GCSE D&T Materials Cheat Sheet — Properties, Uses and Examples
GCSE D&T Materials Cheat Sheet — Properties, Uses and Examples
Materials knowledge is the backbone of GCSE Design and Technology. Whether you are sitting AQA, Edexcel, or OCR, every exam board expects you to know the properties, typical applications, and working characteristics of a wide range of materials across all categories. On AQA 8552 alone, material selection questions appear on virtually every Paper 1 -- and they are among the most straightforward marks available if you have done the groundwork.
This guide covers every material category on the specification, with properties, uses, and comparison tables you can use as a revision reference.
Key Material Properties — Definitions
Before diving into specific materials, make sure you can define these properties precisely. Examiners reward correct use of technical vocabulary.
| Property | Definition |
|---|---|
| Hardness | Resistance to scratching, cutting, or indentation |
| Toughness | Ability to absorb energy and deform without fracturing |
| Malleability | Ability to be permanently deformed (shaped) by compression without cracking |
| Ductility | Ability to be stretched or drawn into wire without breaking |
| Elasticity | Ability to return to original shape after deformation |
| Tensile strength | Resistance to being pulled apart (tension) |
| Compressive strength | Resistance to being crushed (compression) |
| Conductivity | Ability to transfer heat or electricity |
| Density | Mass per unit volume -- how heavy a material is for its size |
| Absorbency | Ability to take in and hold moisture |
| Corrosion resistance | Ability to resist degradation from chemical reactions with the environment |
Papers and Boards
Papers and boards are used for packaging, modelling, and graphic products. They are classified by weight -- paper is typically below 200 gsm (grams per square metre), while board is 200 gsm and above.
| Material | Properties | Typical Uses |
|---|---|---|
| Cartridge paper | Slightly textured surface, good for pencil and ink work, available in various weights (100-150 gsm) | Sketching, drawing, watercolour painting, design development work |
| Layout paper | Thin, semi-translucent, smooth surface, low cost | Tracing, overlay work, rapid idea generation, marker rendering |
| Corrugated card | Lightweight yet strong due to fluted inner layer, good cushioning properties | Packaging, transit boxes, point-of-sale displays, modelling |
| Foam board | Lightweight rigid board with a foam core sandwiched between card surfaces, easy to cut cleanly | Architectural models, presentation boards, display stands, mounting |
| Mount board | Thick, rigid card available in many colours, smooth surface, clean edges when cut | Picture framing, presentation mounting, high-quality models |
| Duplex board | Two layers bonded together (one side often coated white), good printability | Food packaging (cereal boxes), book covers, cartons |
| Solid white board | High-quality board with a smooth white finish on both sides, excellent print surface | Premium packaging, cosmetics boxes, pharmaceutical packaging |
Timbers
Timbers fall into three categories: hardwoods, softwoods, and manufactured boards. Despite the names, hardwoods are not always harder than softwoods -- the distinction is botanical. Hardwoods come from deciduous (broad-leaved) trees, and softwoods come from coniferous (needle-leaved) trees.
Hardwoods
| Timber | Properties | Typical Uses |
|---|---|---|
| Oak | Very hard and tough, attractive grain, durable, good resistance to moisture, heavy | Furniture, flooring, boat building, outdoor structures |
| Mahogany | Medium hardness, easy to work, attractive reddish-brown colour, good finish | High-quality furniture, veneers, musical instruments, interior joinery |
| Beech | Hard and tough, fine even grain, prone to warping, not suitable for outdoor use | Furniture, children's toys, tool handles, steam bending |
| Ash | Tough and flexible, absorbs shock well, straight grain, good for bending | Sports equipment (cricket stumps, hockey sticks), tool handles, furniture |
| Balsa | Extremely lightweight and soft, very low density, easy to cut with a craft knife | Model making, prototyping, lightweight structures, insulation |
Softwoods
| Timber | Properties | Typical Uses |
|---|---|---|
| Pine (Scots pine) | Relatively soft, easy to work, light colour with visible knots, widely available, inexpensive | Construction framing, interior furniture, shelving, cladding |
| Spruce | Light, strong for its weight, straight grain, slightly harder than pine, resonant | Construction, aircraft, musical instruments (soundboards), paper pulp |
| Cedar (Western red cedar) | Lightweight, naturally resistant to rot and insect attack, attractive reddish colour, aromatic | Outdoor cladding, fencing, decking, garden furniture, sheds |
| Larch | Tough and durable for a softwood, naturally resistant to rot, attractive grain | Exterior cladding, fencing, boat planking |
Manufactured Boards
Manufactured boards are made from processed wood. They are available in large, uniform sheets, are generally cheaper than solid timber, and are less prone to warping.
| Board | Composition | Properties | Typical Uses |
|---|---|---|---|
| Plywood | Thin layers (veneers) of wood glued with grains at right angles | Very strong, resists warping, available in marine-grade, good structural properties | Furniture backs, flooring, boat hulls, structural panels |
| MDF (Medium Density Fibreboard) | Fine wood fibres bonded with resin and compressed | Smooth surface ideal for painting, easy to machine, no grain direction, produces harmful dust when cut | Furniture, cabinets, shelving, decorative mouldings |
| Chipboard | Wood chips and particles bonded with resin | Inexpensive, weaker than plywood and MDF, swells if exposed to moisture, often veneered or laminated | Flat-pack furniture, kitchen worktops (when laminated), flooring |
| Hardboard | Very fine wood fibres compressed at high pressure | Thin, dense, one smooth side and one textured, lightweight | Drawer bottoms, cabinet backs, templates, door panels |
Metals
Metals are divided into ferrous metals (containing iron) and non-ferrous metals (not containing iron). Alloys are mixtures of two or more metals, or a metal and another element, combined to improve properties.
