... [1]
(g) Fig. 20 shows one metal support rod that fits into a Ø8 hole in a shelf.
Use sketches and notes to show how the metal support rod could be fixed to the shelf to
support the weight when in use.
Ø8 metal support rod
15 thick shelf
Fig. 20
[4]
© UCLES 2018 0445/32/O/N/18

19
(h) Describe two good design features of the shelving system.
1 .................................................................................................................................................
2 ............................................................................................................................................ [2]
© UCLES 2018 0445/32/O/N/18

20
BLANK PAGE
© UCLES 2018 0445/32/O/N/18

* 9 9 2 1 5 7 0 0 9 0 *

1 hour
Section A
Section B
DC (NF/FD) 117566/5
2
Section A
1 Name the two standard metal sections shown below.
......................................... ............................................... [2]
2 (a) Name the type of tools shown in Fig. 1.
Fig. 1
.............................................................................................................................................. [1]
(b) Give one reason why the tools in Fig. 1 can remove wood quickly and efficiently.
.............................................................................................................................................. [1]
3 Fig. 2 shows three different holes drilled before woodscrews can be used to join the two pieces of
wood. Each hole has a different purpose.
woodscrew
Fig. 2
Name each type of hole, A, B and C.
A .......................................................................................................................................................
B .......................................................................................................................................................
C .................................................................................................................................................. [3]
© UCLES 2018 0445/33/O/N/18
3
4 Complete the table below by naming a different material that matches each of the descriptions.
Material Description
hard plastic, wide range of colours, used to make
car rear light clusters
manufactured board made by gluing layers together
at 90° to each other
close-grained hardwood used to make mallet heads
and children’s toys
an alloy of copper and zinc, metal with corrosion
resistance, electrical conductivity
[4]
5 Fig. 3 shows an incomplete drawing of a marking gauge.
Fig. 3
Complete the drawing of the marking gauge by adding:
(a) the thumbscrew;
(b) the pin or spur. [2]
6 Fig. 4 shows equipment used in a moulding process.
pegs
finished moulding
Fig. 4
(a) Name the moulding process shown in Fig. 4.
.............................................................................................................................................. [1]
(b) State the purpose of the pegs in the moulding process.
.............................................................................................................................................. [1]
4
7 Fig. 5 shows two sit-on toys used by children.

Toy A is made from wood and toy B from plastic.
A B
Fig. 5
Describe one benefit to the user of making a sit-on toy from:
wood .................................................................................................................................................
plastic ...............................................................................................................................................
[2]
8 Fig. 6 shows a wooden frame construction, a hardboard corner plate and a corrugated fastener.
A
80
B 80
hardboard corner plate
15
25
corrugated fastener
Fig. 6
Draw on Fig. 6 to show how the frame construction could be strengthened by means of:
(a) the hardboard corner plate at A; [1]
(b) the corrugated fastener at B. [1]
© UCLES 2018 0445/33/O/N/18

5
9 Fig. 7 shows a metric micrometer and a close-up view of the sleeve and thimble.
sleeve
30
0 5
thimble 25
20
sleeve
thimble
Fig. 7
State the exact reading to one hundredth of a mm (0.01).
..................................................................................................................................................... [3]
10 Fig. 8 shows an item of workshop equipment.
Fig. 8
(a) State one specific use for the item of equipment shown in Fig. 8.
.............................................................................................................................................. [1]
(b) Give two safety precautions, other than wearing safety glasses, that must be taken when
using the item of equipment.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]

6
Section B
11 Fig. 9 shows a storage unit. A printer will be placed on top of the unit, which will be positioned
under a desk. The unit has shelves that will be used to store printer paper.
0
35 45
0
top
500
end
shelf
not all dimensions are given
Fig. 9
(a) An incomplete parts list for the storage unit is shown below.
Complete the parts list.
Number
required
Top 1 450 × ................ × 19 Veneered chipboard
Shelf 2 ................ × ................ × 19 Veneered chipboard
End 2 ................ × 350 × 19 Veneered chipboard
[4]
(b) Give two advantages of using veneered chipboard rather than solid wood for the storage
unit.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2018 0445/33/O/N/18
7
(c) Sketch and name a pre-manufactured component that would enable the storage unit to be
moved about easily.
[3]
(d) Use sketches and notes to show how one shelf could be joined to one end using knock-down
(KD) fittings.
[4]

8
(e) Fig. 10 shows part of the top of the storage unit.
veneered surface
Fig. 10
Use sketches and notes to show how a solid wood lipping could be applied to one edge.
[3]
(f) Use sketches and notes to show a modification to the storage unit so that a quantity of paper
clips, pens, pencils and a 300 mm plastic rule could be stored safely.
[5]
© UCLES 2018 0445/33/O/N/18
9
(g) There is a possibility that the paper stored on the shelves could fall through the back of
the unit.
Use sketches and notes to show how this could be prevented.
[4]

10
12 Fig. 11 shows a headphone stand made from 5 thick acrylic.

