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This lesson brings together everything you have learned about materials and their properties for AQA GCSE Design and Technology (8552), Section 3.1.6. It provides exam-style questions, model answers and material selection strategies.
| Category | Sub-categories | Key Examples |
|---|---|---|
| Papers & boards | Paper, board | Cartridge paper, corrugated card, foam board, mount board, duplex board |
| Timber | Hardwood, softwood, manufactured board | Oak, beech, pine, cedar, plywood, MDF, chipboard |
| Metals | Ferrous, non-ferrous, alloys | Mild steel, stainless steel, cast iron, aluminium, copper, brass, pewter |
| Polymers | Thermoplastics, thermosets | Acrylic, PP, HDPE, PET, ABS, nylon, epoxy, melamine, polyester resin, UF |
| Textiles | Natural fibres, synthetic fibres | Cotton, wool, silk, linen, polyester, nylon, acrylic, elastane |
Q: Name the category of material (ferrous metal, non-ferrous metal, thermoplastic, thermosetting polymer, hardwood, softwood, manufactured board) for each of the following: (a) Acrylic (PMMA) (b) Oak
Model Answer: (a) Thermoplastic (1) (b) Hardwood (1)
Q: Define the following material properties: (a) Malleability (1 mark) (b) Toughness (1 mark) (c) Ductility (1 mark)
Model Answer: (a) Malleability is the ability of a material to be permanently deformed by compression (hammering, pressing, rolling) without cracking. (1) (b) Toughness is the ability of a material to absorb energy and resist fracture when subjected to impact or shock loading. (1) (c) Ductility is the ability of a material to be drawn (stretched) into a wire or thin shape without breaking. (1)
Q: A designer is creating a children's outdoor climbing frame. Recommend a suitable metal for the main structural tubes and justify your choice.
Model Answer: I would recommend mild steel (with a galvanised or powder-coated finish). (1)
Mild steel has high tensile strength, meaning the tubes will resist the pulling forces created when children hang and swing from the frame without deforming or breaking. (1)
Mild steel is also malleable and ductile, so the tubes can be bent and formed into the required shapes during manufacture. (1)
However, mild steel rusts when exposed to rain and moisture, so it must be galvanised (coated with zinc) or powder-coated (coated with a durable plastic finish) to protect it from corrosion in the outdoor environment. (1)
Q: Explain two differences between thermoplastics and thermosetting polymers. For each difference, give an example.
Model Answer:
Difference 1: Thermoplastics can be repeatedly heated and reshaped because they have weak intermolecular forces between their polymer chains. For example, acrylic can be heated with a strip heater and line-bent into a new shape. Thermosetting polymers cannot be reheated and reshaped because they have permanent cross-linked bonds. For example, melamine formaldehyde will char and decompose if overheated. (2)
Difference 2: Thermoplastics are recyclable — they can be melted down and reformed into new products. For example, PET bottles are recycled into polyester fleece fabric. Thermosetting polymers are not recyclable by melting because their cross-links cannot be broken. For example, epoxy resin in a carbon fibre composite cannot be melted and reused. (2)
Q: A furniture maker is designing a garden bench. Explain why they might choose Western Red Cedar rather than beech.
Model Answer: Western Red Cedar is naturally resistant to rot, decay and insect attack because it contains natural oils that act as preservatives. This means it can be used outdoors without requiring chemical treatment, reducing maintenance costs and environmental impact. (2)
In contrast, beech has poor outdoor durability — it is susceptible to rot when exposed to moisture and would need regular treatment with wood preservative to survive in a garden setting. (1)
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