AQA Product Design AS Full Revision Exam with Questions and Answers – 100%
Solved
3 Types of plastic - ✔✔✔-Thermoplastics- can be reheated and reshaped as they have loose
monomer chains, can be recycled and coloured pigments can be added to make it more
aesthetically pleasing.
Thermosets - undergo a chemical change so permanently rigid, cannot be reheated or reshaped
as it forms rigid cross links, e.g. spoons.
Elastomers - can be distorted under pressure but will return to their original shape.
ABS - ✔✔✔-High impact strength, giving good toughness and strength, scratch- resistant,
lightweight, durable.
Kitchen products, mobile phone cases, safety helmets, toys, car parts
Injection moulded.
Additives - ✔✔✔--Fillers - used to reduce bulk of plastic so cheaper e.g. sawdust (increases
strength and hardness).
-Flame retardants - used to reduce risk of combustion, releases agents that stifle it.
-Anti-static agents - reduce effect of static charges that could build up.
-Plasticiser - added to improve the flow properties of plastics when being moulded by reducing
softening temperature and brittleness.
-Stabilisers - used to reduce the effect of ultraviolet light by making plastic more resistant to
being broken down by sunlight.
Advantages and Disadvantages of Glass - ✔✔✔-Advantages:
-More rigid than polymers
-Ore scratch resistant than most polymers
-More transparent
-Is not effected by heat
-Better sense of quality
,AQA Product Design AS Full Revision Exam with Questions and Answers – 100%
Solved
Disadvantages:
-Glass is heavy
-High melting point
-More easily broken
Advantages and Disadvantages of Injection Moulding - ✔✔✔-Advantages:
-Produces very complex 3D shapes.
-Large numbers can be produced with consistent quality.
-Metal inerts can be included.
Disadvantages:
-Initial set up costs are high.
-Moulds are expensive.
Advantages and Disadvantages of Sand Casting - ✔✔✔-Advantages:
-Complex 3D shapes can be made.
-Cores can be used to produce hollow sections.
-Automated processes are suitable for longer runs.
Disadvantages:
-Due to poor surface finish, some machining is necessary.
-Its not as accurate as die or investment casting.
Advantages of man-made board - ✔✔✔--Larger areas can be covered with one sheet as can be
made on a larger scale than timber.
-The cost is reduced.
, AQA Product Design AS Full Revision Exam with Questions and Answers – 100%
Solved
-They are stable, meaning they will not warp or twist like natural timber due to changes in
temperature, and free of defects (knots, splits).
-They can be covered in a veneer or more expensive material to improve their aesthetic
qualities.
-Chipboard is normally covered with a thermosetting plastic to give the impression of a higher
quality.
-More environmentally friendly as more sustainable as made of softwoods.
Aluminium - ✔✔✔-Lightweight, easy to machine, does not corrode easily, excellent conductor
of electricity, strong, used for kitchenware, overhead power cables.
Annealing, hardening, tempering, nitriding - ✔✔✔-Annealing is heating the material so the
material becomes softer and more ductile and left to cool.
Hardening is heating the metal to cherry red followed by fast cooling (Quenching) to harden and
strengthen the material. Followed by tempering which reduces the brittleness by allowing
atoms to relax by heating to tempering colour and quenching.
Nitriding involves putting the materials in nitrogen while heating to 500c to harden them.
Bending - ✔✔✔-Thermoplastics cannot be bent when cold. They are bent using a strip heater
or line bender which will heat the plastic in a straight line, so it can be bent by hand.
Biodegradable plastics - ✔✔✔-Plastics do not break down easily normally and a lot is thrown
away, biodegradable plastics degrade in a biologically rich environment. Used for shopping bags,
food trays, bottles, gardening, medical and sanitary products. They can be produced from
wheat, corn and potatoes. PHAs and PHBs are made from bacteria and it is similar to
polypropylene and used in packaging and medicine, it breaks down completely when exposed
to micro-organisms.
Block Board - ✔✔✔-Generally used for table tops and furniture carcasses.
