_______________________

Name:
_
3.3.10 Specialist tools and
equipment _______________________
Class:
_

_______________________
Date:
_

Time: 162 minutes

Marks: 148 marks

Comments:

Page 1 of 48
Q1.
This question is about plastics manufacturing processes and scales of production.

One-off / prototype production

Explain the advantages of using the rapid prototyping process to manufacture a plastic
component.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 3 marks)

Q2.
Making cases for electronic products in the school workshop involves many processes
such as:

•        drilling
•        sawing
•        sanding
•        heating and forming plastics
•        sewing
•        batik
•        die cutting
•        printing.

Discuss the health and safety issues for two of these processes:

•        describing any hazards identified

•        stating any precautions you can take to reduce the risk.

You will be tested on the Quality of Written Communication in this question.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

Page 2 of 48
 _______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 8 marks)

Q3.
Suggest two safety hazards that might need to be considered when making and
populating a PCB.

1. _____________________________________________________________________

2. _____________________________________________________________________
(Total 2 marks)

Q4.
Give two safety precautions that are necessary when using the following equipment.

(a)     Craft knife

Precaution 1 _______________________________________________________

Precaution 2 _______________________________________________________
(2)

(b)     Aerosol spray

Page 3 of 48
 Precaution 1 _______________________________________________________

Precaution 2 _______________________________________________________
(2)
(Total 4 marks)

Q5.
Explain the difference between Computer-Aided Design (CAD) and Computer-Aided
Manufacture (CAM).

Give an example to support your answer.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 4 marks)

Q6.
Before using tools and equipment you should always complete a risk assessment.

Select one tool or piece of equipment from the list below. Circle your choice.
 
Soldering iron Sewing machine Pillar drill

Paper and card die Vacuum forming

Vertical belt sander
cutting machine machine

Laser cutter    

An example risk assessment for the use of a craft knife has been completed below.
 
Potential hazard Action to minimise hazard

When possible use a safety ruler

You can cut your fingers.
to protect your fingers.

In the table below complete a risk assessment for two hazards associated with the tool or
piece of equipment you have selected.
 
Potential hazards Action to minimise hazards

Page 4 of 48
 1 ____________________________ 1 ____________________________

______________________________ ______________________________

______________________________ ______________________________

2 ____________________________ 2 ____________________________

______________________________ ______________________________

______________________________ ______________________________
(Total 4 marks)

Q7.
Name two tools or pieces of equipment needed to make a product you are familiar with.
Give one health and safety consideration for each.

Product ________________________________________________________________

1. _____________________________________________________________________

_______________________________________________________________________

Health and safety consideration _____________________________________________

_______________________________________________________________________

2. _____________________________________________________________________

_______________________________________________________________________

Health and safety consideration _____________________________________________

_______________________________________________________________________
(Total 6 marks)

Q8.
Study the two tools shown.

Page 5 of 48
 Explain the advantages and disadvantages of using a cordless drill / driver rather than a
screwdriver.

Quality of Written Communication will be assessed in this question.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 8 marks)

Q9.
Study the note pad holder shown below.

The note pad holder could be made from wood, metal or plastic.

Select a material for the note pad holder.

 

Wood

Metal

Page 6 of 48
 Plastic

Use notes and sketches to show how you would make a batch of ten note pad holders in
a school workshop.

At each stage, name all the tools, equipment or software you would use.
 
Stage 1: Marking out or CAD (Computer Aided Design)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 2: Cutting and shaping or CAM (Computer Aided Manufacture)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 3: Bending/forming the note pad holder
 
 

Page 7 of 48
  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 4: Finishing the note pad holder
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(2)
(Total 14 marks)

Q10.
Study the wooden lamp shown below.

Page 8 of 48
  

Use notes and sketches to show clearly how you would make a batch of ten lamps in a
school workshop.

At each stage, name all the tools, equipment or software you would use.
 
Stage 1: Marking out or CAD (Computer-Aided Design)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 2: Cutting and shaping or CAM (Computer-Aided Manufacture)
 
 
 
 
 
 

Page 9 of 48
  
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 3: Show how the base could be joined to the stem

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 4: Show how the wires could be secured to the back of the switch

Page 10 of 48
  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
(Total 16 marks)

Q11.
The process of soldering can be a dangerous activity.

Complete the table shown below.

 
Health and safety issue Hazard Precaution

_________________ _________________

The tip of the soldering _________________ _________________

iron gets hot.

_________________ _________________
(1) (1)
Soldering gives off fumes.
_________________ _________________

_________________ _________________

Page 11 of 48
 _________________ _________________
(1) (1)
(Total 4 marks)

Q12.
Compare the effectiveness of using each saw.

                    Saw A                                                    Saw B

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 6 marks)

Q13.
On the clock shown below, the acrylic numbers have been glued to the wooden clock
face.

Page 12 of 48
  

(a)     Name the adhesive you would use to glue the acrylic numbers on to the wooden
clock face.

___________________________________________________________________
(1)

(b)     Explain why you have chosen this adhesive.

___________________________________________________________________

___________________________________________________________________
(1)

(c)     Give details of any safety precautions that you would need to take when using the
adhesive you have named in part (a).

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)
(Total 4 marks)

Q14.
Study the picture of the disc sander shown below.

Complete the table below by identifying a hazard and stating a precaution.

Page 13 of 48
 An example has been given.
 
Hazard Precaution

Long hair could get caught in the disc Ensure long hair is tied back

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________

__________________________________ __________________________________
(Total 10 marks)

Q15.
Two designs for a kitchen roll holder are shown below.
Both of them could be made in a school workshop.

Choose one of the kitchen roll holders and tick the appropriate box.
 