The headphone stand has two main parts: a base and a support.
support
headphones
base
10 overall height 230

0
Fig. 11
(a) Give two items of research that would need to be considered when designing the headphone
stand.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
(b) Give two reasons why you would make a model of the headphone stand before making it
from acrylic.
1 ...............................................................................................................................................
2 .......................................................................................................................................... [2]
© UCLES 2018 0445/33/O/N/18

11
(c) Fig. 12 shows the base of the headphone stand made from acrylic.
Fig. 12
(i) Use sketches and notes to show how the bend at A could be formed.
[4]
(ii) Explain why acrylic can be considered to be a ‘smart’ material.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]

12
(d) (i) Describe how the support could be joined permanently to the base of the headphone
stand using acrylic cement.
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) Give two safety precautions that must be taken when using acrylic cement.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(e) Fig. 13 shows a different design of headphone stand made from hardwood.
support 200 high × 15 thick
base 100 × 100 × 15
Fig. 13
(i) Sketch and name a suitable joint used to join the support to the base at A in Fig. 13.
[4]
© UCLES 2018 0445/33/O/N/18

13
(ii) Fig. 14 shows the shape of the support drawn on paper and glued onto a block of
hardwood.
Fig. 14
Give the correct term for the paper shape.
...................................................................................................................................... [1]
(iii) Name two types of saw that could be used to cut out the shape.
1 .......................................................................................................................................
2 .................................................................................................................................. [2]
(f) Use sketches and notes to show a modification to either the acrylic headphone stand or the
hardwood headphone stand that would allow the cable to be stored neatly.
[4]
14
13 Fig. 15 shows two designs of shelf units.

Both designs are manufactured and sold as self-assembly products.
Design A Design B
hardwood shelf and brackets veneered manufactured board
and stainless steel brackets
Fig. 15
(a) Give one reason why the parts of Design A would have a finish applied before they are
assembled.
.............................................................................................................................................. [1]
(b) Give one benefit of using stainless steel for the brackets in Design B.
.............................................................................................................................................. [1]
(c) (i) Explain why there is a possibility that the hardwood shelf could split if it was fixed
permanently to the bracket in Design A.
...........................................................................................................................................
...........................................................................................................................................
...................................................................................................................................... [2]
(ii) Use sketches and notes to show a method of fixing the shelf to the bracket in Design A
that would prevent it from splitting.
[2]
© UCLES 2018 0445/33/O/N/18

15
(d) Fig. 16 shows details of one bracket used with Design A.

The bracket is made by joining three strips of wood together.
200
hardwood 25 × 25
Fig. 16
(i) Use sketches and notes to show a design for a sawing jig that could be used when
sawing 200-long strips from a length of hardwood.
The sawing jig must:

• hold the hardwood securely;
• allow the hardwood to be cut accurately to length.
[6]

16
(ii) Sketch and name a suitable joint at X in Fig. 16.
[4]
(iii) Name three tools used to produce the joint named in (ii).
Do not include marking-out tools.
1 .......................................................................................................................................
2 .......................................................................................................................................
3 .................................................................................................................................. [3]
(e) Use sketches and notes to show details of one functional improvement that could be made to
shelf unit Design A shown in Fig. 15.
[2]
© UCLES 2018 0445/33/O/N/18

17
(f) Explain which of the shelf brackets, Design A or Design B, could be more expensive to
mass-produce.
...................................................................................................................................................
...................................................................................................................................................
.............................................................................................................................................. [2]
(g) (i) Give one benefit to the consumer of buying self-assembly products.
...................................................................................................................................... [1]
(ii) Give one benefit to the manufacturer of making self-assembly products.
...................................................................................................................................... [1]
© UCLES 2018 0445/33/O/N/18

18
BLANK PAGE
© UCLES 2018 0445/33/O/N/18

19
BLANK PAGE
© UCLES 2018 0445/33/O/N/18

20
BLANK PAGE
© UCLES 2018 0445/33/O/N/18

Cambridge Assessment International Education
* 3 5 6 9 2 5 4 8 7 4 *

1 hour
Write your centre number, candidate number and name on all the work you hand in.
Section A
Section B
DC (JC/SG) 178848
2
Section A
1 Two signs used in a workshop are shown below.
Describe a specific workshop process when:
ear defenders must be worn
..........................................................................................................................................................
safety glasses must be worn.
..........................................................................................................................................................
[2]
2 Fig. 1 shows two different methods of filing metal.
cross filing draw filing
Fig. 1
Describe the purpose of each method of filing.
Cross filing .......................................................................................................................................
..........................................................................................................................................................
Draw filing ........................................................................................................................................

