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DescriptionA rack which could be used to hold newspapers,magazines, books etc. Supplied as two identicalsides, flat packed.

MaterialsSides - birch plywoodRods - polished steel

Process of manufactureSides - mitre joint / gluedRods - extruded

Method of assemblyRods to sides - push fitSides - slotted together

Questions ?1 Explain the advantages of using plywood insteadof solid timber for the manufacture of the sides.

2 Describe the processes which have been usedto manufacture the rack sides.

3 Describe the aesthetics of the rack in terms ofbalance, proportion and texture.

4 State a suitable finish for the rack parts andexplain why it may be necessary.

5 State an alternative material which could havebeen used to manufacture the rack sides andexplain the process which would be used with thismaterial.

6 This product has been designed as a ‘magazinerack’. Describe how the rack could be used aspart of another, different product. Sketches shouldbe used in your answer.

AssignmentWhen built, the rack sits at a fixed angle giving ita wide vee shape.Produce a design solution which would allow therack to have either an adjustable angle or anoption of three possible f ixed angles.

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DescriptionA chair for children available in a range of primarycolours.

Materials All parts - polypropylene

Process of manufactureAll parts - injection moulding

Method of assemblyRails to back rest and seat - push fitLegs to seat - push fit

Questions ?1 Explain why primary colours have been usedin the design of the chair .

2 State three properties of polypropylene whichmake it a suitable material for this product.

3 Describe the process of injection moulding.Sketches should be used in your answer.

4 State two alternative materials which could havebeen used in the manufacture of the chair.

5 Describe two ways in which the designer couldhave obtained the relevant sizes required for thedesign of the chair.

AssignmentIt is decided to produce an alternative chair of thesame type but with armrests.Produce a design solution for an identical chairbut with armrests.

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DescriptionIce cube tray in a variety of colours. Very flexibleto allow for easy removal of ice cubes. Comeswith a rigid holder.

MaterialsTray - SEBSHolder - PCCO

Process of manufactureTray - injection mouldingHolder - injection moulding

Method of assemblyTray is placed in holder.

Questions ?1 Explain why SEBS was chosen as the materialfor this product ?

2 Describe the process of injection moulding.Sketches should be used in your answer.

3 Describe the ice cube tray in terms of its aestheticappeal and state its possible market niche.

4 The tray could have been manufactured fromaluminium. State and describe the process whichcould have been used to manufacture the tray inaluminium.

AssignmentThe ice cube tray has been selected as a productfor possible redesign.State and justify three aspects of the design whichcould be evaluated.Describe the strategies which could be used toevaluate these three aspects.

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DescriptionA modern looking chair in two materials. Noticethe pattern and translucent effect of the seat allowsyou to see the positioning of the legs underneath.

MaterialsSeat - polypropyleneFixing plate - polypropyleneLegs - aluminium

Process of manufactureSeat - injection mouldingFixing plate - injection mouldingLegs - extrusion / formed

Method of assemblyLegs to legs - boltsLegs to seat - clamped by fixing plate/screwed

Questions ?1 Explain which properties of aluminium make ita suitable choice for this product.

2 Describe the process of extrusion. Sketchesshould be used in your answer.

3 State three ergonomic factors which the designerwould have considered when designing the chair.

4 The two materials used in the manufacture ofthe chair can both be recycled. What are thebenefits to society of recycling and why is itnecessary?

AssignmentIt has been decided to produce a version of thechair with an all aluminium seat. The ‘solid’ seatdesign however is both heavy and uses a largeamount of material. Produce a design solution forthe seat which will eliminate the weight andmaterial problems.

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DescriptionA food grater with a number of possible gratingsizes.

MaterialsGrater - stainless steelHandle - stainless steel

Process of manufactureGrater - pierced, blanked and formedHandle - cut and formed

Method of assemblyHandle to grater - welded

Questions ?1 Safety was an important factor in the design ofthe grater. State two safety aspects which wouldhave been considered and explain why they areimportant for this product.

2 Explain three properties of stainless steel whichmake it a suitable choice for the manufacture ofthe grater.

3 Describe two aspects of the design where thedesigner will have to use anthropometric data.

4 State two methods the designer could use toobtain this data.

5 The designer would also have consideredphysiology in the design of the grater. Describean aspect of the design which would require thedesigner to consider physiology.

AssignmentIt is decided that the introduction of wood into thedesign of the grater will widen its appeal.Produce a design solution which will use birchplywood for the handle of the grater.