Plastic kitchen roll holder

Metal kitchen roll holder

Wooden kitchen roll holder

A plastic or metal kitchen roll holder                A wooden kitchen roll holder

Page 14 of 48
  

Use clear notes and sketches to show how you would make a batch of ten of your chosen
kitchen roll holders in a school workshop.

At each stage, name all the tools, equipment or software you would use.
 
Stage 1: Marking out or CAD (Computer Aided Design)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 2: Cutting and shaping or CAM (Computer Aided Manufacture)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Page 15 of 48
  
(4)
 
Stage 3: Bending or joining
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 4: Applying the surface finish
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(2)
 
Stage 5: Producing the ‘kitchen roll’ text
 
 
 
 
 
 
 
 
 

Page 16 of 48
  
 
 
 
 
 
 
 
(2)
(Total 16 marks)

Q16.
State two hazards and two relevant safety precautions to be taken when soldering
components to a PCB.

Hazard 1 _______________________________________________________________

_______________________________________________________________________

Safety precaution 1 _______________________________________________________

_______________________________________________________________________

Hazard 2 _______________________________________________________________

_______________________________________________________________________

Safety precaution 2 _______________________________________________________

_______________________________________________________________________
(Total 4 marks)

Q17.
Explain what is meant by the term ‘risk assessment’.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 2 marks)

Q18.
The images in the chart below show tools and equipment for cutting fabric.

(a)     Fill in the table by completing the empty boxes. An example has been done for you.
 
  Tool or equipment Reason for using this tool
or equipment

Page 17 of 48
 Small sharp scissors To cut detailed work
accurately by hand.

   

   

   

   

(8)

(b)     Name the machine that both cuts and stitches over the edge of fabric to neaten it.

___________________________________________________________________
(1)
(Total 9 marks)

Q19.
Look at the plain white T-Shirt in the drawing below.

The T-Shirt is made from 50% polyester / 50% cotton.

Page 18 of 48
  

(a)      Name a printing method to add a design to the T-Shirt.

___________________________________________________________________

___________________________________________________________________
(1)

(b)     Use notes and diagrams to explain the method of printing you have suggested in
part (a).

Marks will be given for:

•        a list of equipment needed

(1)

•        step-by-step instructions
(3)

•        quality of notes and sketches.

(2)
 
 

Page 19 of 48
 (Total 7 marks)

Q20.
Study the photograph of the textile factory worker. Answer the following questions.

(a)     The textile factory worker in the photograph above is wearing ear defenders and a
face mask.

Give one reason why these items are worn.

Ear defenders _______________________________________________________

___________________________________________________________________

Face mask _________________________________________________________

Page 20 of 48
 ___________________________________________________________________
(2)

(b)     Explain what is meant by the term ‘risk assessment’.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)

(c)     Describe the dangers of working on an industrial sewing machine.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(3)

(d)     List two safety measures that are used to help prevent injury to the sewing
machinist.

Safety measure 1 ____________________________________________________

___________________________________________________________________

___________________________________________________________________

Safety measure 2 ____________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)
(Total 9 marks)

Q21.
(a)     Health and Safety Officers display safety rules and fire exit signs in the workplace.

List three other safety measures that could keep workers safe.

Explain your answers.

1. _________________________________________________________________

___________________________________________________________________

Page 21 of 48
 ___________________________________________________________________

2. _________________________________________________________________

___________________________________________________________________

___________________________________________________________________

3. _________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(6)

(b)     Explain how computer aided manufacture can improve safety for the workers on the
production line.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)
(Total 8 marks)

Page 22 of 48
Mark schemes

Q1.
Rapid prototyping – up to 3 marks
Reference to:
Complex 3-D shapes can be produced
Good for prototyping before production
Product can be made from 3-D graphical image
Complex components can be produced quickly.

1 mark for each simple response.

2 marks for a justified or explained point.
[3]

Q2.
QWC Question

Looking for details of hazards and precautions for two processes.

Hazards could include:

•        Material in eyes
•        Hands trapped or injured
•        Clothing caught in machinery
•        Cuts to fingers
•        Breathing-in dust
•        Burns to hands or other parts of body
•        Tripping
•        Irritation to skin

Precautions could include:

•        Wearing of goggles / safety glasses

•        Use of clamps and vices
•        Wearing aprons
•        Rolling-up sleeves
•        Removal of ties
•        Wearing of face masks / filters
•        Wll-ventilated environment
•        Wearing gloves
•        Good workshop safety practice

Consider the technical content and quality of communication.

Marks awarded as follows:

0 marks – no answer worthy of credit.

1-2 marks
Very limited coverage of just hazards or precautions, or just one process discussed.
Many spelling and punctuation mistakes. Limited use of technical vocabulary.

3-4 marks
Some coverage of hazards and precautions for two processes using some technical
terms. Some spelling, punctuation or grammar errors. Poor structure of answer, and

Page 23 of 48
 repetition made.

5-6 marks
Good coverage and a well-structured response. Hazards and precautions for two
processes discussed using specific terms and vocabulary. There may be one or two
spelling or punctuation mistakes, or minor grammar error.