[2]
© UCLES 2019 0445/31/M/J/19

3
3 Complete the drawing below to show an exploded view of a stopped housing joint.
[3]
4 Fig. 2 shows a small dish made from plastic. The dish has been vacuum formed.
Fig. 2
(a) The former used to vacuum form the dish could be made from hardwood or MDF.
Give two advantages of making the former from MDF rather than hardwood.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(b) Describe two features of the design of the former to ensure that the dish will be vacuum
formed successfully.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]

4
5 Fig. 3 shows two electric drills.
aluminium alloy casing plastic body
rechargeable battery
mains cable
Drill A Drill B
Fig. 3
(a) Name the manufacturing process used to produce the casing for drill A.
............................................................................................................................................. [1]
(b) Give one advantage of using drill B compared to drill A.
............................................................................................................................................. [1]
6 Fig. 4 shows a kitchen roll holder made from acrylic.
kitchen roll
Fig. 4
Explain how the designer has used the flexible property of acrylic in the design of the kitchen roll
holder.
..........................................................................................................................................................
..........................................................................................................................................................
.................................................................................................................................................... [2]
© UCLES 2019 0445/31/M/J/19
5
7 Fig. 5 shows a basic design for a desk tidy made in a school workshop.
The desk tidy is made from 4 mm thick acrylic.
Fig. 5
Use sketches and notes to show one functional improvement to the design of the desk tidy.
[2]
8 Fig. 6 shows part of a garden tool rack.
Fig. 6
(a) Indicate clearly on Fig. 6 one example of ‘short grain’. [1]
(b) Explain why ‘short grain’ is a problem that occurs only in solid wood and not in manufactured
boards.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
6
9 Fig. 7 shows a round tube that will be joined to a metal strip made from mild steel.
tube Ø20
strip 20 × 3
Fig. 7
Add sketches and notes to Fig. 7 to show how they could be joined together.
Your method must allow the tube and strip to be taken apart. [3]
10 Fig. 8 shows two different wall brackets.
18
0
230
bracket A fabricated from softwood bracket B moulded plastic
Fig. 8
(a) Describe one quality control check that would be carried out during the manufacture of
bracket A.
...................................................................................................................................................
............................................................................................................................................. [1]
(b) Describe one quality control check, different to that in part (a), that would be carried out
during the manufacture of bracket B.
...................................................................................................................................................
............................................................................................................................................. [1]
© UCLES 2019 0445/31/M/J/19

7
Section B begins on page 8.

8
Section B
11 Fig. 9 shows views of a child’s counting toy. When the discs are stacked on the rod, the collar
slides down on top of the discs to show the number of discs stacked.
Ø5 rod
collar
10
9
upright 8
7
discs 6
5
4
base 3
2
1
disc Ø40 × 15
Fig. 9
(a) Fig. 10 shows the base of the counting toy. The base is made from beech.
slot 40 × 12
15
centre for hole
0
15
10
0
Fig. 10
(i) Give two reasons why beech is commonly used to make children’s toys.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
© UCLES 2019 0445/31/M/J/19
9
(ii) Name three marking out tools, other than a pencil, that could be used to mark out the
centre for the hole and the slot.
1 ........................................................................................................................................
2 ........................................................................................................................................
3 ........................................................................................................................................
[3]
(iii) Describe how the slot could be cut out 10 mm deep to take the upright.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
..................................................................................................................................... [3]
(b) The Ø5 rod is made from non-ferrous metal.
(i) Name a suitable non-ferrous metal for the rod.
..................................................................................................................................... [1]
(ii) Give one reason why a non-ferrous metal could be more suitable than a ferrous metal
for the rod.
..................................................................................................................................... [1]
(c) Use sketches and notes to show how ten identical wooden discs could be made in a school
workshop. Show clearly how the holes in each disc could be produced accurately.
[5]

10
(d) The discs could also be made from plastic and produced by injection moulding.
Give two advantages of using the injection moulding process to produce plastic discs rather
than making them from wood.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(e) Fig. 11 shows a length of beech that will be used to make the four parts of the collar.
45
25
collar
6
Fig. 11
Use sketches and notes to show how the collar could be constructed.
Name the tools and equipment used to construct the collar.
[4]
(f) Describe how CAD/CAM could be used to produce the numbers on the upright.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [4]
© UCLES 2019 0445/31/M/J/19
11
12 Fig. 12 shows an incomplete design for a reading lamp to be made in a school workshop.
The arms, base and supports are made from hardwood.
lamp shade
arm
arm
support
base
Fig. 12
(a) Fig. 13 shows details of the base and supports.
15
60
15
15 0
0 15
Fig. 13
Use sketches and notes to show how the base and supports could be joined permanently.
[3]
12
(b) Fig. 14 shows views of parts of both arms of the reading lamp.
centre for fitting
34
15
Fig. 14
(i) Draw on Fig. 14 to show a metal fitting that could be used to join the arms together and
allow them to be adjusted and locked in position.
Add two important sizes to the fitting. [4]
(ii) The fitting will be chrome plated.