Solved
3 Types of plastic - ✔✔✔-Thermoplastics- can be reheated and reshaped as they have loose
monomer chains, can be recycled and coloured pigments can be added to make it more
aesthetically pleasing.
Thermosets - undergo a chemical change so permanently rigid, cannot be reheated or reshaped
as it forms rigid cross links, e.g. spoons.
Elastomers - can be distorted under pressure but will return to their original shape.
ABS - ✔✔✔-High impact strength, giving good toughness and strength, scratch- resistant,
lightweight, durable.
Kitchen products, mobile phone cases, safety helmets, toys, car parts
Injection moulded.
Additives - ✔✔✔--Fillers - used to reduce bulk of plastic so cheaper e.g. sawdust (increases
strength and hardness).
-Flame retardants - used to reduce risk of combustion, releases agents that stifle it.
-Anti-static agents - reduce effect of static charges that could build up.
-Plasticiser - added to improve the flow properties of plastics when being moulded by reducing
softening temperature and brittleness.
-Stabilisers - used to reduce the effect of ultraviolet light by making plastic more resistant to
being broken down by sunlight.
Advantages and Disadvantages of Glass - ✔✔✔-Advantages:
-More rigid than polymers
-Ore scratch resistant than most polymers
-More transparent
-Is not effected by heat
-Better sense of quality
,AQA Product Design AS Full Revision Exam with Questions and Answers – 100%
Solved
Disadvantages:
-Glass is heavy
-High melting point
-More easily broken
Advantages and Disadvantages of Injection Moulding - ✔✔✔-Advantages:
-Produces very complex 3D shapes.
-Large numbers can be produced with consistent quality.
-Metal inerts can be included.
Disadvantages:
-Initial set up costs are high.
-Moulds are expensive.
Advantages and Disadvantages of Sand Casting - ✔✔✔-Advantages:
-Complex 3D shapes can be made.
-Cores can be used to produce hollow sections.
-Automated processes are suitable for longer runs.
Disadvantages:
-Due to poor surface finish, some machining is necessary.
-Its not as accurate as die or investment casting.
Advantages of man-made board - ✔✔✔--Larger areas can be covered with one sheet as can be
made on a larger scale than timber.
-The cost is reduced.
, AQA Product Design AS Full Revision Exam with Questions and Answers – 100%
Solved
-They are stable, meaning they will not warp or twist like natural timber due to changes in
temperature, and free of defects (knots, splits).
-They can be covered in a veneer or more expensive material to improve their aesthetic
qualities.
-Chipboard is normally covered with a thermosetting plastic to give the impression of a higher
quality.
-More environmentally friendly as more sustainable as made of softwoods.
Aluminium - ✔✔✔-Lightweight, easy to machine, does not corrode easily, excellent conductor
of electricity, strong, used for kitchenware, overhead power cables.
Annealing, hardening, tempering, nitriding - ✔✔✔-Annealing is heating the material so the
material becomes softer and more ductile and left to cool.
Hardening is heating the metal to cherry red followed by fast cooling (Quenching) to harden and
strengthen the material. Followed by tempering which reduces the brittleness by allowing
atoms to relax by heating to tempering colour and quenching.
Nitriding involves putting the materials in nitrogen while heating to 500c to harden them.
Bending - ✔✔✔-Thermoplastics cannot be bent when cold. They are bent using a strip heater
or line bender which will heat the plastic in a straight line, so it can be bent by hand.
Biodegradable plastics - ✔✔✔-Plastics do not break down easily normally and a lot is thrown
away, biodegradable plastics degrade in a biologically rich environment. Used for shopping bags,
food trays, bottles, gardening, medical and sanitary products. They can be produced from
wheat, corn and potatoes. PHAs and PHBs are made from bacteria and it is similar to
polypropylene and used in packaging and medicine, it breaks down completely when exposed
to micro-organisms.
Block Board - ✔✔✔-Generally used for table tops and furniture carcasses.
