AQA GCSE Workbook
Design & Technology
Topic – Materials and manufacturing
Name:
Form:
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Contents. Materials and their working properties
The working properties of materials P 3 – 5
Material modification P 7 – 10
Material classification, papers abd boards P 10 –16
Timber stock form P 16 - 19
Hardwoods P 19 –26
Softwoods P 26 – 30
Manufactured boards P 30 – 36
Metals, ferrous and non-ferrous P 36 – 40
Alloys P 40 – 42
Plastics, thermoforming P 42 – 46
Plastics, thermosetting P 46 – 49
Textiles P 49 – 52
Knowledge test P 53 – 55
Modern and smart materials P 55 – 60
Composite materials P 60 – 62
Technical Textiles P 62 – 65
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Knowledge organiser
Physical properties. A physical property is an inherent property of a material. For example, metals are
generally good conductors of electricity and natural textiles, papers and boards will readily absorb
moisture.
Absorbency the tendency to attract or take on an element, usually a liquid such as water or moisture,
could include light or heat.
Density - the mass of material per unit of volume; how compact a material is.
Fusibility - the ability of a material to be converted through heat into a liquid state and combined with
another material (usually the same) before cooling as one material.
Electrical conductivity - the ability to conduct electricity.
Thermal conductivity - the ability of a material to conduct heat.
Working properties. Working properties describe how a material responds to use in a certain
environment or in a certain way. For example, steel is malleable when heated as it can be shaped
without cracking or tearing, and felt can be formed into a hat or similar when wet.
Strength - the ability of a material to withstand a force such as pressure, tension or shear. A material might
possess one type of strength and not another, therefore it may be better to justify the type of strength it
possesses rather than simply to say it is 'strong'.
Hardness - the ability to resist abrasive wear and indentation through impact. Very hard materials can
become brittle and can crack, snap or shatter.
Toughness - the ability to absorb energy through shock without fracturing.
Malleability- the ability to deform under compression without cracking, splitting or tearing.
Ductility - the ability to be stretched out or drawn into a thin strand without snapping.
Elasticity - the ability to return to its original shape after being compressed or stretched
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Lesson 1
Materials and their working properties
Material properties – read through this
Each of the specialist material areas cover material categories that have a range of different physical and
working properties. The terms and descriptions mentioned below are given to help support the
understanding and identification of the right material or material category for any given task throughout
the specialist material areas.
When selecting materials for making into a product or prototype it is essential to know how those
materials will react and cope in different conditions. The following physical and working properties need to
be considered so the correct selection is made.
Do Now. read the statement above and answer the following question selecting the appropriate
properties below.
1. The suspension spring in a car needs to have certain properties to withstand constant impact and
forces. Which properties does the metal spring need to have?
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2. Why is it important to select the correct materials for the application indented use?
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The physical and working properties of materials can often be adapted and modified using different
processes and techniques.
Physical properties
A physical property is an inherent property of a material. For example, metals are generally good conductors of
electricity and natural textiles, papers and boards will readily absorb moisture.
Absorbency - the tendency to attract or take on an element, usually a liquid such as water or moisture, but
could include light or heat.
Density - the mass of material per unit of volume; how compact a material is.
Fusibility - the ability of a material to be converted through heat into a liquid state and combined with
another material (usually the same) before cooling as one material.
Electrical conductivity - the ability to conduct electricity.
Thermal conductivity - the ability of a material to conduct heat.
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Working properties
Working properties describe how a material responds to use in a certain environment or in a certain way. For
example, steel is malleable when heated as it can be shaped without cracking or tearing, and felt can be formed into
a hat or similar when wet.
Strength - the ability of a material to withstand a force such as pressure, tension or shear. A material might
possess one type of strength and not another, therefore it may be better to justify the type of strength it
possesses rather than simply to say it is 'strong'.
Hardness - the ability to resist abrasive wear and indentation through impact. Very hard materials can
become brittle and can crack, snap or shatter.
Toughness - the ability to absorb energy through shock without fracturing.
Malleability- the ability to deform under compression without cracking, splitting or tearing.
Ductility - the ability to be stretched out or drawn into a thin strand without snapping.
Elasticity - the ability to return to its original shape after being compressed or stretched.
Compressive strength – the ability to withstand being crushed or shortened by pushing forces
(compression)
Tensile strength – the ability to withstand stretching or pulling forces(tension)
Forces in action.
Tensile Strength – being able to withstand being pulled apart.
3. What many other materials can you think of that come under tensile stresses when in use.
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Torsion occurs when a material is being twisted.
The two ends of the material rotate in opposite directions creating a twist, like wringing out a wet towel.
4. Study the image below and label the two forces:
Explain why the ropes on the bridge are under Tensile forces.
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The Physical and working properties of materials
Using the material property list above, answer the following questions.
5. Explain why it is important to select the appropriate materials when making a prototype.
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The physical and working properties of materials can and are often modified for purpose. For
example;
Forging can produce a piece that is stronger than an equivalent cast or machined part. As
the metal is shaped during the forging process, its internal grain texture deforms to follow the
general shape of the part. Thus, making it stronger
Forged steel is generally stronger and more reliable than castings and plate steel due to the
fact that the grain flows of the steel are altered, conforming to the shape of the part. The
advantages of forging include:
The tight grain structure of forgings making it mechanically stronger.
Forging provides better mechanical properties, ductility and impact resistance because this process refines
and directs the grain flow according to the shape of the piece.
The Following are some of the most common mechanical properties of metals.
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Hardness. A material's power to resist a permanent change in shape when acted upon by an external force
is known as hardness. ...
Brittleness.
Ductility.
Toughness.
Strength.
6. What physical property would you associate with metals? Can you give a specific metal as an
example?
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Lesson 2. Material modification
Forging steel to make it stronger; making it tougher.
Do Now.
7. Explain how altering the grain structure of a material can improve it’s properties.
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8. Explain why steel may be forged during the manufacture of tools such as a pick axe
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9. Discuss what properties have been modified during the forging process
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Support video; https://www.youtube.com/watch?v=G60llMJepZI
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Summery. This is a perfect example of how the physical and mechanical properties of raw material
can be modified for purpose.
- Don’t confuse this with reinforcing a material – most materials can be reinforced
e.g., concrete is reinforced with steel beams, carboard can be reinforced with
plastic
Why concrete is reinforced?
 To understand this, we need to understand the properties of concrete.
The strengths and weaknesses of concrete.