Give two benefits of chrome plating metal fittings.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
(c) Fig. 15 shows one of the four sides that will be joined together to make the lamp shade.
The sides are made from 3 mm thick veneered plywood.
80
120
120
Fig. 15
(i) Give two advantages of using 3 mm thick veneered plywood rather than solid wood for
the sides of the lamp shade.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
© UCLES 2019 0445/31/M/J/19

13
(ii) Use sketches and notes to show how the sides could be joined together to form the lamp
shade. Consider carefully that the veneered plywood is only 3 mm thick.
[4]
(d) The lamp shade shown in Fig. 15 could be made from brass.
State two properties of brass that make it suitable for the lamp shade.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]

14
(e) Fig. 16 shows a template of the lamp shade glued onto a sheet of 1 mm thick brass.
B
template
A
brass sheet
Fig. 16
Use sketches and notes to show how the lamp shade could be made from one piece of
brass. Include the method of:
• cutting out the shape
• bending the brass to shape
• soldering edge A to edge B
• cleaning and finishing.
[8]
© UCLES 2019 0445/31/M/J/19

15
13 Fig. 17 shows views of a children’s play table. The height of the table can be adjusted by means of
sleeves that fit over the ends of the legs.
The table is produced as flat-pack for self-assembly.
A
end rail
long rail
leg
sleeve
Fig. 17
(a) (i) Name a suitable manufactured board for the table top.
..................................................................................................................................... [1]
(ii) Name a suitable softwood for the legs and rails.
..................................................................................................................................... [1]
(b) Describe two benefits of covering the manufactured board used for the table top with
melamine sheet.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(c) (i) Explain why the designer has made the table height adjustable.
...........................................................................................................................................
...........................................................................................................................................
..................................................................................................................................... [2]

16
(ii) The height of the table can be adjusted by means of sleeves that fit over the ends of the
legs. The sleeve shown below will be produced by the extrusion process.
150
65
22
Fig. 18 shows part of an extrusion moulding machine.

Add notes to Fig. 18 to describe the extrusion process.
Fig. 18
[3]
(iii) The height of the table can be adjusted by moving the sleeve up or down and locking it in
position.
Use sketches and notes to show how the table could be set at three different heights.
Include details of any fittings and materials used.
[4]
© UCLES 2019 0445/31/M/J/19
17
(d) The legs and rails are made from the same size section softwood, 60 × 20.
Explain one benefit to the manufacturer of using the same size section softwood.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
(e) The parts of the table shown in Fig. 17 will be assembled using dowels and screws.
(i) Use sketches and notes to show how screws could be used to join two rails at A.
[3]
(ii) Use sketches and notes to show how dowels could be used to join the table top to the
rails.
[3]

18
(f) Explain one benefit to manufacturers of making products that can be self-assembled by
consumers.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
(g) Use sketches and notes to show one functional improvement to the design of the children’s
play table.
[2]
© UCLES 2019 0445/31/M/J/19

19
BLANK PAGE
© UCLES 2019 0445/31/M/J/19

20
BLANK PAGE
To avoid the issue of disclosure of answer-related information to candidates, all copyright acknowledgements are reproduced online in the Cambridge
Assessment International Education Copyright Acknowledgements Booklet. This is produced for each series of examinations and is freely available to download
at www.cambridgeinternational.org after the live examination series.
Cambridge Assessment International Education is part of the Cambridge Assessment Group. Cambridge Assessment is the brand name of the University of
Cambridge Local Examinations Syndicate (UCLES), which itself is a department of the University of Cambridge.
© UCLES 2019 0445/31/M/J/19

* 3 5 1 8 6 4 9 9 1 0 *

1 hour
Section A
Section B
DC (NH/SG) 168522/2
2
Section A
1 Fig. 1 shows a kitchen pedal bin.
lid
body
pedal
Fig. 1
Complete the list below by adding two specification points for the kitchen pedal bin.
1 The lid must open easily when the pedal is pressed.
2 .......................................................................................................................................................
3 .......................................................................................................................................................
[2]
© UCLES 2019 0445/32/M/J/19

3
2 Complete the table by stating the manufacturing process used to make each product.
Product Manufacturing process
metal model toy vehicle
plastic tubes
wooden chair legs

[3]
3 Fig. 2 shows a length of veneered chipboard marked out, ready to be cut into four pieces.
20
0
00 15 mm thick
10
10 mm waste
Fig. 2
(a) Give one reason why the lines would be marked out using a marking knife rather than a
pencil.
............................................................................................................................................. [1]
(b) Give one reason why 10 mm waste has been allowed between the marked lengths.
............................................................................................................................................. [1]