Ferrous Metals
| Metal | Composition | Properties | Typical Uses |
|---|---|---|---|
| Mild steel | Iron + 0.1-0.3% carbon | Tough, ductile, malleable, relatively inexpensive, poor corrosion resistance (rusts), magnetic | Car bodies, structural steel, nuts and bolts, general fabrication |
| Stainless steel | Iron + chromium (min 10.5%) + nickel | Excellent corrosion resistance, hard, tough, difficult to work, more expensive than mild steel | Cutlery, kitchen sinks, surgical instruments, food processing equipment |
| Cast iron | Iron + 2-4% carbon | Very hard, brittle, excellent compressive strength, good vibration damping, can be cast into complex shapes | Engine blocks, manhole covers, vices, railings, cooking pans |
| High carbon steel | Iron + 0.6-1.4% carbon | Very hard, can be hardened and tempered, less ductile, brittle if not heat-treated properly | Cutting tools, chisels, springs, drill bits |
Non-Ferrous Metals
| Metal | Properties | Typical Uses |
|---|---|---|
| Aluminium | Lightweight, good corrosion resistance (forms protective oxide layer), good conductor of heat and electricity, soft and malleable, low density | Aircraft bodies, drinks cans, cooking foil, window frames, bicycle frames |
| Copper | Excellent electrical and thermal conductor, malleable, ductile, antimicrobial, develops green patina (verdigris) over time | Electrical wiring, plumbing pipes, roofing, printed circuit boards |
| Brass (alloy: copper + zinc) | Gold-coloured, hard-wearing, good corrosion resistance, can be cast and machined, not magnetic | Door handles, musical instruments, decorative fittings, plumbing connectors |
| Zinc | Low melting point, good corrosion resistance, relatively soft | Galvanising steel, die casting, batteries, roofing |
| Tin | Very low melting point, non-toxic, soft, excellent corrosion resistance | Tin plating (tin cans), soldering alloys, food-safe coatings |
Polymers
Polymers are divided into thermoplastics (can be reheated and reshaped repeatedly) and thermosetting polymers (set permanently during moulding and cannot be reshaped).
Thermoplastics
| Polymer | Properties | Typical Uses |
|---|---|---|
| Acrylic (PMMA) | Transparent, hard, scratch-resistant, good weather resistance, can be laser cut and heat formed, brittle compared to polycarbonate | Display cases, signs, light fittings, baths, protective screens |
| HDPE (High Density Polyethylene) | Stiff, strong, chemical resistant, good impact resistance, lightweight, recyclable | Bottles, pipes, crates, playground equipment, chopping boards |
| PET (Polyethylene Terephthalate) | Transparent, lightweight, good barrier properties, recyclable, tough | Drinks bottles, food packaging, synthetic textile fibres (polyester) |
| ABS (Acrylonitrile Butadiene Styrene) | Tough, impact resistant, good surface finish, can be injection moulded and 3D printed, opaque | LEGO bricks, electronic housings, car dashboards, helmets |
| Polypropylene (PP) | Lightweight, flexible, fatigue resistant (living hinges), chemical resistant, recyclable | Food containers, bottle caps, living hinges, rope, medical equipment |
| HIPS (High Impact Polystyrene) | Rigid, inexpensive, good for vacuum forming, lightweight, can be printed on | Packaging, yoghurt pots, CD cases, vacuum-formed trays |
| PVC (Polyvinyl Chloride) | Rigid or flexible (with plasticisers), chemical resistant, durable, self-extinguishing | Pipes, window frames (rigid), cable insulation, clothing (flexible) |
| Nylon (Polyamide) | Tough, hard-wearing, low friction, self-lubricating, good chemical resistance | Gears, bearings, combs, textiles, cable ties, hinges |
Thermosetting Polymers
| Polymer | Properties | Typical Uses |
|---|---|---|
| Epoxy resin | Very strong adhesive, excellent chemical resistance, hard, can be reinforced with fibres, brittle alone | Adhesives, GRP (fibreglass) matrix, circuit board coating, surface coatings |
| Melamine formaldehyde | Very hard, heat resistant, scratch resistant, hygienic, good electrical insulator | Kitchen worktop laminates, children's tableware, electrical fittings |
| Polyester resin | Hard, can be reinforced with glass fibre, weather resistant, brittle alone, cheaper than epoxy | Boat hulls (GRP), car body panels, casting, encapsulation |
| Urea formaldehyde | Hard, brittle, good electrical insulator, heat resistant, can be moulded with wood flour filler | Electrical fittings (plug sockets), MDF adhesive, toilet seats |
Textiles
Natural Fibres
| Fibre | Source | Properties | Typical Uses |
|---|---|---|---|
| Cotton | Seed head of the cotton plant | Soft, absorbent, breathable, comfortable, strong when wet, creases easily, biodegradable | T-shirts, jeans, bed sheets, towels, underwear |