Properties of concrete.
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The tensile strength of concrete is relatively low.
Concrete is not very ductile.
Concrete has an extremely high strength to weight ratio;
Concrete is very hard which is good as it can withstand great impacts and abrasion.
But this can also make it brittle.
Concrete has excellent compressive strength
10. Study the image below. Imagine the object in which the force is being applied to is
concrete.
We can see where the tensile strength is being applied – the material is being stretched and
pulled.
What do you think will happen to the concrete?
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By adding steel rods or a mesh and reinforcing the concrete, the steel bars absorb the tensile
stresses in a concrete structure.
In reinforced concrete, the tensile strength of steel and the compressive strength
of concrete work together to allow the material to sustain these stresses over considerable spans.
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Task 2)
This is an independent task.
11. Study the images below and associate the material requirements with the Physical and
Working properties. Use the list of properties on the previous pages to help you.
One has been done for you. Complete the table.
Product / Material
Physical and working properties required
Plastic plug socket –
The material needs to be of poor
electrical conductivity and
thermal conductivity properties.
Plastic is a good insulator which is why it used for pan
handles.
The product should also be TOUGH to some extent as
it is used to enclose dangerous electrical components
that are of live connection.
Lead weight used for fishing -
Copper wiring with a plastic coating
Climbing rope
Metal pan with plastic handle.
Sports headband
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Sledge hammer
Protective vest
Cycling Helmet
Lesson 3.
The classification of materials and their working properties; papers and boards
Do Now. Read the following statement and answer the questions
Material selection significantly impacts upon the potential success of a manufactured product. A great
design may fail if the material properties are not suitable for the product function. A designer and
engineers' knowledge of these properties is essential. Choosing the wrong material can be the difference
between failure and success; there are also many Health and Safety implications that need to be considered
with products, their uses and the materials they are made from.
12. Explain why making a picnic table made from Pine, if left untreated, would fail if left outside
for a long period of time.
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13. suggest three different material properties that a designer would need to consider when
designing and manufacturing a watering can for the garden.
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14. Explain why concrete is a composite material and why it needs to be reinforced with steel (3
marks
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Material classification
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Materials for product design and engineering are generally split into groups or classifications:
metals, woods, polymers, papers and boards, composite materials, smart materials and
modern materials.
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Some materials have more than one classification, for example metals can be classified as ferrous,
non-ferrous or alloy. Woods can be classified as softwoods, hardwoods and manufactured
boards.
The classification of materials has been is shown below in a table –
15. how many materials can you think of and where do they go?
Metals
Woods
Polymers
Copper
Pine
Polypropylene
Paper /
board
Corrugated
card
Composites
Materials
Concrete
Smart
Materials
Litmus paper
Moden
Materials
Graphene
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Performance characteristics of materials Papers / Boards
Paper and boards are compliant materials, meaning they are suitable for scoring, cutting, folding to
produce items such as packaging. Paper is made from pulp which is naturally grey – bleech is added to
make the pulp white. Paper and board is highly suited for recycling or if left in landfill – it will naturally
decompose.
Material
Bleed proof paper
Properties
White
Slightly textured
70GSM
Used with markers
Uses
Marker pens
Final design
presentation -
Cartridge paper
Thick white paper
Rougher texture
150GSM
Pencil and ink drawings
Watercolour
Grid paper
80GSM
Faint lines and grids
printed on
Mathematical diagrams
Architecture diagrams
Plotting grids and charts
Layout paper
Smooth finish
Slightly transparent
40 GSM
Sketches
Initial ideas
Copying and tracing
with felt pens and
markers
Tracing paper
Translucent
40GSM
Takes pencil well
Image
Copying and tracing
images
Used with a light box
Overlays for design
adaptations.
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Corrugated cardboard
300GSM
Good strength to weight
ratio
Strong
Rigid perpendicular to
corrugations
Easily printed on
Two layers of card
bonded together
Often white external
layer for printing
500GSM
Stiff and lightweight
Often has a waxy
coating – sheen
Packaging boxes
Impact protection
Good insulation for hot
food delivery
Foil lined board
White card laminated
with foil
400 GSM
Stiff
Reflects heat
Water resistant
Foam board
Thickness of 4 MM
Rigid
Very lightweight
Architecture models
Prototyping
Mounting artwork and
displays
Duplex board
Food boxes
Drinks containers
Cake box
Takeaway container lids
Drink cartons
Stock form of paper.
Papers are available in different stanard sizes from A0 (largest) to A8 (smallest). Each A size is half the size
of the previous; for example, A5 is half the size of A4.
The sheets in this booklet have been printed in A3 but folded in half to make A4 pages.
Task – take a piece of A4 paper – fold it into A5 – then A6 – then A7 – then A8. - how far go you go?
Paper is measured in weight (GSM) - this paper has been printed on 80GSM (grams per square metre).
Mounting board tends to be around 1000 GSM
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The lighter the paper, the easier it is to manipulate; bend, score and cut.
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16. What does GSM stand for?
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Task 2)
You should each get a sample of the papers of most of the papers above.
If this is not possible, how many of the following papers can you find in your house?
Use the table to help answer the following questions.
17. Discuss the properties of foam board and explain why It is used architectural model making and
mountboards
Model answer; foam board has two outer layers with a foam centre; the two outer layers create rigidity
and give the material strength. Foam board is also light weight – giving it good strength to weight ratio.
Foam board is also easy to cut and shape.
18. explain which paper you would choose if sketching in maker pens, justify your answer.
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19. explain which paper you would use if creating a hand-made Birthday card that was to be
finished with watercolours.
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20. explain why corrugated cardboard is used for packaging (3 marks)
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21. corrugated card has an excellent strength to weight ratio – explain how this is achieved through
reinforcement. (3marks)
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22. explain the difference between foil lined board and duplex board.
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Duplex board is often used for food and drinks boxes.
IT IS MADE OF TWO LAYERS – THE OUTER LAYER HAS A WAXY LAYER TO
GIVE IT A WATER - RESISTANT COATING AND A GLOSSY SHEEN WHICH
ATTRACTS CUSTOMERS – LIKE MOTHS TO A FLAME !
