A-Level Product Design – Materials & Manufacturing

A set of concise Q&A flashcards covering key concepts from A-Level Design & Technology: materials properties, testing, classifications, manufacturing processes, finishing, digital tools, safety, marketing and more. Use them for rapid revision before exams.

What property describes a material’s ability to resist scratching, wear and indentation?

Hardness

Which metal classification includes stainless steel and die steel?

Ferrous alloys

Give one advantage of lamination as a paper/board finish.

Enhances appearance, increases durability, offers some water/grease resistance and has no set-up costs.

What is the basic principle of tensile testing in industry?

A sample is clamped between vices and pulled apart by a motor until it snaps; the dial reading gives tensile strength.

Name the three categories of wood stock that a designer must know.

Softwoods, hardwoods, and manufactured boards

Which printing process is most suitable for short runs and variable data?

Digital printing (inkjet or laser/xerography)

What workshop test uses a hammer to assess a material’s ability to absorb sudden shock?

Toughness test

List two advantages of MIG welding.

Produces high-quality welds quickly and with little spatter; versatile for many metals and alloys.

What is the main purpose of die cutting in paper and board manufacture?

To mass-produce identical nets/packages using a steel stamp with blades and crease lines.

Define ‘thermoplastic’.

A polymer that softens when heated and can be re-moulded multiple times.

Which smart material returns to a preset shape when heated?

Shape Memory Alloy (SMA)

Explain the term ‘case hardening’.

A surface-hardening process where low-carbon steel absorbs additional carbon on the skin, increasing external hardness while core remains tough.

What does JIT stand for and why is it used?

Just In Time; to minimise stock, reduce waste and respond rapidly to customer demand.

State one disadvantage of UV spot varnishing.

Cracks over creases and incurs extra set-up/die charges, making it longer and costlier than lamination.

Which property measures a material’s ability to withstand pulling forces?

Tensile strength

Give two examples of biodegradable polymers.

PLA (polylactide) and PHAs (polyhydroxyalkanoates)

What is flexographic printing mainly used for?

Large runs of packaging and labels

Describe the main feature of a CNC router.

Computer-controlled cutting machine capable of routing complex shapes in wood, plastics, composites and metals with high precision.

What wood joint is commonly used in traditional drawer construction for its strength and aesthetics?

Dovetail joint

Why are AGVs used in factories?

To transport materials automatically along pre-programmed routes, reducing labour and increasing efficiency.

Name two additive types used to enhance polymers and their functions.

Plasticisers – lower softening temperature and improve flow; UV stabilisers – reduce degradation from sunlight.

What is the purpose of anodising aluminium?

To thicken the oxide layer, improving corrosion resistance and enabling colouring.

Which property indicates how well a metal conducts heat?

Thermal conductivity

What advantage does rapid prototyping offer designers?

Allows quick, inexpensive creation of physical models for evaluation before full production.

Define ‘modular/cell production’.

Grouping machines/workstations into cells that produce complete sub-assemblies, enabling flexible, efficient flow based on demand.

Name a composite used for high strength-to-weight sports equipment.

Carbon fibre reinforced plastic (CFRP)

What is the primary difference between thermoplastics and thermosets?

Thermoplastics can be reheated and reshaped; thermosets set permanently after curing and cannot be remoulded.

Explain ‘design for disassembly’.

Designing products so they can be easily taken apart for repair, recycling or reuse, using minimal fasteners and clear material labelling.

Which finishing process involves heating a metal then dipping it in molten zinc?

Hot-dip galvanising

State one benefit of powder coating over liquid paint.

Produces a durable, uniform finish with minimal VOC emissions and overspray can be recycled.

What property of paper allows accurate folding without cracking?

Ability to be scored/creased

How does photochromic pigment respond to external stimuli?

It darkens when exposed to UV light and lightens when UV is removed.

Name the three stages of hardening and tempering high-carbon steel in a workshop.

Heat to red, quench in water (harden), reheat to tempering colour then air/slow cool (toughen).

Which polymer process is best for hollow products like bottles?

Blow moulding

Give an example of a modern material developed for modelling that machines easily.

High-density modelling foam

What is the key advantage of offset lithography for large print runs?

Consistent high image quality with low unit cost once set up.

Why is grain direction important in woodworking?

Affects strength, ease of machining, warpage and aesthetic appearance.

What does FEA stand for and what does it analyse?

Finite Element Analysis; predicts stresses, deflection and failure points in components under load.

Which material stock form is identified by ‘H-beam’ or ‘I-beam’?

Structural steel sections

Describe ‘vacuum forming’.

Heating a thermoplastic sheet until soft, draping it over a mould and using vacuum to suck it onto the form.

List two disadvantages of oxy-acetylene welding compared to MIG/TIG.

Rougher weld appearance requiring finishing; larger heat-affected zone leading to property changes.

What is the role of the Lion Mark on toys?

Indicates the toy is made by a BTHA member adhering to safety and ethical standards beyond CE marking.

Name an industrial toughness test and its principle.

Izod or Charpy pendulum impact test – measures energy absorbed in fracturing a notched sample.

Why might a designer choose polypropylene (PP) for a food container?

Good chemical resistance, suitable melting point for hot-fill, tough, lightweight and recyclable.

Define ‘open design’.

Sharing design information publicly so products can be co-created and improved for the common good, often via online platforms.

What is a master production schedule (MPS)?

A detailed plan outlining what, when and how much of each product will be produced to meet demand.

Which joining method uses an electric current and copper electrodes to fuse sheet metal at contact points?

Spot welding

Give one environmental advantage of using recycled materials in manufacturing.

Reduces resource extraction and energy consumption, lowering environmental impact and often cost.

What makes Kevlar suitable for bullet-resistant vests?