4
4 Name the three standard metal sections shown below.
...................................... ..................................... ..................................... [3]
5 Complete the drawing below to show a finger (comb) joint.
[3]
6 Composite materials are made by combining materials with different properties to make a material
with more useful properties.
Name two composite materials.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
[2]
© UCLES 2019 0445/32/M/J/19

5
7 The table shows two different centre lathe processes used when turning round metal bar.
Complete the table by naming each process.
Process Description of process Name of process
Cutting across the end of the

round bar
Cutting off a length of round

bar
[2]
8 Fig. 3 shows hardwood strips being glued together to make a chopping board.
chopping board
scrap wood
cramp
Fig. 3
(a) Name the type of cramps used.
............................................................................................................................................. [1]
(b) Give two reasons why scrap wood is used between the cramps and the chopping board.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]

6
9 Fig. 4 shows a toast rack made from stainless steel.
Fig. 4
Give two reasons why stainless steel is a suitable material for a toast rack.
1 .......................................................................................................................................................
2 .......................................................................................................................................................
[2]
10 Fig. 5 shows a wooden chair.
legs 30 × 30
Fig. 5
Use sketches and notes to show how the chair could be modified so that it can be linked, side by
side, to an identical chair and could be easily separated for stacking.
[3]
© UCLES 2019 0445/32/M/J/19
7
Section B
11 Fig. 6 shows an incomplete design of a child’s novelty clock.

The clock shape could be made from 5 mm thick manufactured board or 1.5 mm thick non-ferrous
metal. The clock will be placed on a shelf.
12
300
11 1
10 2
9 3
8 4
7 6 5
400
Fig. 6
(a) (i) Name a suitable manufactured board for the clock shape.
..................................................................................................................................... [1]
(ii) Name a suitable non-ferrous metal for the clock shape.
..................................................................................................................................... [1]
(b) Fig. 7 shows a template of the shape glued to a sheet of 5 mm thick manufactured board. The
centre for a hole to be drilled for the clock mechanism is shown.
waste to be removed
centre for hole
Fig. 7
(i) Give two reasons why the sheet of manufactured board must be clamped down securely
when drilling the hole.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
8
(ii) Use sketches and notes to show how the shape could be cut out by hand and the edges
made smooth.
[3]
(c) Fig. 8 shows the clock shape made from manufactured board joined to a wooden base.
12 1 2
11 3
10 4
9 5
8 6
7
wooden base 400 × 40 × 10
Fig. 8
Use sketches and notes to show how the clock shape could be joined to the base.
[3]
© UCLES 2019 0445/32/M/J/19

9
(d) The manufactured board clock shape will be finished with spray paint.
Give two advantages of spray paint rather than applying the paint with a brush.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(e) Fig. 9 shows the clock shape made from 1.5 mm thick non-ferrous metal.
Legs have been joined to the shape so that it could stand on a shelf.
12 1 2
11 3
10 4
9 5
8
7 6 legs 60 × 20 × 1.5
Fig. 9
Use sketches and notes to show how the legs could be made from non-ferrous metal and
joined permanently to the clock shape. Name all the tools and equipment used.
[5]
(f) When the clock shape is made from non-ferrous metal it could be self-finished.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
10
(g) Describe in detail how CAD/CAM could be used to produce the numbers 1 to 12 on the 5 mm
thick manufactured board clock face.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [4]
(h) State two ways, other than shape and colour, by which designers make products used by
young children appealing and exciting.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
© UCLES 2019 0445/32/M/J/19

11
12 Fig. 10 shows views of a storage unit designed to hold a tablet, mobile phone and remote control.
tablet
200
slot
phone
base
strip
23
0
0
12
Fig. 10
(a) Give two reasons why acrylic would be a suitable material for the storage unit.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(b) Fig. 11 shows the development (net) of the storage unit made from 5 mm thick acrylic.
slot A 190 × 60
A B
slot B 190 × 40
Fig. 11
Use sketches and notes to show how the slots could be cut out by hand and the edges made
smooth.
[4]
12
(c) The development (net) and slots could be cut out using a CNC machine.
Describe the stages involved when using a CNC machine to cut out the development (net)
and slots.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [4]
(d) Use sketches and notes to show how the acrylic development (net) could be bent to shape.
[3]
© UCLES 2019 0445/32/M/J/19

13
(e) Fig. 12 shows one of the strips that will be joined to the base of the storage unit using acrylic
cement.
strip 200 × 10 × 5
Fig. 12
(i) Use sketches and notes to show how the strip could be held in place while the acrylic
cement sets.
[2]
(ii) Give one reason why each of the following items would be worn when using acrylic
cement:
disposable gloves
...........................................................................................................................................
face mask.
...........................................................................................................................................
[2]
(f) The storage unit could also be made by laminating five wood veneers, each 1 mm thick.
Use sketches and notes to show how the laminate could be formed to the shape of the
storage unit.
[4]
14
(g) Describe how you would evaluate the success of the final product.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
(h) Explain why consumer demand for storage units of the type shown in Fig. 10 has increased
in recent years.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
© UCLES 2019 0445/32/M/J/19