Natural and manufactured timbers
Lesson 4
23. Do Now – complete the statements below by selecting an appropriate material.
explain which material you would select for the following:
a) food packaging, disposable cups, plates ______________________
b) presenting artwork, picture mounting, modelling __________________________
c) drinks packaging, milk cartons, take-away box lids ____________________________
d) Rendering a final design using coloured markers ______________________________
e) Creating a net for a cake box _______________________________________
f) Manufacturing a point of sale display to hold leaflets __________________________
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24. A disposable coffee cup is made of duplex board with a corrugated cardboard sleeve.
a. Suggest two properties of corrugated cardboard that make it suitable for use as a sleeve
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b. Explain how corrugated cardboard is reinforced to give it better strength and insulation and
thermal properties.
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Natural and manufactured timbers
Natural wood
Natural wood is categorised as hardwood
the tree and not the strength of the wood.
or softwood. These names reflect the cell structure of
Hardwood is from a deciduous tree, usually a broad-leafed variety that drops its leaves in the winter.
Softwood is from a coniferous tree, one that usually bears needles and has cones. These are frequently
called evergreen trees as most of them keep their needles all year round.
Trees take a very long time to grow. Some softwood trees can reach maturity in around 25 years, but
hardwoods can take hundreds of years or more. A native British oak tree's growth rate slows down after 80
to 120 years. The slow growth of most hardwood trees is the main reason that hardwood tends to be more
expensive than softwood.
25. explain the difference between coniferous and deciduous trees.
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How to buy timber.
If you want to buy timber, you will have to choose from a selection of different sizes.
Timber comes in many different sizes; this is known as Stock Form.
Generally, softwoods and hardwoods will come in planks.
Softwoods and Hardwoods are available in stock form from wood suppliers – think B & Q, for example.
26. explain why materials such as timber being sold in standardised lengths is useful when
planning to build a garden shed?
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Timber generally comes in planks of a standardised size (length, width, thickness – an example of a
standard thickness would be 32MM or 50MM)
The cost of raw material increases with processing and this is true with all manufactured or bought
products or materials.
The more processes a material needs to go through – the more expansive it becomes; this is because
more time is spent on the material.
27. You are an architect and you have been asked to design and build a small garden house. The
design is shown below. The material you have chosen is Air Dired Oak. The Oak comes in lengths
of 2400 CM.
This is useful to know when planning and working out cost of material / how much is needed – how much to order
so you know how much to charge your client.
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Air dried Oak Stock form.
Each length costs £35.99
The architect has calculated that the total length of material to build the structure is 36 meters.
28. How many beams do you need to order?
29. Calculate the total cost to build the Oak timber frame? Show you working out (3 marks)
29) Explain why the architect would want to order an extra plank of Oak?
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Lesson 5
Do Now
30. Disucss the disadvantages of CAD design
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31. What does NIMBY mean?
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32. Discuss which sources of energy the above statement may relate to.
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Main content.
If you go order timber – you will have two choices.
Timber comes in two different conditions: Rough Sawn or Planned all Round (PAR)
Rough Sawn – roughly cut to size, has rough edges
Rough sawn wood comes directly from seasoning and has ROUGH edges.
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It won’t be very accurate and will need more work and treatment but this is why it is cheaper.
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Planed all round (PAR)
Planed all round has sides and edges that are planed square, straight and level, leaving a smooth finish.
33. explain why Planed all Round (PAR) is more expensive than Rough Sawn timber.
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34. explain which timber you would use to build a garden fence, justify your answer.
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35. explain which timber you would use to make a kitchen counter top, justify your answer.
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Material selection: Hardwoods
Hardwoods are generally a lot more expensive that softwoods.
They generally have a more attractive grain – a more condensed grain structure
Hardwoods are generally harder and will last longer
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Material
Oak - 600 years old
Properties
Very hard – Very tough
Attractive grain
Has good weather
resistance
Uses
Furniture
Flooring – floor boards or
veneers on floor boards
Boat building
Grain structure
Oak chest of drawers (below)
£ 499.00
Scale of production. Made in batches
Finished with Danish Oil to bring out the grain structure and protect against moisture.
Material
Beech
Properties
Very Tough
A hard material
Very close tight grain
This makes it naturally
water resistant
Uses
Chairs
Chopping boards
Tools (mallets)
Workbench tops
Childrens toys
Grain structure
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Product
Childrens rocking horse
Material
Solid Beech children's rocking
horse.
£ 450
Oil finish for water resistance
and attractive sheen
Scale of production; small batch
production
Plastic rocking horse.
£ 24.99
Scale of production; mass
produced
Injection moulded - no finish
needed as plastic is naturally
waterproof.
Cost
Scale of production
£ 450
Batch production
Made by hand, hand tools and
machines.
Danish Oil Finish - finished by
hand
Enhance grain attraction
Protect against moisture
£ 24. 99
Mass production
Injection moulded by machine
Finish or post – treatment
36. Circle the movement that a rocking horse makes.
Rotary
No finish needed
Plastic is naturally waterproof
Reciprocating.
Oscillating.
37. Explain why the rocking horse made from beech is nearly 20 times more expensive that the
rocking horse made from plastic (6 marks)
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Material
Ash
Properties
Very tough
Attractive open grain
pattern
Shock resistant and
flexible
38. explain why Ash is a suitable material
for the handle of this spade.
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Uses
Tool handles
Sporting equipment
Baseball bat
Cricket bat
Grain structure
39. explain why Ash is used to make baseball bats
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Material
Properties
Uses
Mahogany
Has a very rich dark
red colour which
some see as very
attractive.
Very durable and
finishes very well
Indoor furniture
Cabinets
Veneers – used on
manufactured boards
Grain structure
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Product description
Cost
Scale of production
Finish
Mahogany display cabinet
Solid Mahogany and glass
£ 1049
One off – made to order
Danish Oil finish
To enhance rich grain and
protect against moisture
Manufactured board (MDF)
Venner finish
£ 250
Large batch production
CNC machined
Veneer finish
40. explain why mahogany is such a popular material for high-end furniture.
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Material
Properties
Uses
Balsa wood
The Balsa tree is a
fast-growing
hardwood making it
very unique.
Very open grained
Very soft
Extremely
susceptible to water;
almost sponge like in
texture
Very light weight
– used for model
aircraft
- Snaps
easy
Architecture
Model
making
Grain structure
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Balsa is a popular hard wood for model making
because it is soft and easy to work with.
Because balsa has such an open grain, this makes it
extremely light in weight and this makes it ideal for
modelling air craft
Lesson 6
Do Now.