High tensile strength-to-weight ratio and excellent impact resistance.

State two reasons for applying polyurethane varnish to wood.

Provides durable, heat- and chemical-resistant protection and enhances colour/depth of grain.

Which printing method uses a rubber blanket to transfer ink from plate to substrate?

Offset lithography

Explain the concept of ‘batch production’.

Manufacturing a set quantity of identical products on a line before switching to the next batch.

What is ‘plasma cutting’ mainly used for?

Cutting electrically conductive metals using an accelerated jet of ionised gas.

Why are ribs/webbing included in injection-moulded parts?

Increase stiffness without thick walls, reducing material use and sink marks.

Name a biodegradable additive that accelerates polymer breakdown.

Bio-batch additive

What does CFD simulate for product testing?

Computational Fluid Dynamics – models gas or liquid flow around/in products to assess aerodynamics, cooling etc.

Give one benefit of using standardised bought-in components.

Reduces production time and cost while ensuring consistent quality and compatibility.

Which act sets out employer duties to protect worker health and safety in the UK?

Health and Safety at Work Act 1974

What tool measures electrical resistance to test conductivity of materials?

Voltmeter or multimeter in a four-point probe setup

State one disadvantage of die casting.

High capital cost for dies and equipment; porosity limits heat treatment or welding.

Why is spruce commonly used for indoor joinery?

Lightweight softwood with straight grain, easy to machine and cost-effective.

What is the purpose of a risk assessment?

Identify hazards, evaluate risks and establish control measures to prevent injury or harm.

Describe ‘electro-plating’.

Using electric current to deposit a thin metal coating onto a conductive substrate for appearance or protection.

Which thermoset is widely used for kitchen laminates due to heat resistance?

Melamine formaldehyde

Explain ‘cathodic protection’.

Controlling corrosion by making the protected metal the cathode of an electrochemical cell, often using sacrificial anodes.

What finishing technique raises a paper surface to create a 3D effect?

Embossing

Name the moulding process for large hollow products like kayaks.

Rotational moulding

Which wood wasting process shapes cylinders by rotating the workpiece?

Turning on a lathe

What advantage does thermochromic pigment give to baby spoons?

Indicates temperature by colour change, warning if food is too hot.

State one key feature of glulam compared with solid timber beams.

Greater strength and stability in long spans due to layered, adhesive-bonded construction.

What is ‘line bending’ used for in plastics fabrication?

Heating a straight line in thermoplastic sheet to create precise bends (e.g., display stands).

Give two typical stock forms of metal bar.

Round bar and square bar (others: flat, hexagonal).

Why are surface finishes applied to metals?

Enhance appearance, prevent corrosion, reduce wear or provide specific functional properties.

Which polymer stock form is supplied as small beads for moulding?

Granules

Describe ‘investment casting’.

Lost-wax process where a wax pattern is coated with ceramic shell, melted out, then molten metal poured in for high-precision parts.

What is the role of ‘fillers’ in plastic formulations?

Reduce cost and may improve strength or hardness by increasing bulk.

How does spot UV differ from full-surface UV varnish?

Applied only to selected areas (text/logo) for contrast and emphasis, not over the entire sheet.

Name the standard symbol system used for third-angle orthographic drawings.

BS8888 standard third-angle projection symbol

Why is teak oil suitable for outdoor furniture?

Replaces natural oils lost by weathering, enhancing water resistance and appearance of hardwoods.

What advantage does laser cutting offer over flame cutting for thin sheet?

Higher precision, cleaner edge, smaller heat-affected zone and ability to cut complex shapes.

Explain the term ‘self-finishing’ in polymers.

Material comes out of mould with final surface quality/colour, eliminating separate finishing operations.

Which property of polymers is crucial for cable insulation?

Electrical insulation (high resistivity)

What is the main benefit of using VOC-low water-based paints?

Reduced environmental impact and odour while providing quick drying and easy clean-up.

In CNC milling, what does ‘feed rate’ refer to?

Speed at which the workpiece advances past the cutter (distance per revolution or per minute).

Why is copper often used for electrical busbars?

Excellent electrical conductivity and good thermal conductivity.

State one disadvantage of batch production compared with mass production.

Higher unit cost due to frequent changeovers and limited economies of scale.

What classification of metals does aluminium belong to?

Non-ferrous metal

Give an example of a safety precaution when laser cutting plastics.

Ensure fume extraction to remove harmful gases such as hydrogen chloride from PVC.

What does ‘toughness’ mean in materials science?

Ability to absorb energy and plastically deform without fracturing.

Name two common knock-down fittings for flat-pack furniture.

Cam lock connectors and cross dowels with bolts

Explain why plywood has greater dimensional stability than solid wood.

Cross-laminated veneers with alternating grain directions reduce warping and splitting.

What is the key marketing purpose of corporate identity?

Creates consistent brand recognition and conveys professionalism to customers.

Which law gives consumers rights to repair or replace faulty digital content?

Consumer Rights Act 2015

Define ‘tolerance’ in engineering drawings.

Permitted variation in a dimension, ensuring interchangeability and proper fit.

Why are photo-realistic CAD renders valuable in client presentations?

Allow stakeholders to visualise materials, lighting and form before prototypes, aiding approvals.

What machining process uses rotary cutters to remove material on multiple axes?

Milling

State one benefit of cellulose paint on metal surfaces.

Dries to a very hard, durable finish suitable for high-wear automotive applications.

What does ‘vertically integrated manufacturing’ mean?

Company controls multiple stages of its supply chain, from raw materials to distribution.

Which smart pigment stores light energy and glows in the dark?

Phosphorescent pigment

How does pressure treatment protect timber?

Forces chemical preservatives deep into wood, increasing resistance to insects and decay.