15
13 Fig. 13 shows a child’s ride-on toy made mainly from wood.
Ø8 axles
Ø100 wooden wheel
B
Fig. 13
(a) Fig. 14 shows details of part A and the hardwood from which it is made.
A
150
10
25
0
Fig. 14
Use sketches and notes to show how part A could be produced from the hardwood shown.
Include details of marking out. Name all the tools and equipment used.
[5]

16
(b) Give two features of the ride-on toy that make it safe for children to use.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(c) Fig. 15 shows one wheel marked out ready to be shaped on a woodturning lathe.
wheel Ø100 × 15
waste
Fig. 15
(i) Explain why the corners would be removed before the wood is set up on the woodturning
lathe.
...........................................................................................................................................
...........................................................................................................................................
..................................................................................................................................... [2]
(ii) Name two tools or items of equipment that could be used when making the wheels on a
woodturning lathe.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
(iii) Give two advantages of making the wheels from plywood rather than hardwood.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
© UCLES 2019 0445/32/M/J/19

17
(d) Fig. 16 shows details of part B of the ride-on toy. Holes will be drilled to take the axles.
axle
B
50
32 axle Ø8
Fig. 16
(i) Use sketches and notes to show a design for a drilling jig to ensure the holes are drilled
accurately. Name the material from which the jig is made.
[5]
(ii) The axles will be glued into part B.

Use sketches and notes to show how one wooden wheel, Ø100 × 15, could be fitted
onto an axle and allowed to rotate freely.
[3]

18
(e) Fig. 17 shows a different design of a child’s ride-on toy.
moulded plastic seat
tubular steel frame
plastic wheels
Fig. 17
(i) Name a process that could be used to produce the plastic wheels.
..................................................................................................................................... [1]
(ii) Give one method of joining lengths of steel tube permanently.
..................................................................................................................................... [1]
(iii) Name two types of finish that could be applied to the steel frame of the ride-on toy.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
© UCLES 2019 0445/32/M/J/19

19
BLANK PAGE
© UCLES 2019 0445/32/M/J/19

20
BLANK PAGE
© UCLES 2019 0445/32/M/J/19

* 6 8 4 9 5 7 0 2 5 7 *

1 hour
Section A
Section B
DC (NH/SG) 168523/1
2
Section A
1 Two signs used in a workshop are shown below.
Describe a specific workshop process when:
ear defenders must be worn
..........................................................................................................................................................
safety glasses must be worn.
..........................................................................................................................................................
[2]
2 Fig. 1 shows two different methods of filing metal.
cross filing draw filing
Fig. 1
Describe the purpose of each method of filing.
Cross filing .......................................................................................................................................
..........................................................................................................................................................
Draw filing ........................................................................................................................................

[2]
© UCLES 2019 0445/33/M/J/19

3
3 Complete the drawing below to show an exploded view of a stopped housing joint.
[3]
4 Fig. 2 shows a small dish made from plastic. The dish has been vacuum formed.
Fig. 2
(a) The former used to vacuum form the dish could be made from hardwood or MDF.
Give two advantages of making the former from MDF rather than hardwood.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(b) Describe two features of the design of the former to ensure that the dish will be vacuum
formed successfully.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]

4
5 Fig. 3 shows two electric drills.
aluminium alloy casing plastic body
rechargeable battery
mains cable
Drill A Drill B
Fig. 3
(a) Name the manufacturing process used to produce the casing for drill A.
............................................................................................................................................. [1]
(b) Give one advantage of using drill B compared to drill A.
............................................................................................................................................. [1]
6 Fig. 4 shows a kitchen roll holder made from acrylic.
kitchen roll
Fig. 4
Explain how the designer has used the flexible property of acrylic in the design of the kitchen roll
holder.
..........................................................................................................................................................
..........................................................................................................................................................
.................................................................................................................................................... [2]
© UCLES 2019 0445/33/M/J/19
5
7 Fig. 5 shows a basic design for a desk tidy made in a school workshop.
The desk tidy is made from 4 mm thick acrylic.
Fig. 5
Use sketches and notes to show one functional improvement to the design of the desk tidy.
[2]
8 Fig. 6 shows part of a garden tool rack.
Fig. 6
(a) Indicate clearly on Fig. 6 one example of ‘short grain’. [1]
(b) Explain why ‘short grain’ is a problem that occurs only in solid wood and not in manufactured
boards.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
6
9 Fig. 7 shows a round tube that will be joined to a metal strip made from mild steel.
tube Ø20
strip 20 × 3
Fig. 7
Add sketches and notes to Fig. 7 to show how they could be joined together.
Your method must allow the tube and strip to be taken apart. [3]
10 Fig. 8 shows two different wall brackets.
18
0
230
bracket A fabricated from softwood bracket B moulded plastic
Fig. 8
(a) Describe one quality control check that would be carried out during the manufacture of
bracket A.
...................................................................................................................................................
............................................................................................................................................. [1]
(b) Describe one quality control check, different to that in part (a), that would be carried out
during the manufacture of bracket B.
...................................................................................................................................................
............................................................................................................................................. [1]
© UCLES 2019 0445/33/M/J/19