Knowledge test: Practice exam questions
41. Name a hardwood (1 mark) Beech
42. give a typical use for this hardwood (1 mark)
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43. Explain why the hardwood is an appropriate choice for this application (2 marks)
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44. Name a hardwood (1 mark)
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45. Give a typical use for this hardwood (1 mark)
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46. Explain why the hardwood is an appropriate choice for this application (2 marks)
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47. Name a hardwood (1 mark)
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48. Give a typical use for this hardwood (1 mark)
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49. Explain why the hardwood is an appropriate choice for this application (2 marks)
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Softwoods
Softwood is from a coniferous tree, one that usually bears needles and has cones. These are frequently called
evergreen trees as most of them keep their needles all year round. Think of a Christmas tree (it loses its needles
because it has been felled)




Softwoods grow quicker and taller which is why they are used in the construction industry
Softwoods are much cheaper because they grow all year round
Because they grow quicker – their grain structure is more open.
This makes softwoods more susceptible to moisture
Material
Properties
Uses
Larch
Hard for a softwood.
Has good resistance
to moisture
Attractive grain
pattern
Garden furniture
Decking
Fencing
Cladding
Grain structure
Outside garden bench made from solid Larch
26
£ 235.00
Larch has good water resistance (this is because of the natural oils found in the wood)
Manufacture - Scale of production: batch.
50. explain why the garden bench made from larch will need a protective layer of varnish or oil.
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Spruce
Working properties - Has a very straight grain More resistant to splittingEasy to work with Good stiffness to weight
ratio
Material
Uses
Grain structure
Spruce
Indoor furniture
Musical instruments
Material
Pine
Properties
Very straight
Tall
Can be very
knotty
Light weight
Easy to work
Uses
Construction
Indoor frames
Roof beams
Takes stain
and
treatments
well
Cheap furniture
Grain structure
Can be used outdoor
– needs treating.
27
Pine VS Oak
Material
Price
Properties of material
Solid Pine
Chest of drawers
£ 129. 00
Pine is the cheapest softwood.
It takes stain well – so can be
made to look like hardwoods
Pine has a good strength to
weight ratio
It is lightweight so cheaper to
transport around.
Solid Oak
£ 499.00
Oak is expensive
It is a harder material to work
with
It has a closer grain – which is
seem as more attractive
It is much heavier than pine so
more expensive to transport
around.
51. Name a softwood, larch
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52. Give a typical use for this softwood (1 mark)
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53. Explain why the softwood is an appropriate choice for this application (2 marks)
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54. Name a softwood
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55. Give a typical use for this softwood (1 mark)
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56. Explain why the softwood is an appropriate choice for this application (2 marks)
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Lesson 7. Manufacrured boards
Do Now.
57. explain what a composite material is
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58. explain why composite materials are harder to recycle.
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59. name a smart material and explain what its external stimuli are.
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60. name a modern material and discuss two of its properties.
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Manufactured Boards
What are manufactured boards?
Manufactured boards are sheets of made from natural timber waste products (sawdust / small off-cuts).
Manufactured boards can be made from recycling timber (shredding it down and re-producing it).
The material is bonded and compressed together using a glue called Urea Formaldehyde.
Urea Formaldehyde is classified as a thermoset plastic – it cannot be re-used.
Manufactured bords can be easily covered with thin slices of wood – called veneers.
Veneers come in thin sheets rolled up – almost like toilet paper
This is done for aesthetic reasons; making cheap material look more attractive, expensive and appealing.
29
Manufactured boards offer many advantages. One of these is the size they are available in or
manufactured in; large sheets.
These large sheets usually come in sheets of 2440 MM x 1220MM.
This means a wide or large surface area can be produced from just one sheet.
Office desk made from Chipboard veneered with a black polyester sheet
61. Explain how this large surface area would be achieved from using traditional planks of wood;
for example, Pine.
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62. explain why manufactured boards are often coated with veneers
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Advantages of manufactured boards:



Readily available in long wide boards of uniform thickness and quality
Uniform strength across the board – no grain or knots that can weaken the material
Because of the flat surface, it is easier to apply veneers to enhance the aesthetics.
30
MDF – Medium Density Fiberboard
Material
MDF
Medium Density Fibre Board
Properties
Uses
Rigid and Stable.
It has two very smooth faces.
It is very good under
compression because of how
dense it is.
Because of its smooth surface, it
is ideal for veneering or painting.
It is very absorbent (almost like
cardboard) - not good for damp
environments.
Flat-pack furniture
Kitchen units
Internal construction
Ikea bedroom unit.
£ 299
Material: MDF with Beech veneer.
63. explain why MDF is a suitable material for the large Ikea bedroom unit.
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31
Material
Plywood
Properties
Thin layers of wood are placed
and glued at 90 degrees to each
other and compressed to form a
board.
This gives the material good
strength and makes it stable in
all directions (no grain weakness
as you are cancelling this out by
rotating the material)
Uses
Furniture
Shelving
Toys
Construction; interior and
exterior
Desk tops
64. explain how plywood is manufactured for reinforced strength
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65. explain why plywood is used a lot in the construction industry
…………………………………………..…………………………………………………………………………………………………………………………
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Why ars skateboards are made from plywood?
The image shown how the layers of wood are sandwiched together with glue to form the shape.
This compression combined with the glue and the natural strength of the material results in a very
strong and table board.
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66. explain why plywood is a suitable material for a skateboard
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CHIPBOARD
Material
Properties
Uses
Chipboard
Wood chips compressed with resins
such as Urea Formaldehyde.
Good compressive strength
Corners and edges prone to
chipping
Good value
Venerable to water
Kitchen worktops
Flooring
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67. explain why chipboard is a suitable material for the initial layer of a dining room floor.
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68. explain why the material would need to be coated before kitchen tiles were placed on top.
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It is often asked, what is the difference between chipboard and MDF;
Medium density fibreboard is stronger than chipboard because the board has a higher
density. ... Medium density fibreboard also has a much smoother surface than chip
board which allows for a better finish. MDF outperforms chipboard because it is water
resistant (not water-proof). Chipboard is cheaper than MDF.
69. from the manufactured boards list, select an appropriate material to build a shelf in a
bathroom, justify your answer.
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70. state one way in which softwoods can be made to appear as hardwoods
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71. state one way in which manufactured boards can be made to appear as hardwoods
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Exam practice
72. Study the image below. The product has been manufactured using CAD and CNC machinery.
Suggest a suitable material and explain why it would be suitable for the products shown below (4 marks).