7-8 marks
Good coverage and depth of answer, and a well-structured response.
Hazards and precautions for two processes discussed using technical terms, and
specific names of tools and equipment.
Excellent spelling, grammar and punctuation. Avoidance of repetition.
[8]

Q3.
Any 2 safety hazards described to include:

Sharp edges
Sharps from side cutter (eg. component tails)
Solder fumes
Solder heat
Drilling safety / goggles / fixing / snapping drill
Residual chemicals on PCB
Possibly shorting out supply leads (leading to overheating)
Fume extraction
2 × 1 mark
[2]

Q4.
Craft knife.
Award 1 mark for each correct answer:

Using a cutting mat / self-healing mat

Using a safety rule (Maun)
Carry either on a cutting mat or blade down
Keep spare hand behind the craft knife
Cut away from yourself
Retractable blade or lid or lock
Do not accept gloves, metal rule, keeping hands away, don’ cut yourself.
2
Aerosol spray.
Award 1 mark for each correct answer:

Use a spray booth or well ventilated room

Use outside
Use away from a naked flame
Wear a mask
Use extractor
2
[4]

Q5.
Input / output, design Vs manufacture, computer Vs CNC machines etc

Page 24 of 48
 High level: Thorough explanation of difference
3

Medium level: Some understanding

2

Low level: Limited understanding, confused

1

None
0

Supporting example eg. 2D design, laser or laser printer or vinyl cutters, 3D printer
etc.
1
[4]

Q6.
Check table over
1 mark for single word response
2 marks for detailed hazard
1 mark for single word response
2 marks for detailed action
 
Tool / Equipment Potential Hazard Action to minimise hazard

Soldering iron     •    Risk of burn from     •    Only hold the polymer

         heating element / tip.     
    •    Damaged / melted     
         plug cable     
    •    Risk of electrocution     
    
    
    
    
    
    
    
    
     / plastic handle.
•    Soldering iron stands
     to prevent accidental
     contact.
•    PAT tested. Check
     condition of cable.
•    Silicon rubber
     insulation on the lead
     to prevent melting.
•    Use of low voltage
     (24V or less) irons to
     prevent critical shock

Paper & die cutting     •    Sharp edges on the     
machine          work pieces.     
    •    Finger entrapment.     
    
    
    •    Exposed blades and     
         creasing tools.     
    
    
•    Do not handle cut
     pieces on edges.
•    Only one person
     operating the machine
     at a time
•    Make sure protective
     release rubbers are in
     good condition and in
     place.

Sewing machine     •    Handling & moving.     •    Ensure carried to

         avoid lower back
         injury.
         Possibly use trolley.
    •    Electrocution - live     •    Unplug the machine

Page 25 of 48
          contacts when    
         changing light bulb.     
    •    Entanglement in     
         machine.     
    •    Needle can pass     
         through finger and     
         nail.     
    •    Danger of tripping.     
    
    •    Broken needles     
    
    
Vacuum forming     •    Finger traps on toggle     
machine          clamps.     
    •    Handling hot plastic     
    
    •    Hot surfaces e.g.     
         ceramic heating
         elements     
    
Laser cutter     •    Harmful fumes /     
         particles created     
    •    Fire - possible ignition     
         of combustible     
         materials.     
    
    •    Do not engrave or cut     
         PVC based materials.     
    •    Do not cut reflective     
         surfaces.     
    
    
    •    Risk of burns.     
    
    
    
    
    
    
    
Pillar drill     •    When drilling dust and     
    
         debris can get into
         your eyes.     
    •    Unless secured work     
         might suddenly move     
         and hit the operator.     
    •    Incorrect drill speed     
         selected can cause     
         smoke, fire and     
         possibly lead to     
         excessive drill wear of
Page 26 of 48
      before carrying out
     maintenance.
•    Tie hair and clothing
     back.
•    QA correct training of
     use. Well lit working
     location
•    Site machine close to
     power outlet and avoid
     trailing leads.
•    Careful instruction in
     use.
•    Keep fingers away
     from clamps.
•    PPE wear heat proof
     gloves.
•    Leave warning sign for
     hot surfaces – DO
     NOT TOUCH HOT!
•    Make sure extractor
     on.
•    Removal of small
     atomised / cut
     particles.
•    Air assist on
•    Ever leave the laser
     cutter unattended.
     Constant supervision.
•    Fumes are toxic if
     inhaled.
•    The laser beam can
     reflect off some
     materials resulting
     in damage to the
     laser.
•    Do not remove
     material parts from
     laser immediately in
     case hot.
•    PPE- wear a face
     visor or goggles.
•    Always hold work
     securely e.g. use a
     machine vice or G
     clamp.
•    Select the correct
     speed for the drill
     being used and the
     material being worked.
          breakage.

Vertical belt sander     •    Touching moving     •    Keep fingers away

         abrasive surface.          from abrasive surface
         & always wait by
         machine until it has
         stopped moving.
    •    Sanded particles in     •    PPE – goggles / visor
         eyes.
    •    Dust and vapours     •    Extraction on / well
         being breathed in.          ventilated room.

[4]

Q7.
Correctly named tool or piece of equipment for major stages of manufacture.
1 mark each

Appropriate H&S rule identified and described in sufficient detail.

2 marks each

Appropriate H&S rule identified but may not be sufficiently described.

1 mark

No generic H&S rules e.g. do not run, tie hair back unless relevant to process / tool
or equipment.

No repetition.
[6]

Q8.
Award marks for details relating to advantages and disadvantages of using a
cordless drill / driver rather than a screwdriver.

Candidates can get 1 mark for stating an advantage / disadvantage and a second
mark for explaining the advantage / disadvantage.

Mark the candidates answer on its technical merit first, then, apply the QWC
descriptors. This may increase or decrease the candidate’s marks by 1 or 2 marks
depending on the quality of the QWC.

Note: Candidates must address advantages and disadvantages for 8 marks. If a

candidate fails to address both aspects then they can only score a maximum of 7
marks.