7
Section B begins on page 8.

8
Section B
11 Fig. 9 shows views of a child’s counting toy. When the discs are stacked on the rod, the collar
slides down on top of the discs to show the number of discs stacked.
Ø5 rod
collar
10
9
upright 8
7
discs 6
5
4
base 3
2
1
disc Ø40 × 15
Fig. 9
(a) Fig. 10 shows the base of the counting toy. The base is made from beech.
slot 40 × 12
15
centre for hole
0
15
10
0
Fig. 10
(i) Give two reasons why beech is commonly used to make children’s toys.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
© UCLES 2019 0445/33/M/J/19
9
(ii) Name three marking out tools, other than a pencil, that could be used to mark out the
centre for the hole and the slot.
1 ........................................................................................................................................
2 ........................................................................................................................................
3 ........................................................................................................................................
[3]
(iii) Describe how the slot could be cut out 10 mm deep to take the upright.
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
..................................................................................................................................... [3]
(b) The Ø5 rod is made from non-ferrous metal.
(i) Name a suitable non-ferrous metal for the rod.
..................................................................................................................................... [1]
(ii) Give one reason why a non-ferrous metal could be more suitable than a ferrous metal
for the rod.
..................................................................................................................................... [1]
(c) Use sketches and notes to show how ten identical wooden discs could be made in a school
workshop. Show clearly how the holes in each disc could be produced accurately.
[5]

10
(d) The discs could also be made from plastic and produced by injection moulding.
Give two advantages of using the injection moulding process to produce plastic discs rather
than making them from wood.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(e) Fig. 11 shows a length of beech that will be used to make the four parts of the collar.
45
25
collar
6
Fig. 11
Use sketches and notes to show how the collar could be constructed.
Name the tools and equipment used to construct the collar.
[4]
(f) Describe how CAD/CAM could be used to produce the numbers on the upright.
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [4]
© UCLES 2019 0445/33/M/J/19
11
12 Fig. 12 shows an incomplete design for a reading lamp to be made in a school workshop.
The arms, base and supports are made from hardwood.
lamp shade
arm
arm
support
base
Fig. 12
(a) Fig. 13 shows details of the base and supports.
15
60
15
15 0
0 15
Fig. 13
Use sketches and notes to show how the base and supports could be joined permanently.
[3]
12
(b) Fig. 14 shows views of parts of both arms of the reading lamp.
centre for fitting
34
15
Fig. 14
(i) Draw on Fig. 14 to show a metal fitting that could be used to join the arms together and
allow them to be adjusted and locked in position.
Add two important sizes to the fitting. [4]
(ii) The fitting will be chrome plated.

Give two benefits of chrome plating metal fittings.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
(c) Fig. 15 shows one of the four sides that will be joined together to make the lamp shade.
The sides are made from 3 mm thick veneered plywood.
80
120
120
Fig. 15
(i) Give two advantages of using 3 mm thick veneered plywood rather than solid wood for
the sides of the lamp shade.
1 ........................................................................................................................................
2 ........................................................................................................................................
[2]
© UCLES 2019 0445/33/M/J/19

13
(ii) Use sketches and notes to show how the sides could be joined together to form the lamp
shade. Consider carefully that the veneered plywood is only 3 mm thick.
[4]
(d) The lamp shade shown in Fig. 15 could be made from brass.
State two properties of brass that make it suitable for the lamp shade.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]

14
(e) Fig. 16 shows a template of the lamp shade glued onto a sheet of 1 mm thick brass.
B
template
A
brass sheet
Fig. 16
Use sketches and notes to show how the lamp shade could be made from one piece of
brass. Include the method of:
• cutting out the shape
• bending the brass to shape
• soldering edge A to edge B
• cleaning and finishing.
[8]
© UCLES 2019 0445/33/M/J/19

15
13 Fig. 17 shows views of a children’s play table. The height of the table can be adjusted by means of
sleeves that fit over the ends of the legs.
The table is produced as flat-pack for self-assembly.
A
end rail
long rail
leg
sleeve
Fig. 17
(a) (i) Name a suitable manufactured board for the table top.
..................................................................................................................................... [1]
(ii) Name a suitable softwood for the legs and rails.
..................................................................................................................................... [1]
(b) Describe two benefits of covering the manufactured board used for the table top with
melamine sheet.
1 ................................................................................................................................................
2 ................................................................................................................................................
[2]
(c) (i) Explain why the designer has made the table height adjustable.
...........................................................................................................................................
...........................................................................................................................................
..................................................................................................................................... [2]

16
(ii) The height of the table can be adjusted by means of sleeves that fit over the ends of the
legs. The sleeve shown below will be produced by the extrusion process.
150
65
22
Fig. 18 shows part of an extrusion moulding machine.