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Lesson 8
Do Now
73. explain the term ‘tough’ when referring to material properties
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74. explain the term ‘ductile’ when referring to material properties
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75. discuss the advantages of using CAD software (4 marks)
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Metals and alloys
Metals
Metals generally have a high strength to weight ratio and have become an essential construction material
in our modern society.
Metals are categorised as either ferrous or non-ferrous, although a third group, known as alloys, is created
when two or more elements are blended together, where at least one is a pure metal.
Some pure metals are mined as a whole metal but many are extracted from an ore. Ore is a type of rock
that contains a pure metal in small quantities. The ore is obtained through mining, then the metal is often
extracted from the ore using large furnaces.
The extreme heat of the furnace separates the metal from the ore and it is drawn off as a molten liquid
and processed into the metals that we commonly use.
Aluminium ore in the form of Bauxite is crushed and the aluminium is extracted via the process of
electrolysis.
Common ferrous metals
Ferrous metals contain iron and can rust
Metal
Carbon
content
Properties
Uses
Low Carbon Steel
Also known as Mild
Steel
0.05 %
Tough and Ductile
Easily machined
Screws, nails, nuts and
bolts.
Car body panels
Image
36
High Carbon Steel
Also known as Tool
Steel
1.5 %
Less ductile but much
harder
Very hard wearing
Garden and Workshop
tools
Cutting tools
Cast Iron
3%
Hard but can be
brittle
Very good under
compression
High melting point
Easily cast into
complex shapes
Disc brakes
Engines parts
Machine parts
Kitchen pots and pans
76. explain why cast iron is a suitable material for brake discs (2 marks)
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77. explain why low carbon steel is often used for car body panels (2 marks)
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78. explain what can happen to a garden spade made from high carbon steel if left outside (2
marks)
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Non- ferrous metals; do not rust but CAN oxidise
The statue of liberty in New York is made from copper.
Copper’s natural colour is Goldish Orange shiney colour.
Over the years, the copper has Oxidised and become and blue green colour.
37
Common non-ferrous metals.
Metal
Aluminium
Properties
Lightweight
High strength to
weight ratio
Ductile
Uses
Drinks cans
Bike frames
Aircraft Bodies
Copper
Good electrical
conductor
Ductile
Corrosion
resistant
Electrical wire
Plumbing and
piping
Central heating
systems
Tin
Low melting point
Corrosion
resistant
Malleable
Solder
Coatings for food
cans to preserve.
Roofing
Image
Tin cans are actually made from mild
steel and coated in Tin to stop it
corroding. Tin as a pure metal is actually
quite rare.
Zinc
Good corrosion
resistance
Galvanising steel
to form a
protective layer:
buckets
Steel bucket with Zinc coating
Zinc is also used as a coating but Zinc is
more reactive than tin so will react with
the food if it were used for a can.
38
79. explain why aluminium is sometimes used for more expensive car body parts
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80. Copper is a ductile material and is therefore suitable for heating systems. Explain why this is
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Copper central heating system
81. buckets are often made from steel but coated in zinc, explain what makes zinc an appropriate
material to coat buckets with
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Lesson 9
Alloys
Do Now.
82. Why is an alloy classified as a composite material?
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83. Explain why corrugated card is used for pizza boxes
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84. Explain why manufactured boards are a suitable and common material used for flat-pack
furniture.
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85. Discuss how manufactured boards are coated, referencing a specific board.
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Main content of the lesson.
Alloys are a mixture of at least one pure metal and another element. The alloying process combines the
metals and other elements in such a way as to improve the working properties or/and the aesthetics.
Alloy wheels are a type of car wheel made from an
alloy of aluminium, nickel and titanium. They differ
from standard steel wheels in that they're lighter and
stronger, which can improve handling and fuel
economy.
Common Alloy metals
Metal
Brass
Zinc and Copper
Stainless steel
Low carbon, chromium
and nickel
Properties
Heavy and dense
Easy to cast into
complex shapes
Corrosion resistant
Good aesthetic
properties
Uses
Musical instruments
Door handles
Taps and fittings
Hard with smooth finish
Corrosion resistant
Kitchen appliances
Cutlery
Sinks
Medical apparatus
Image
40
High Speed Steel
(HSS)
Made from:
Tungsten
Chromium
Vanadium
Cobalt
Carbon
Able to withstand great
temperatures created
from friction
Extremely hard
Extremely tough
Drill bits
Milling cutters
Cutting tools
86. stainless steel is a very common metal in every household. The chances are that the cutlery in
your kitchen is made from this metal. State the different metals that make up stainless steel.
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87. when an engineer or manufacturer needs to drill into metal, they use a metal drill bit but not
any metal will do the job. High Speed Steel was designed for this use, explain the properties of
High-Speed Steel that make it suitable for drilling into other metals.
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88. Task. Place the metals into the relevant category in the table below.
Aluminium. Copper. Low Carbon Steel. Stainless Steel. Brass. Tin. Copper. Tin.
Cast Iron
Ferrous
Non-ferrous
Alloy
41
Lesson 10
Do Now.
89. explain why someone who works for a co-operative may be more motivated than someone who
does not.
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90. what is the main difference between pneumatic and hydraulic systems
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91. explain how Flexible Manufacturing Systems are able to respond to market demand quickly and
efficiently (3 marks)
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Polymers (plastics)
Categorisation
Plastics are categorised into two types; thermoforming and thermosetting plastics. They can be derived
from three sources: synthetic compounds, naturally occurring compounds and plant-based starches.
Synthetic polymers are by far the most common.
The most common thermoforming plastics.
Thermoforming plastics can be formed into complex shapes and many can be reformed multiple times.
Thermoplastics are commonly used in processes such as vacuum forming, injection moulding and blow
moulding.
 Thermoforming plastics are much easier to recycle and reuse – they can be heated
up again and re-moulded or re-formed.
 Thermosetting plastics – cannot be re-used in the same way – once set – they are
set.