Possible responses:
Advantages:
•        Less effort is required to screw in screws
○       The motor does the work for you
•        Greater torque / Tighter screws
○       The motor delivers more power than a person can
•        Adjustable torque
○       You can set the torque so that small screws are not destroyed
•        Magnetic
○       This makes it easier to screw in awkward places

Page 27 of 48
 •        Versatile / interchangeable bits / drill
○       You can change the bit to match the type of screw
○       You can use it as a drill
•        Ergonomic
○       It has lots of moulded / high friction / colour coded areas

Disadvantages:
•        Expensive
○       A cordless drill driver is far more expensive to buy than a screwdriver
•        Bulky
○       The cordless drill driver takes up room in a toolbox / has to have its own box /
is difficult to carry around
•        Battery needs charging
○       The battery may run out during use
○       You need to have access to mains electricity
•        Not environmentally friendly
○       It uses more materials and requires more manufacturing processes to make.
The batteries need mains electricity to recharge.

A detailed and comprehensive response that includes several of the examples

above. The answer is well structured, with good use of appropriate design &
technology terminology and showing a good grasp of grammar, punctuation and
spelling. 7 – 8 marks

A fairly detailed response which refers to some of the examples above. The answer
is fairly well structured, with some use of design & technology terminology and with
a small number of errors in grammar, punctuation and spelling. 5 – 6 marks

A response which contains one or two of the examples above. The answer has
some structure, with some use of design & technology terminology and with a
number of errors in grammar, punctuation and spelling. 3 – 4 marks

A response which contains very limited reference to any of the examples above. The
answer is vague or poorly structured, with little use of design & technology
terminology and with a considerable number of errors in grammar, punctuation and
spelling. 1 – 2 marks

A response which is poorly structured with no relevant examples. There is very little
or no use of design technology terminology and with many errors in grammar,
punctuation and spelling. 0 marks
[8]

Q9.
Candidates can gain marks even if they have answered in the wrong boxes.

Award marks using the following descriptors

Stage 1: Marking out (traditional)

Sufficient detail for most of the design to be marked out by a third party, as a one
off. Most tools and equipment given.
1-2 marks

Look for details relating to use of:

Wood

Page 28 of 48
•        Pencil

•        Rule

•        Tri square

Metal

•        Scriber

•        Rule

•        Engineer’s square

Plastic

•        Spirit based pen / pencil

•        Rule

•        Square

Sufficient detail for most of the design to be marked out by a third party, in quantity,
using a template. Most tools and equipment given.
3-4 marks

Look for details relating to the manufacture of template

Look for details relating to the use of a template

Or

Stage 1: Marking out (CAD)

Sufficient detail for the design to be drawn by CAD by a third party. Most tools,
equipment / software given.

Look for details relating to:

Computer hardware

Naming software

Net on screen

Use of different coloured lines

Power settings
1-4 marks

Stage 2: Cutting and shaping (traditional)

Sufficient detail for some of the design to be cut and shaped by a third party as a
one off. Most tools and equipment given
1-2 marks

Look for details relating to use of:

Wood

Page 29 of 48
•        Tenon / coping saw

•        Drill

•        Sandpaper

Metal

•        Hacksaw / piercing saw

•        Drill

•        File

Plastic

•        Tenon / coping saw

•        Drill

•        File

Sufficient detail for most of the design to be cut and shaped by a third party, in
quantity, using jigs / templates and power tools. Most tools and equipment given.
3-4 marks

Look for details relating to use of:

Wood

•        Band/‘Hegner’ saw

•        Drill

•        Disc sander / Band facer

Metal

•        Guillotine / Bandsaw / Jigsaw / ‘Hegner’ saw

•        Drill

•        File

Plastic

•        Band / ‘Hegner’ saw / jig saw

•        Drill

•        Disc sander / Band facer

Or

Stage 2: Cutting and shaping (CAM)

Sufficient detail for the design to be manufactured by CAM.

Most tools and equipment given.

Page 30 of 48
Look for details relating to:

Transfer of data to CAM

Laser cutter / CNC router

Setting up the laser / holding / autofocus

Coloured lines

Power setting

Safety
1-4 marks

Stage 3: Bending / forming / casting / moulding / rapid prototyping the note

pad holder

Sufficient detail for some of the design to be bent/formed by a third party as a one
off. Most tools and equipment given

Look for details relating to the making of:

Wood

•        Bending, laminating (without a former)

•        cutting from solid

Metal

•        Simple bending (without a former)

Plastic

•        Line bending / oven bending / heat gun (without a former)

1-2 marks

Sufficient detail for most of the design to be bent / formed by a third party, in
quantity, using formers / moulds. Most tools and equipment given.

Wood

•        Laminating

•        Bag press

•        Steam bending

Metal

•        Bending (with a former)

•        Casting

Plastic

•        Line bending / oven heating / heat gun (with former)

Page 31 of 48
 •        Rapid prototyping
3-4 marks

Stage 4: Applying the surface finish (traditional)

Sufficient detail for the design to be finished by a third party.

Most tools and equipment given.

Look for the following details:

Material preparation

Use of a brush / aerosol / rag

Application of varnish / paint

1-2 marks

Or

Stage 4: Applying the surface finish (CAM)

Reference to the fact that a laser cut stand would not need finishing as the laser
produces a good quality finish.

Or

Reference to improving the quality of laser cut edges by use of wet and dry paper,
metal polish ‘Brasso’ and polishing / buffing.
1-2 marks
[14]

Q10.
Award marks using the following descriptors:

If a candidate has chosen just one part of the lamp they can still gain full marks.

Stage 1: Marking out (traditional)

Sufficient detail for a part or parts to be marked out by a third party, as a one off.
Most tools and equipment given.
1−2

Tools: pencil, rule, compass

Sufficient detail for a part or parts of the design to be marked out by a third party, in
quantity, using a template. Most tools and equipment given.
3−4

Tools: pencil, rule, compass, scissors, card / ply template

or

Stage 1: Marking out (CAD)

Sufficient detail fora part or partsof the design to be drawn by CAD by a third party.
Most tools and equipment given.