Add notes to Fig. 18 to describe the extrusion process.
Fig. 18
[3]
(iii) The height of the table can be adjusted by moving the sleeve up or down and locking it in
position.
Use sketches and notes to show how the table could be set at three different heights.
Include details of any fittings and materials used.
[4]
© UCLES 2019 0445/33/M/J/19
17
(d) The legs and rails are made from the same size section softwood, 60 × 20.
Explain one benefit to the manufacturer of using the same size section softwood.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
(e) The parts of the table shown in Fig. 17 will be assembled using dowels and screws.
(i) Use sketches and notes to show how screws could be used to join two rails at A.
[3]
(ii) Use sketches and notes to show how dowels could be used to join the table top to the
rails.
[3]

18
(f) Explain one benefit to manufacturers of making products that can be self-assembled by
consumers.
...................................................................................................................................................
...................................................................................................................................................
............................................................................................................................................. [2]
(g) Use sketches and notes to show one functional improvement to the design of the children’s
play table.
[2]
© UCLES 2019 0445/33/M/J/19

19
BLANK PAGE
© UCLES 2019 0445/33/M/J/19

20
BLANK PAGE
© UCLES 2019 0445/33/M/J/19

D&amp;T-Resistant Materials-Past Papers

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D&amp;T-Resistant Materials-Past Papers

Uploaded by

Copyright:

Available Formats

Cambridge International Examinations

Cambridge International General Certificate of Secondary Education

DESIGN AND TECHNOLOGY 0445/31

READ THESE INSTRUCTIONS FIRST

You may use a calculator.

The total of the marks for this paper is 50.

For Examiner’s Use

This document consists of 16 printed pages.

Answer all questions in this section.

1 Fig. 1 shows a step ladder.

(a) Name a suitable material for the step ladder.

(b) Give one reason for your choice.

© UCLES 2014 0445/31/M/J/14

3 (a) Complete the drawing below to show a hand file.

Tool Name Specific use

© UCLES 2014 0445/31/M/J/14 [Turn over

5 Fig. 3 shows a milk container made from a plastic.

(a) State a suitable method of manufacture for the milk container.

© UCLES 2014 0445/31/M/J/14

1 mm thick mild steel .........................................................................................................................

3 mm thick acrylic ..........................................................................................................................[2]

8 Fig. 6 shows folding bars.

© UCLES 2014 0445/31/M/J/14 [Turn over

9 Fig. 7 shows a student soldering electronic components.

(a) Name the type of solder being used.

10 Fig. 8 shows two sun loungers used in a garden.

Ø20 steel tube

Give two advantages of sun lounger A over sun lounger B.

© UCLES 2014 0445/31/M/J/14

Answer one question from this section.

(a) Sketch and name a suitable corner joint at A.

Time to set .....................................................................................................................[2]

(ii) Name the type of cramps used.

© UCLES 2014 0445/31/M/J/14

(f) The towel holder could be sold as flat-pack for self-assembly.

12 Fig. 10 shows details of a bird table.

Name of method ....................................................................................................................[4]

© UCLES 2014 0445/31/M/J/14 [Turn over

Process Tools/equipment used

(e) The sides will be glued and nailed to the base.

(i) Name a suitable type of nail that could be used.

(ii) Name a suitable glue to join the sides to the base.

© UCLES 2014 0445/31/M/J/14

© UCLES 2014 0445/31/M/J/14 [Turn over

© UCLES 2014 0445/31/M/J/14

(i) sawing in a vice;

(ii) drilling on a bench-mounted drilling machine.

© UCLES 2014 0445/31/M/J/14 [Turn over

© UCLES 2014 0445/31/M/J/14

DESIGN AND TECHNOLOGY 0445/33

READ THESE INSTRUCTIONS FIRST

You may use a calculator.

The total of the marks for this paper is 50.

For Examiner’s Use

This document consists of 19 printed pages and 1 blank page.

Answer all questions in this section.

1 Fig. 1 shows three types of nail.

............................... ............................... ...............................

Product Manufacturing process Specific plastic

© UCLES 2014 0445/33/M/J/14

3 Complete the drawing below to show a biscuit joint.

three jaw chuck four jaw chuck

© UCLES 2014 0445/33/M/J/14 [Turn over

5 A list of metals is given below.

D&T-Resistant Materials-Past Papers

D&T-Resistant Materials-Past Papers