Thermoforming plastics table
42
Material
Acrylic
Properties
Uses – Image
Range of colours
Tough but brittle if too thin
Can be easily scratched
Easily formed and moulded
Car lights
Modern baths
Jumpers / Hats / Gloves
High impact polystyrene
(HIPS)
Flexible
Impact resistant
Lightweight
Food safe
Food containers
Yogurt pots
High density polyethylene
(HDPE)
Lightweight good strength to weight ratio
Rip and tare resistant
Chemical resistance
Impact resistance
Milk bottles
Drain Pipes
Hard hats
Wheelie Bins
Polypropylene
(PP)
Easily coloured
Flexible
Tough
Lightweight
Chemically resistant
Easily cleaned
Kitchen tapware
Medical equipment
Rope
43
Polyvinyl chloride
(PVC)
Very flexible
Chemically resistant
High gloss finish
Tough
Large range of fun colours
Raincoats
Blow up mattress / air-bed
Polyethylene terephthalate
(PTHE)
Very easy to blow mould and
shape
Chemically resistant
Fully and easily recyclable
Good stability
Plastic bottles
Food packaging
Food wrapping
92. explain why PTHE is a suitable material for a bleach container
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44
93. suggest and justify a suitable material for the air – toy
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94. explain why Polypropylene is a suitable material for climbing rope.
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95. explain why High Impact Polystrene is a suitable material for food packaging.
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Lesson 11
Thermosetting plastics
Thermosetting plastics or thermosets are more rigid and, as the name suggests, once they are formed or
'set' they cannot be reformed. The long polymer chains have many more cross links between them which
stops the molecular chains in the plastic moving. As a result, they are generally harder and more brittle
than thermoplastics. They make excellent electrical insulators and have good resistance to heat and
chemicals. When thermosets are heated, they tend to burn rather than melt making most thermosetting
plastics difficult to recycle.
Material
Properties
Use / Image
Epoxy resin
Used as a two-part
glue – creates a
very strong bond –
waterproof
Used for bonding
two or more
materials together
45
Melamine –
formaldehyde
(MF)
Food safe
Hygienic
Very hard
Kitchen ware
Kitchen work-tops
Urea –
formaldehyde
(UF)
White in colour
Heat resistant
Very good
electrical insulator
Hard but brittle
Electrical fittings
Used in some
manufactured
boards as a
bonding agent
Polyester Resin
A two-part resin A hardener and a
catalyst
Phenol
formaldehyde
(PF)
Known as the first
ever plastic –
Bakelite
Very rigid
Very hard
Brittle Was invented for
snooker balls
High gloss finish
Strong
Heat resistant
Transparent
Good insulator
Not really used
very much now
Used in the lamination of fibre glass
products
Used as a protective coating for flooring
The very first plastic made -
96. explain the main difference between thermoforming plastics and thermoset plastics
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97. explain why Urea Formaldehyde is used as a bonding agent in the manufacture of MDF
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98. explain why Urea Formaldehyde is a suitable material for electrical fittings
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99. discuss the consequences on the environment of using Urea Formaldehyde as a bonding agent
on manufactured boards such as MDF (4 marks)
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Lesson12
Do Now.
100. Explain the difference between thermoforming plastics and thermoset, explaining which is
better for the environment and why.
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101.
Order the plastics into the correct category in the table below.
PVC. Polyester resin. Epoxy resin. Acrylic. Polypropylene. Urea Formaldehyde. High
Impact Polystyrene. HIPS. HDPE
Thermoforming plastics
Thermoset plastics
Main content
Textiles
Textiles
Properties of textiles;
Textiles are highly adaptable and can be constructed to maximise different properties
including a very high strength to weight ratio, which means less material can be used to
make strong and robust products.
Categorisation of textiles
The categories of textile that are covered in this chapter include:






natural fibres
synthetic fibres
blended and mixed fibres
woven fabric
non-woven fabric and
knitted textiles.
Plant-based natural fibres
Plant fibres can be spun together to create yarn. Fabrics made from plant-based materials are renewable
but take a long time to grow.
48
Yarn
Cotton Cotton is a soft, fluffy staple fibre that grows in a boll, or protective
case, around the seeds of the cotton plants
Material
Cotton
Properties
Soft and strong
Absorbent and cool
Can be easily washed
Uses
Clothing
Shirts
Towels
Bedsheets
Cotton plant.
Animal-based natural fibers
Material
Wool
Origin – from sheep
Lamb
Alphaca
Goat Wool
Properties
Very warm
Does not crease
Negative – can shrink in
the wash
Uses
Jumpers
Coats
Suits
Even carpets
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Silk
Origin – silk – worm
Very fine
Very soft
Very gentle on skin
Natural sheen
Strong when dry
A sheep being sheered
Luxury clothing
Luxury bedding
A silk work
102. explain why natural materials are often moree expensive than synthetic fibres, you should
reference a material in your answer.
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Synthetic fibers
 Synthetic meaning Man-Made
Synthetic fibers are made mainly from non-renewable coal and oil refined .
The do not degrade easily but they can be made into any length (continuous filament) and thickness and
for any purpose.
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Material
Polyester
Properties
Tough
Stong
Hard wearing
Non-absorbent (plastic)
- quick drying
Polyamide
Nylon
Good strength to weight Parachutes
Hard wearing
Ropes
Non-absorbent
Elastane
(LYCRA)
Has elastic properties –
to add stretch
Quick drying
Added to fabrics to
enhance
103.
Uses /images
Clothing
Back-packs
Umbrellas
Sportswear / Outer
wear / Jackets
Sportswear
Swimsuits
Exercise clothing
Insulating properties
Explain why polester is a suitable material for outdoor clothing.
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How fabrics are made.
Most cotton products are manufactured into a Plain weave
Threads are interlocked at 90 degrees
Simple and cheaper to produce
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Strong solid weave
This is something you can try with strips of paper – you have done
something like this previously.
It creates a strong solid weave and it is simple and easy to manufacture
– which is why it is very common
Lesson 13
Do Now Knowledge test
1. Some board products are coated with aluminium foil on one side.
a. What function does foil serve? (1)
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b. Give one example where foil backed card is used.(1)
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2. Paper products are measured in grams per square metre (gsm). Calculate the weight of the
following paper products to the nearest gram.
1 x A2 sheet of 40gsm tracing paper (A2 = 594mm x 420mm) (3)
3. For each of the applications below, select a suitable type or form of paper or board.
a. An artist drawing a portrait in charcoal. (1)
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b. A picture framer wrapping a framed picture to transport to a customer. (1)
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c. Planning the dimensional layout for a scale model of a building. (1)
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d. Creating the walls for an architectural model. (1)
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e. Wrapping up delicate crockery for storage or transportation. (1)
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4) Give two differences between a hardwood and a softwood (2)
5. Mahogany is a hardwood.
a. Describe the appearance of mahogany. (2)
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b. Give two applications of mahogany. (2)
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6.
a. Name the two elements alloyed to make mild steel. (2)
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b. Give two properties of mild steel. (2)
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Explain two properties of copper which make it an appropriate material for use as electrical cables. (2)
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7. Explain one reason why PET is an ideal material from which to make the fizzy drinks bottle shown below.