Look for details relating to:

Page 32 of 48
•        Computer hardware
•        Drawing on screen
•        Naming software
•        Use of different coloured lines / tool path
1−4

Stage 2: Cutting and shaping (traditional)

Sufficient detail for a part or parts of the design to be cut and shaped by a third party
as a one off. Most tools and equipment given
1−2

Sufficient detail for most of the design to be cut and shaped by a third party, in
quantity, using jigs / templates / power tools. Most tools and equipment given.
3−4

Tools: Jig / Band saw, disc sander, router

or

Stage 2: Cutting and shaping (CAM)

Sufficient detail for the design to be manufactured by CAM. Most tools and
equipment given.

Look for details relating to:

•        Transfer of data to CAM
•        CNC router
•        Clamping work piece
•        Changing tools
•        Safety
1−4

Answers that relate to use of the Laser cutter can only be awarded 2 marks
unless the candidate provides specific details on how the material would be
cut out in thin (3mm layers) and then built up. Or, the candidate may have
indicated that the cutting would be done using multiple passes.

Stage 3: Joining

Limited details of a simple method of joining the stem to the base. Some tools and
equipment given.

E.g.   Gluing
•        Applying glue
•        Clamping
1−2

Detailed description of a suitable method of joining the stem to the base. Most tools
and equipment given.

E.g.   Screwing
•        Pilot hole
•        Clearance hole
•        Countersink
•        Screw
•        Screwdriver

Dowelling

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 •        Marking out holes
•        Drilling
•        Applying glue
•        Fitting dowels
•        Clamping

Mortise and tenon

•        Marking out
•        Cutting mortise hole
•        Cutting tenon
•        Applying glue
•        Clamping

Biscuit
•        Marking out
•        Cutting the slot
•        Applying glue
•        Clamping
1−4

Stage 4: Securing the wires to the switch

Limited details of a simple method of securing the wires to the switch. Some tools
and equipment given.

E.g.   Twisting the wires onto the terminals

1

Detailed description of a suitable method of joining the stem to the base. Most tools
and equipment given.

E.g.   Soldering
•        Stripping the wires
•        Using a soldering iron
•        Adding solder

Using spade connectors

•        Stripping the wires
•        Using a spade connector
•        Using a crimping tool

Small nut, bolt and washer

•        Stripping the wires
•        Using nut, bolt and washer
1−4
[16]

Q11.
Award one mark for each correctly entered cell
 
Health and
Hazard Precaution
safety issue

The tip of the You could burn Keep your fingers

Page 34 of 48
 away from the tip /
soldering iron your fingers / make sure you
gets hot table top replace it into its
(1 mark) device after use.
(1 mark)

 Make sure you are

The fumes could in a well-ventilated
Soldering gives give you area / make sure
off fumes breathing you are using
difficulties extraction
(1 mark) equipment / wear a
mask
(1 mark)

Max 4 marks
[4]

Q12.
Award up to six marks for a suitable detailed answer.
Although these responses deal with the advantages of using the saws, candidates
may correctly refer to the disadvantages

Coping saw

Possible responses:

•        Lighter than the jigsaw

•        Easier to handle
•        Better control
•        Less expensive to buy
•        No power source required
•        Safer to use
•        Environmentally friendly

Jigsaw

Possible responses:

•        Cuts much quicker

•        Less effort required
•        Greater variety of blades available
•        Will cut a wider variety of materials
•        Requires a power source
•        Better ergonomic styling
•        More comfortable to use
•        Safer as guards / soft grip / dust extraction
•        Accurate with a guide
[6]

Q13.

Page 35 of 48
 (a)     Award one mark for correctly identifying the glue

Possible responses:

•        Epoxy resin (Araldite)

•        Contact Adhesive
•        Super glue
•        No nails

Not PVA and Tensol cement

1 mark

(b)     Award 1 mark for any of the following

This can be marked as correct even if the answer to 9a is wrong

Possible responses:
•        It will glue different materials together
•        It is a strong glue
•        It dries clear
•        It’s quick drying
•        It doesn’t need clamping
1 mark

(c)     Award up to two marks for details of a relevant safety precaution.

Possible responses:

•        Avoid contact with your skin

•        Wear gloves
•        Apply with a spatula
•        Avoid contact with the eyes
•        Wear goggles
•        Wear an apron
•        Avoid inhalation
•        Use in a well ventilated room
•        Environmental issues / safe disposal
2 marks
[4]

Q14.
Award one mark for each correctly identified hazard.
Award one mark for each relevant precaution.

Possible responses:
 
Hazard Precaution

Dust or splinters may Wear safety goggles / glasses

fly off the wood

Someone may Only one person should be near

distract / knock you the machine

Your clothing could Ensure that you wear an apron

get trapped in the at all times when working in the

Page 36 of 48
 disc sander workshop

Your fingers could Keep your fingers away from the

come into contact sanding wheel
with the sanding
wheel

Dust could enter Wear a dust mask

your lungs

Dust could enter Ensure the extraction equipment

your lungs is turned on.
10 × 1 marks
[10]

Q15.
Award marks using the following descriptors

Marking out (traditional)

Sufficient detail for most of the design to be marked out by a third party, as a one
off. Most tools and equipment given
1 – 2 marks

Sufficient detail for most of the design to be marked out by a third party, in quantity,
using a template. Most tools and equipment given.
3 – 4 marks

or

Marking out CAD

Sufficient detail for the design to be drawn by CAD by a third party. Most tools and
equipment given.

Look for details relating to:

Computer hardware
Naming software
Net on screen
Use of different coloured lines
Power settings
1 – 4 marks

Cutting and shaping (traditional)

Sufficient detail for some of the design to be cut and shaped by a third party as a
one off. Most tools and equipment given
1 – 2 marks

Sufficient detail for most of the design to be cut and shaped by a third party, in
quantity, using jigs / templates. Most tools and equipment given.
3 – 4 marks

or

Page 37 of 48
Cutting and shaping CAM

Sufficient detail for the design to be manufactured by CAM.

