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This lesson covers the specialist tools and equipment used when working with metals and polymers, as required by AQA GCSE Design and Technology (8552), Section 3.2.8. You must know the correct tools for marking out, cutting, shaping, joining and finishing both metals and polymers.
| Tool | Use |
|---|---|
| Scriber | Scratching fine lines on metal surfaces (more accurate than pencil) |
| Engineer's square | Checking and marking 90° angles on metal |
| Centre punch | Creating a small indentation to prevent a drill bit from wandering |
| Odd-leg calipers | Scribing lines parallel to an edge |
| Dividers | Marking circles and arcs on metal |
| Surface plate | Providing a perfectly flat reference surface for marking out |
| Tool | Use | Example |
|---|---|---|
| Hacksaw | Cutting metal bar, rod and sheet by hand | Cutting mild steel rod for a candle holder |
| Junior hacksaw | Cutting small sections of thin metal and wire | Trimming brass rod |
| Tin snips (aviation snips) | Cutting thin sheet metal | Cutting aluminium sheet for a phone stand |
| Bandsaw (metal-cutting) | Cutting thick sections of metal | Cutting steel bar stock |
| Abrasive disc cutter | Fast cutting of metal sections | Cutting steel tube for a bike rack |
| Plasma cutter | Cutting metal sheet using an ionised gas arc | Cutting steel plate in industry |
| Tool | Use |
|---|---|
| Centre lathe | Turning metal to produce cylindrical shapes (shafts, spindles) |
| Milling machine | Cutting flat surfaces, slots and complex profiles in metal |
| Metal files (flat, half-round, round, triangular) | Hand finishing and shaping metal to size |
| Ball-peen hammer and stake | Shaping sheet metal by hand (planishing, raising) |
| Bending jig / folding bars | Creating accurate bends in sheet metal or bar |
| Fly press | Punching holes and pressing shapes in sheet metal |
AQA Exam Tip: A common 3-mark question is: "Describe how you would mark out and drill a hole in a piece of mild steel." The expected answer: mark the position with a scriber, use a centre punch to create an indent, then drill using a pillar drill at the correct speed with the workpiece clamped in a machine vice.
| Method | Tools/Equipment | Suitable Metals |
|---|---|---|
| Soldering | Soldering iron, solder, flux | Copper, brass, tin plate, electronic components |
| Brazing | Brazing hearth, brazing rod, flux, blowtorch | Steel, brass, copper |
| Welding (MIG) | MIG welder, wire feed, shielding gas | Mild steel, stainless steel, aluminium |
| Riveting | Rivet gun (pop riveter), rivets | Aluminium, steel sheet |
| Nuts and bolts | Spanners, socket sets | All metals (temporary/permanent joint) |
| Adhesive bonding | Epoxy resin (Araldite) | All metals (where heat distortion must be avoided) |
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