(2)
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Give two properties of urea formaldehyde that make it an appropriate material for use as electrical
sockets. (2)
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10.
a. Give two animals that produce wool. (2)
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b. Wool is one natural fibre. Give two other natural fibres. (2)
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11. Explain why fibres are blended together. (2)
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12. Explain why a plain weave is commonly used to manufacture shirts (2).
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Lesson 14
Do Now.
104.
Explain the difference between modern material and smart materials.
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105.
Suggest a suitable material for a plug socket – you should justify your answer,
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106.
Explain why Stainless steel is classified as a composite material.
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Main lesson content.
Modern materials
Technology is constantly progressing and new materials, as well as new ways of working with materials, continue to
be developed. A good designer will utilise and exploit these materials where appropriate and keep up-to-date with
the latest developments.
Materials
Titanium
Graphene
Properties
Very high – strength to
weight ratio.
Anti – corrosive
Hypo-allergenic - unlikely
to cause an allergic
reaction.
Easily formed and molded
200 times stronger than
steel
Highly conductive
Incredibly strong
Flexible
Can stretch
Uses
Watches
Medical use
Dental implants
Aircraft parts
High-end sports
equipment
Image
Still in development Possible areas:
Technology
Green energy
Protective clothing
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Metal foam
Think metal sponge
Open cell structure –
Strong – lightweight
Excellent at sound and
impact absorption
Medical implants
Aircraft and car parts
Impact absorption in
vehicles
Smart materials
A smart material is one which reacts to an external stimulus or input. This means that it can alter its functional or
aesthetic properties in response to a changing environment. This group of materials can react to stimuli such as heat,
pressure, moisture, stress, PH level, light (including UV) and electricity.
Material
Thermochromic
pigment
Stimulus
Heat
Properties
The pigments change
colour they heat up or
cool down
Use
Temperature indicators
Clothing
Novelty goods
Photochromic pigments UV light
The pigments are
imbedded into
products that respond
to changes in UV light.
Novelty goods
Sunglasses
Glass windows
buildings
Nitinol
Shape memory alloy
The shape of the metal
is set at 500 degrees.
The metal can bedeformed and will
always return to its
original shape when
heat is applied of 70
degrees.
Frames for glasses
Dental braces
Fire sprinklers
Heat
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Composite materials
Composite materials are produced by combining two or more different materials to create
an enhanced material.
Two examples that you need to know about are:
Both are based on a matted or woven material that is combined with a thermosetting plastic to produce
very lightweight and very strong composites.
Material
GRP
Glass Reinforced Plastic
CFRP
Carbon fiber reinforced plastic
Properties
Used to make complex shapes
Colours can be easily added –
pigmented
Lightweight - good strength to
weight ratio
Good corrosion resistance
Good chemical resistance
Good heat resistance
labour intensive to produce parts –
expensive
Very high strength to weight ratio
Good tensile strength
Stiff and rigid
Very expensive
Good heat and chemical resistance
Very labour intensive
Uses
Boat Hulls
Truck body parts
Storage tanks
Motorbike helmets
Seating
Supercars and sports cars; parts
Top-end sporting equipment
Bespoke boats and yachts
Prophetic limbs
Glass reinforced plastic (GRP)
Glass –reinforced plastic is fibre glass mixed with Resin – which is a thermosetting plastic that comes in a
liquid form.

107. Carbon fibre reinforced plastic (CFRP)
strands of carbon fiber mixed with Resin
Why is Polyester Resin used in the moulding process of carbon fiber parts?
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108.
Task. Link the key words to the pictures: Woven Carbon Fibre.
Liquid polyester resin. Mould
Activity Although the processes do vary slightly from each other, the basic principles are the same:
1 . Prepare a mould or former for the required shape
2. Apply release agent to the mould or former
3. Apply the first resin coat (or gel coat for GRP) to the mould or former
4. Apply the GRP matting or woven carbon fibre sheet on top of the first coat
5. Apply another coat of resin and work into the material
6. Repeat stages 4 and 5 until the required thickness of material is achieved
7. Seal the workpiece in a vacuum bag and place in an oven for the resin to cure. (The workpiece could
alternatively be clamped and left to cure naturally in a workshop.)
8. Release the workpiece from the mould or former
9. Trim and finish the workpiece
109.
Explain why carbon fiber parts are so expensive
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110.
Discuss why carbon fiber is a suitable material for a proshetic limb
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Lesson 15
Do Now.
111.
Why is it difficult to recycle many composite materials?
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112.
Softwoods
Complete the table below from memory – here’s one to start you off.. COPPER
Hardwoods
Manufactured
boards
Ferrous metals
Non – ferrous
metals
Alloys
Main lesson conent.
Technical textiles
A technical textile is one which has been developed with enhanced properties to withstand specific uses.
The function is often vastly more important than the aesthetic qualities of the material. The following
technical textiles perform specific roles and because of the research and development involved in
creating them, they can often be perceived as expensive.
Many technical textiles perform their function owing to the special way they have been manufactured
and in many cases, the way they have been spun and woven.
How fibers can be spun to make enhanced fabrics e.g., conductive fabrics, fire resistant fabrics, Kevlar and
microfibers incorporating micro encapsulation.
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Kevlar®
Kevlar® is a fiber developed by DuPont™ that has high tensile strength, has great heat resistance and is
extremely hard-wearing. It is a flexible and lightweight synthetic fiber from the class of fibers known as
aramids which are modified polyamide (nylon) fibers. Kevlar® is used for many applications including body
armour and personal protective equipment for use in hazardous situations. It has also been found to have
useful acoustic properties and is used in the production of quality loudspeakers and some
Material
Properties
Uses
Kevlar
Extremely strong and hard wearing
Excellent cut and tear resistance
High thermal protection
Non – flammable
Good chemical resistance
Very high Tensile strength
Personal armor
Helmets
Bullet proof vests
Motor cycle safety clothing
Extreme sports equipment
113.
What is Kevlar made from?
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114.
Explain how Kevlar is made to get its superior strength
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115.
Discuss why Kevlar is a suitable material to be used for Motor Cycle gloves.