Most tools and equipment given.

Look for details relating to:

Transfer of data to CAM

Laser cutter / CNC router
Clamping work piece
Changing tools
Safety
1 – 4 marks

Bending / joining

Sufficient detail for some of the design to be bent and joined as a one off by a third
party. Most tools and equipment given
1 – 2 marks

Sufficient detail for most of the design to be bent / joined, in quantity, by a third
party with use of jigs / formers. Most tools and equipment given.
3 – 4 marks

Applying the surface finish (traditional)

Sufficient detail for the design to be finished by a third party.

Most tools and equipment given.

Look for the following details:

Material preparation

Use of a brush / aerosol / rag

Application of varnish / paint

1 – 2 marks

or

Applying the surface finish (CAM)

Reference to the fact that a laser cut stand would not need finishing as the laser
produces a good quality finish.
or
Reference to improving the quality of laser cut edges by use of wet and dry paper,
‘Brasso’ and polishing / buffing
1 – 2 marks

Producing the ‘kitchen roll’ text (traditional)

Sufficient detail for the logo to be applied by a third party, tools and equipment given

Look for the following details:

Use stencil / template

Application of varnish / paint
1 – 2 marks

Page 38 of 48
 or

Producing the ‘kitchen roll’ text (CAD / CAM)

Reference to the fact that the logo would be etched in by the laser

Look for the following details:

The logo being produced on a graphics software package (2D design)

The logo being etched by the laser cutter
The logo being produced by the vinyl cutter
1 – 2 marks
[16]

Q16.
Good hazard
(1 mark)

Good safety precaution

(1 mark) × 2

Do not accept Protective Clothing as not a Safety Precaution, e.g. gloves, apron

e.g.
Hazard 1
Toxic fumes from hot solder
Safety precaution 1
Use fume extraction when soldering to prevent inhalation of fumes

Hazard 2
Solder can spit and get in your eyes
Safety precaution 2
wear safety glasses when soldering to protect eyes from hot solder
[4]

Q17.
The dangers, hazards or risks involved in making a product are identified, described
and listed in a document as part of health and safety regulations.

Do not give a mark for just one word ‘dangers’.

Marks awarded as follows:

•        No answer worthy of credit (0 marks)
•        Basic understanding, may be unclear or confused (1 mark)
•        Clearly understands what is meant and may give an example or dangers in
detail. (2 marks)
[2]

Q18.
(a)
Tool or equipment Reason for using
  this tool or
equipment

Page 39 of 48
 To cut fabric in
Straight knife, band multiple layers to
saw / band knife, speed cutting.
vertical blade, jig saw,
straight knife cutting
machine, mass saw
cutter.
 
Allow machine cutter
if reasoning given.

No to scroll saw, giant

cutter, pattern cutter.

Pinking shears To cut to give a zigzag

edge that will prevent
fabric from fraying
  Allow zig zag scissors
and so neaten edge,
to give a decorative
edge.

Laser cutting / CAM To cut intricate

cutter designs in fabric,
accurately and
consistently, and to
 
seal cut edges.

Also allow to cut a

stencil

Large / long scissors,

Long scissors to cut
shears, fabric
fabric quickly by hand
  scissors, tailor
scissors or shears
No to cut paper

(8 marks)

Marks awarded as follows:

No answer worthy of credit
0 marks

(b)     Marks awarded as follows:

No answer worthy of credit

0 marks

Overlocker
1 mark
(1 mark)
[9]

Q19.
(a)      Marks awarded as follows:
No answer worthy of credit

Page 40 of 48
 0 marks
Any printing method – block, screen, roller, stencil, heat printing, laser and
bubble jet, transfer, sublimation, digital.
Not tie-dye, batik
(1 mark)

(b)     If a different method of printing is described – not the one given in answer to
(a), mark as seen but only up to 5 marks.
If a different method of applying colour is described, not a printing method,
only up to 4 marks.

6 marks will be given for

List of equipment needed

No answer worthy of credit
0 marks
More than 1 item such as print paste / fabric paint with block or screen etc
(1 mark)

Step-by-step instructions
No answer worthy of credit
0 marks
Explanation is confused or method very basic.
1 mark
Explanation of method is adequate and would mostly work. This candidate has
a good grasp of the method of printing.
2 marks
Accurate explanation of method of printing including use of correct materials
and equipment. Candidate understands method and can clearly explain it.
3 marks
(3 marks)

Quality of notes and sketches

No answer worthy of credit
0 marks
Basic detail, simple diagrams, few steps.
1 mark
Detailed diagrams with clear labels, neat presentation,
2 marks
(2 marks)
[7]

Q20.
(a)    No answer worthy of credit
0 marks
Ear defenders to protect his hearing from being damaged by the continual
noise of weaving loom / machinery.
1 mark for each correct point.
1 mark
Face mask to prevent him from inhaling fibres / dust / fumes from the yarns /
weaving loom / machinery.
No answer worthy of credit
0 marks
1 mark for each correct point.
(1 mark)
(2 marks)

(b)     No answer worthy of credit

0 marks

Page 41 of 48
 The dangers, hazards or risks involved in making a product are identified,
described and listed in a document as part of health and safety regulations.
Assessing the risk or danger. 0 mark if answer ‘checking machines’. If answer ’
looking for dangers’ only 1 mark.
Basic understanding may be unclear or confused.
1 mark
Clearly understands what is meant and may give an example.
2 marks
(2 marks)

(c)      Marks awarded as follows:

No answer worthy of credit
0 marks
Finger and hand injuries from sharp needles and blades. Stitching fingers. Eye
injuries from broken needles thrown up in air. Trailing wires. Over heating
machines / fire risks. Pulled hair / clothing / jewellery from thread or fabric
feed. High noise level may damage hearing. Seating may cause back injuries.
Electrocution. Inhalation of textile dust.
1 mark for each correct point.
(3 marks)

(d)     Marks awarded as follows:

No answer worthy of credit
0 marks
Finger guards. Thimble used. Eye shields / goggles. Long hair tied up.
Remove all loose clothing or jewellery. Seats adjusted for correct posture.
Training.
Tidy / organised work area. Wires vertical to ceiling. Power stop buttons.
‘Sharps’ boxes. No drinks. Warning signs. Adequate lighting, ventilation.
Regular machine checks. Regular staff breaks.
Not wear gloves.
Any 2 correct points 1 mark each.
(2 marks)
[9]

Q21.
(a)     •        Organise safety training, including first aid, for the work force.

•        Ensure machinery, equipment, tools and materials are stored safely,

have safety guards and are safe for use, and are regularly tested for
safety.

•        Check that workers wear protective clothing, ear defenders, masks,

safety gloves and footwear.

•        Ensure that all processes are safe and will not damage health of the
employees.

•        Chemicals used in manufacturing processes are recorded, stored and

used safely, then recycled or disposed of safely.

•        Check environment is safe with clean and tidy work areas, adequate
ventilation to remove dust and fumes, and has noise level control.

•        Proper training of machine operators

Marks awarded as follows:

Page 42 of 48
 No answer worthy of credit
0 marks
Any 3 points
1 mark for simple statement e.g. Wear protective clothing
(1x3 marks)
2 marks for more detailed statement
e.g. Check that workers wear protective clothing, ear defenders, masks, safety
gloves and footwear.
(2x3 marks)
(6 marks)

(b)     Safety can be increased by using automated machinery and computers to

assist in materials handling, particularly where loads are heavy, or with fast
running machinery where heat, or sharp blades or needles are involved.
Safety devices are used to check machine settings are correct and to stop
machinery in an emergency.

Marks awarded as follows:

No answer worthy of credit
0 marks
Simple statement e.g. Computers can stop machine in an emergency
1 mark

Simple statement with example given e.g. Safety devices are used to check
machine settings are correct and to stop machinery in an emergency.
2 marks
(2 marks)
[8]

Page 43 of 48
Examiner reports

Q1.
Around forty percent of candidates scored at least two marks with this question. Many
clearly discussed the advantages of using a rapid prototyping process, but there were also
candidates who simply discussed the advantages of prototyping in general. They wrote
about testing and evaluating prototypes as part of a development process, and not
specifically about the use of, for example, a 3-D printer or similar.

Q2.
This was the QWC question asking candidates to discuss the health and safety issues for
two processes. This was well-answered with 24% of candidates scoring at least seven
marks and 46% scoring at least six. Almost all candidates who responded to the question
showed a good knowledge of health and safety issues and precautions, and there is a lot
of good practice in all centres. Some candidates only discussed one process, thus not
giving themselves access to full marks and some candidates tended to repeat
themselves. The quality of spelling, punctuation and grammar seemed to be better than
previous years showing centres had prepared their candidates well for this type of
question.

Once again this year, there were a high number of additional sheets submitted by the
candidates and centres are reminded that the QWC question tests, amongst other things,
a candidate’s ability to be clear and succinct.

Q3.
Focusing on designing and making electronic parts it was anticipated this would be an
area with a strong response. This was the case throughout with this question.

Safety hazards should be a key area of working practice and theory too. Far too many
responses did not correctly identify safety hazards.

Q4.
This question was generally answered well, although some responses were too generic to
give a mark. For example 'keep away from young children or don’t spray in your mouth'.

Q5.
Most candidates were able to successfully identify the difference between CAD and CAM
and were able to provide suitable examples, many relates to either Techsoft 2D Design
software and / or a Laser Cutter.

Q6.
A well attempted question, with many candidates selecting a tool / piece of
equipment that they were familiar with from the list given. Many recognised hazards
were identified and actions to minimise hazards given.

Q7.
Candidates sometimes gave irrelevant responses which did not focus on health and
safety considerations relating to the tools and equipment. Many candidates gave materials

Page 44 of 48
 or components such as pin for the badge, paint or glue which were not acceptable.
Popular correct responses gave equipment such as the laser cutter with the relevant
health and safety precautions of extraction of fumes, danger to eyes if watching the laser
during cutting and supervision due to the fire risk. Some candidates gave incorrect
responses for the laser cutter such as ensure lid is closed, wear goggles and apron, don’t
touch as it is hot which were not accepted. Many responses warned ‘to take care’ which
were insufficiently descriptive to be awarded marks.

Q8.
A well answered question. Most candidates knew some advantages of using a cordless
drill/driver rather than a screwdriver. Reference to it being ‘easier to use’, ‘providing a
tighter screwed joint’ and ‘requiring less effort’, were the most common correct responses.
Most candidates knew some disadvantages of using a cordless drill/driver rather than a
screwdriver. Reference to ‘the battery running out’, ‘it being heavier’ and ‘being less
environmental friendly’ were the most common correct responses. Candidates are aware
that QWC will be marked within this question as there is a noticeable improvement in
spelling, punctuation, grammar and handwriting.

Q9.
Stage 1

The majority of candidates were able to gain 2 of the 4 marks available by giving
details of how they would mark out the note pad holder. Plastic was the most
common material used. The use of CAD (2D design) was the most popular chosen
method.