| Wool | Fleece of sheep | Warm, elastic, naturally flame retardant, absorbent, felts easily, can shrink in hot water | Jumpers, suits, carpets, blankets, insulation |
| Silk | Cocoon of the silkworm | Very strong for its weight, lustrous, smooth, comfortable, expensive, drapes well | Formal clothing, ties, scarves, linings |
| Linen | Stem of the flax plant | Strong, cool to wear, absorbent, creases easily, more expensive than cotton | Summer clothing, tablecloths, furnishing fabric |
Synthetic Fibres
| Fibre | Properties | Typical Uses |
|---|---|---|
| Polyester | Strong, crease resistant, quick drying, lightweight, recyclable (from PET bottles), blends well with cotton | Sportswear, workwear, furnishing fabrics, fleece, bottle-to-fibre recycling |
| Nylon | Very strong, lightweight, elastic, abrasion resistant, low absorbency, quick drying | Tights, waterproof jackets, rucksacks, parachutes, rope |
| Elastane (Lycra/Spandex) | Extremely elastic (can stretch 5-8 times its length), lightweight, blended with other fibres for stretch | Sportswear, swimwear, underwear, stretch denim |
| Acrylic | Soft, warm, lightweight, resistant to moths and chemicals, less durable than wool | Knitwear, fake fur, blankets, carpets |
Properties Comparison Summary
This table compares general property levels across material categories. Use it for quick reference when answering material selection questions.
| Property | Hardwoods | Softwoods | Ferrous Metals | Non-Ferrous Metals | Thermoplastics | Thermosets | Natural Textiles | Synthetic Textiles |
|---|---|---|---|---|---|---|---|---|
| Hardness | Medium-High | Low-Medium | Medium-High | Low-Medium | Low-Medium | High | N/A | N/A |
| Toughness | High | Medium | High | Medium-High | Medium-High | Low (brittle) | Medium | High |
| Malleability | Low | Low | High | High | High (when heated) | None | N/A | N/A |
| Ductility | N/A | N/A | High | High | Medium (when heated) | None | N/A | N/A |
| Thermal conductivity | Low | Low | High | High | Low | Low | Low | Low |
| Electrical conductivity | None | None | High | High | None | None | None | None |
| Density | Medium-High | Low-Medium | High | Low-High | Low | Low-Medium | Low | Low |
| Corrosion resistance | Low (rots) | Low (rots) | Low (rusts) | Medium-High | High | High | Low (biodegrades) | High |
Common Exam Question Patterns
Material questions follow predictable patterns. Here are the types you should practise:
"Identify a suitable material for... and justify your choice." Name a specific material (not just "metal" or "plastic"), then link two or three of its properties directly to the requirements of the product. For example: "Stainless steel would be suitable for a kitchen utensil because it has excellent corrosion resistance, meaning it will not rust when washed, and it is food-safe and hygienic."
"Explain the difference between hardwoods and softwoods." The distinction is botanical, not about hardness. Hardwoods come from broad-leaved deciduous trees, softwoods from coniferous trees. Give an example of each.
"Explain why a manufacturer might choose a manufactured board over solid timber." Key points: available in large uniform sheets, cheaper than solid timber, less likely to warp or split, consistent properties throughout, can be veneered for an attractive finish.
"Compare thermoplastics and thermosetting polymers." Thermoplastics can be reheated and reshaped because their polymer chains are held by weak intermolecular forces. Thermosetting polymers undergo a chemical change during moulding, forming permanent cross-links between chains, so they cannot be reshaped.
"Explain why aluminium is used for drinks cans." Lightweight (easy to transport), non-toxic (food-safe), good corrosion resistance, malleable (can be pressed into shape), recyclable (reduces environmental impact).
Revising Materials Effectively
The volume of material knowledge required for D&T can feel overwhelming. The most effective approach is to revise one material category at a time, and for each material, learn the same four things: what it is made from, its key properties, what it is used for, and how it is typically worked or processed.
Flashcards work exceptionally well for materials revision. Write the material name on one side, and on the reverse list its properties, uses, and one or two exam-style sentences justifying its selection for a product. Test yourself daily.
LearningBro courses break materials into focused modules with exam-style questions attached to each topic, so you can test your knowledge immediately after learning. This active recall approach -- learning then testing in quick succession -- is one of the most effective ways to commit material properties to long-term memory.
Invest the time in materials knowledge now, and you will find that material selection questions become some of the easiest marks on the paper.