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Fire resistant fabrics
Heat and flame resistant fabrics such as Nomex® and Kevlar® have been developed to withstand high temperatures
and reduce combustion when exposed to a naked flame. There are many different brands of fabric that have
differing levels of heat and flame protection. Most of these fabrics are based on a group of synthetic fibres known as
aramid fibres. They are generally very strong and heat-resistant.
Flame retardants are different and can be applied to a range of regular fabrics, in particular, curtains and sofa
fabrics. They are designed to produce a chemical reaction that slows down and even stops ignition taking place.
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116.
Explain the difference between Fire resistant and Flame retardant
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Conductive fabrics
Also known as e-textiles, these highly conductive threads and fabrics allow an electrical signal to pass through them
with very little resistance. The fabric can be used in strips so as to create paths for electricity to flow along,
connecting components such as LEDs, headphones and microphones. It is even possible to remotely connect a
smartphone in an inside coat pocket to controls on a cuff or a pair of gloves. Connective thread is effectively single
strands of conductive material that can be sewn onto or into non-conductive fabrics to create an electrical pathway
or circuit; handy for connecting individual components.
117.
Explain how conductive fibres could be used in a motor cycle helmet
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118.
Natural fibres
Complete the following table
Sythetic Fibres
Smart Materials
Modern Material
Technical Textiles
END OF UNIT
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Key terms glossary
Alloy; a mixture of two or more metals, or a metal mixed with one or more elements.
Anthropometrics; human body measurement data.
Automation; the use of mechanics to do a task automatically without much, or any human input.
Batch production; the production method used to make a specific quantity (a batch) of identical products.
CAD/CAM; computer aided design/manufacture. Designing and manufacturing using a computer.
Carbon footprint; The amount of greenhouse gases released into the atmosphere by making, using and eventually
reusing, recycling or disposing of something at the of its lifetime.
Composite; A material made by bonding two or more different materials together.
Continuous production; the production used to make large amounts of a product non-stop.
Corrosion; The gradual destruction the gradual destruction of a material as it reacts with a substance e.g. rusting of
iron.
Deforestation; cutting down large areas of forest without planting new trees to replace the old ones.
Design brief; the instructions that a client gives to a designer about what they want a product to be like.
Design specification; a list of criteria that a product should meet.
Ergonomic; A product that is easy and comfortable for people to use.
Ferrous metal; a metal or alloy that contains iron.
Fibre; a thin, hair-like strand. Fibres can be spun into yarn, or used as they are, to make fabrics.
Finite resources; a resource that will run out eventually e.g. crude oil. Also called non-renewable resources.
Flexible manufacturing systems (FMS); a set of different machines which carry out the different stages of
production. These computer-based controlled, automated systems are designed to be easy to adapt: can be
retooled, recalibrated, and reprogrammed.
Hardwood; a type of wood that comes from slow-growing trees with broad leaves (mainly deciduous trees). It’s
usually denser and harder than softwoods – usually but not always.
Integrated circuit (IC); a tiny, self-contained circuit which can contain billions of components.
Iterative design; a design strategy that involves constantly evaluating and improving a product’s design.
Lean manufacturing; An approach to manufacturing that aims to minimise to resources used and waste produced.
Manufactured board; a material made by compressing a mixture of glue and processed pieces of wood into panels.
Manufacturing specification; a series of written statements, or working drawings and a sequence of diagrams, that
tells the manufacturer exactly how to make the product.
Market pull; when a product is made due to consumer demand.
Market research; asking the target market questions to find out their likes/dislikes, needs and wants, to help the
designer understand what the target group wants from a product.
Marking out; making a mark in a material to show where it is to be cut, drilled or bent.
Mass-production; the production method used to produce a large number of identical products on an assembly line.
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Microcontroller; a type of integrated circuit that can be programmed. Works as a mini-computer.
Modern material; a material that has been developed for a specific application. They are often developed through
the innovation of a new process or the improvement of an existing one.
Natural fibre; a type of fibre that is harvested from natural sources e.g. plants and animals. Wool and Silk
Non-ferrous metal; a metal or allow that doesn’t contain iron.
Non-finite resources; a resources that can be replaced by natural processes as fast as it’s consumed by humans e.g.
softwood trees plantation. Also called renewable sources.
Non-woven fabric; a fabric made from layers of fibres (not yarns) held together by bonding or felting.
One-off production; production method used to produce a single, unique product at a time.
Orthographic projection; a 2D scale drawing of a 3D object showing the front, plan (top) and end (side) views.
Planned obsolescence; when a product is designed to become useless quickly, e.g. a disposable razor.
Printed circuit board (PCB); a board with copper tracks that connect components in a circuit.
Product analysis; Examining and disassembling a current product to get ideas for a new product or design.
Production aid; a tool or technique used to speed up, simplify or help control the accuracy of a production process.
Prototype; A full-size, fully functioning product or system. It is built so that the product and production methods can
be evaluated before the product is manufactured on a larger scale.
Quality control; the checks that are carried out on a sample of materials, products or components throughout the
production to make sure standards are being met.
Seasoning; the drying of wood to make it stronger and less likely to rot or twist.
Smart material; a material that changes its properties in response to stimuli (a change in the environment).
Softwood; a type of wood that comes from fast-growing trees with needle-like leaves (mainly evergreen trees). It’s
usually less dense and softer than hardwoods.
Standard components; Common fixings and parts that manufactures buy instead of manufacturing themselves –
making the production process quicker. Bike manufactures only design and manufacture the frame and buy the rest
of the parts in.
Stock forms; the different shapes that materials can be bought in – metals and woods – large sheets of wood boards
(MDF and Plywood).
Sustainable; a sustainable process or material is one that can be used without causing permanent damage to the
environment or using up finite resources.
Synthetic fibre; a man-made fibre that is produced from polymers (plastics) – polymer is plastic.
System; a collection of parts that work together to do a particular function. Made up of inputs, processes and
outputs.
Technology push; when advances in technology drive the design of new products and the redesign of old ones.
Thermoforming plastic; a type of plastic that can be melted and remoulded over and over again.
Thermosetting plastic; a type of plastic that undergoes a chemical change when heated, which makes it
permanently hard and rigid. Thermosetting plastics can’t be remoulded.
Tolerance; a margin of error allowed for a measurement of part of a product. Tolerances are usually given as an
upper and lower limit e.g. 23mm (+/- 2).
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Woven fabric; a fabric made by interlacing two sets of yarn.
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