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DescriptionA small rotating castor which could be fixed to avariety of products by means of four screws orbolts.

MaterialsWheel - low density polyethyleneAxle bracket - steelCup - steelFixing plate - steel

Process of manufactureWheel - injection mouldingAxle bracket - pierced,blanked and formedCup - pierced, blanked and formedFixing plate - pierced, blanked and formed

Method of assemblyWheel to axle bracket - steel pinAxle bracket to cup - captivated to allow rotationCup to fixing plate - riveted over

Questions ?1 Explain which properties of low densitypolyethylene make it a suitable choice for themanufacture of the wheel.

2 Describe the process of piercing and blanking.Sketches should be used in your answer.

3 State a suitable finish for steel used in the castorand explain why it is necessary.

AssignmentThe castor is to be redesigned to fit onto the endof a 50mm diameter beech table leg.Produce a design solution which will allow thecastor to fit securely on to the leg.

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DescriptionA mesh bowl with a variety of uses from holdingfruit to acting as a waste paper bin.

MaterialsTop/bottom rim - aluminiumSide/base - aluminium

Process of manufactureTop/bottom rim - pierced, blanked and formed.Side/base - cut and stretched

Method of assemblyRims to side/base - crimped

Questions ?1 Describe two advantages of the method ofmanufacture for the side/base over using apierced/blanked sheet.

2 State two properties of aluminium which makeit suitable for this product.

3 Aluminium can be recycled. State two advantagesto the consumer of recycling products.

4 Explain the difference between the reuse andthe recycling of a product.

5 This bowl is made solely from aluminium.Statetwo other product made solely from aluminium .

6 Describe two tests which could be carried outon a product to establish whether or not it wasmade from aluminium.

7 Describe the bowl using four aesthetic terms.

8 Explain the effect on the cost/aesthetics of thebowl, if the rims had been manufactured in brass.

AssignmentIn order to widen market appeal the bowl is to beredesigned as a basket. This will mean the additionof a carrying handle to the original design.Produce a design solution for the basket handle.

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DescriptionThis peeler, used for peeling foods such aspotatoes and apples is available with handles ina variety of colours.

MaterialsBlade - stainless steelHandle - ABS

Process of manufactureBlade - pierced, blanked and formedHandle - injection moulding

Method of assemblyBlade moulded into handle.

Questions ?1 Aesthetics and fashion are closely linked. Forthis product describe the aesthetic styling whichprove this to be the case.

2 The blade of the peeler has been moulded intothe handle. From your knowledge of injectionmoulding, describe how this would have beendone. Use sketches in your answer.

3 User trials were conducted with the peeler beforeit went into production. State two aspects of thepeeler where user trials would have proved useful.

4 Explain how the designer would have used theinformation obtained form the user trials.

AssignmentIt is decided that due to the popularity of the peelera ‘set’ will be produced comprising of the peeler,a bottle opener and a small hand whisk.Produce design solutions for the bottle openerand hand whisk incorporating the original peelerhandle.

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DescriptionA traditional cast pot stand used in the kitchen forprotecting surfaces from hot objects such ascooking pots and tea pots.

MaterialsStand - cast iron

Process of manufactureStand - sand cast

Method of assemblyNon

Questions ?1 Some products are often used in ways whichthe designer did not intend. Describe two ways inwhich this pot stand could be used apart from itsintended function.

2 Describe the process of sand casting. Sketchesshould be used in your answer.

3 State two properties of cast iron which make itsuitable for the pot stand.

4 Explain, with reference to psychology andaesthetics why black has been chosen for thefinish of this product.

AssignmentThe pot stand is to be redesigned with feet whichwill raise it 50mm from the surface it is place on.Produce a design solution which will incorporatea number of feet and raise the stand by 50mm.

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DescriptionThis small box has a lift off lid and can be usedfor a variety of uses from holding herbs in thekitchen to jewellery in the bedroom.

MaterialsBox - hardwoodLid - hardwood

Process of manufactureBox - laminated then turnedLid - turned

Method of assemblyLid placed on box

Questions ?1 Describe the process used to manufacture thebox and lid, sketches should be used in youranswer.

2 State two aspects of the design where thedesigner would have considered anthropometrics.

3 Explain the importance of these aspects in thedesign of the box and lid.

4 The box and lid could have been manufacturedin aluminium. State and describe the processwhich would have been used.

AssignmentMarket research has revealed that the loose fittinglid is not suitable for certain uses of the box.Produce a design solution which will keep the lidfirmly secured to the box.

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