Stage 2

Most candidates were able to gain 2 of the 4 marks available by giving details of
how they would cut note pad holder. The use of CAM (laser cutter) was the most
popular chosen method. Candidates should include some understanding of ‘power
settings’ to ensure they get full marks.

Stage 3

Again, the majority of candidates were able to gain 2 of the 4 marks available by
giving details of how they would bend the note pad holder. Where candidates had
utilised a bending jig/former they invariably produced high quality responses. Most
used the strip heater to heat the plastic before bending.

Stage 4

This was very well answered. Most knew of a polishing technique that could be used
to finish acrylic. Buffing or using ‘Brasso’ were the most popular methods employed
by the candidates. Candidates also gained marks by acknowledging that laser cut
plastic would not require an applied finish.

Q10.
Stage 1     The majority of candidates gained 2 out of 4 marks available by detailing how
they would mark out the lamps. A small proportion of candidates achieved full
marks by considering how the lamp would be batch produced. Candidates
who gained full marks included details of templates in their answer.

          Stage 2     Most candidates gained 2 out of 4 marks available by detailing how they would

Page 45 of 48
 cut and shape the lamps. A small proportion of candidates achieved full marks
by considering how the lamp would be batch produced. Candidates who
chose to use CAM to manufacture their lamp tended to give simplistic
answers.

          Stage 3     The majority of candidates gained 2 out of 4 marks available by giving details
of how they would join the base of the lamp to the stem. A small number of
candidates achieved full marks by detailing the type of joint they would use.
Gluing was the most popular and insufficient response.

          Stage 4     The majority of candidates gained 2 out of 4 marks available by giving details
of how they would secure the wires to the back of the switch. A small number
of candidates achieved full marks by giving a detailed response which
included the soldering process or a suitable mechanical method. Simple
responses included pushing the wires through the holes on the posts or
‘gluing’ the wires in position.

Q11.
Many candidates gained three of the four marks available by displaying knowledge of the
health and safety issues concerned with the process of soldering. Candidates who stated
that users should wear gloves when soldering were not awarded a mark.

Q12.
A wide range of responses were given in answer to this part of the question. Most
candidates gave details of how the jig saw was faster and easier to use because it was
powered by an electric motor. Many correctly suggested that the coping saw was better at
cutting fine detailed pieces of work.

Q13.
(a)     Many candidates knew of a suitable adhesive for gluing the numbers to the wooden
clock face. Weak candidates incorrectly suggested PVA.

(b)     Most candidates correctly explained why they had chosen this adhesive. Strong and
quick drying were the most common correct responses.

(c)     Many candidates correctly identified 1 or 2 safety precautions that they would need
to take when using the adhesive. Many went on to qualify their answer.

Q14.
This question was well answered. The majority of candidates gained high marks by
correctly identifying a hazard that could occur when using the disc sander and then
improved their mark by correctly identifying a precaution that should be taken. Candidates
lost marks for repeating answers already given.

Q15.
Stage 1
The majority of candidates were able to gain two of the four marks available by giving
details of how they would mark out the kitchen roll holder. Few candidates achieved full
marks by addressing the issue of the kitchen roll having to be being batch produced.

Stage 2

Page 46 of 48
 Most candidates were able to gain two of the four marks available by giving details of how
they would cut and shape the kitchen roll holder. Few candidates achieved full marks by
addressing the issue of the kitchen roll having to be being batch produced. Candidates
who chose to use CAM to manufacture their kitchen roll holder tended to give simplistic
answers.

Stage 3
Again, the majority of candidates were able to gain 2 of the 4 marks available by giving
details of how they would bend or join the kitchen roll holder. Fewer candidates achieved
full marks by addressing the issue of the kitchen roll having to be being batch produced.

Stage 4
This part of the question was answered well with many candidates giving correct details of
how to apply a relevant finish to the kitchen roll holder.

Stage 5
Candidates provided a variety of ways in which to produce the ‘kitchen roll’ text. Many
candidates correctly chose to engrave the text by a laser cutter.

Q16.
Generally well answered.

Q17.
Candidates answered this question very well; many had a clear understanding and could
explain the term ‘risk assessment’.

Q18.
(a)      Candidates generally showed good subject knowledge in answer to this question
but some failed to gain marks because simple one word answers gave insufficient
information to award a mark.

(b)     Some candidates gave correct answers, whilst others were too vague in their
responses generally.

Q19.
(a) and (b)
Most candidates were able to give an appropriate method of printing and describe the
process in detail. Some candidates gave a different colouring technique such as tie dye
and the mark scheme was adjusted to award some marks for part (b) in these instances to
take the information given in notes and diagrams into consideration and award some
marks as appropriate.

Q20.
(a)     The majority of candidates were able to correctly identify the specific reasons
relating to ‘hearing’ and ‘inhaling’. They knew it was to protect the ears / stop
deafness or to prevent inhaling toxic fumes / dust.

(b)    Most candidates stated that possible dangers / hazards were looked at but not all
mentioned the control / prevention aspect of risk assessment.

(c)      Lower ability candidates referred to one issue repeatedly. Most described electric

Page 47 of 48
 shock, hair caught, fingers / limbs sewn / cut, deafness with noise and damaging
lungs due to inhaling dust.

(d)     On the whole most candidates achieved full marks but many still think you sew
wearing gloves.
This health & safety question was generally very well answered by all candidates
and meant that even lower ability candidates successfully reached the end of the
paper. Higher ability candidates related their answers to industrial practice rather
than to classroom safety rules.

Q21.
(a)      Although there were some correct answers for this question, they were not always
detailed enough to gain 2 marks. There was also some confusion between school
rules and factory safety.

(b)     Candidates found it difficult to apply their subject knowledge about the benefits of
using computers in manufacturing, to the specific context of safety.

Page 48 of 48