01 Question Paper Jun 05 - Queen Katherine School

OXFORD CAMBRIDGE AND RSA EXAMINATIONS
Advanced GCE
D&T: PRODUCT DESIGN 2524/01
UNIT 7 Product Design 2
Papers 2524/01 and 2524/02 should be available to candidates for the full
2 hour 30 minutes examination session.
Tuesday 21 JUNE 2005 Afternoon 1 hour
This paper is to be taken with 2524/02 in the same examination session of 2 hours
30 minutes.
Additional materials:
Answer booklet
TIME Approximately 1 hour should be spent on this paper (Paper 2524/01)
INSTRUCTIONS TO CANDIDATES
This paper is to be taken with 2524/02 in the same examination session of 2 hours 30 minutes.
This paper (2524/01) contains seven questions.
• You are required to answer two questions.
• Please note that the instruction ‘discuss’ denotes that you should:
• Identify a range of relevant issues/points raised by the question;
• Explain why you consider these issues to be relevant;
• Use specific examples/evidence to support your answer.
INFORMATION FOR CANDIDATES
• The intended mark for each question or part question is given in brackets [ ].
• The total number of marks for 2524/01 is 48.
• All dimensions are in mm.
SP (CW/JG) S77053/2
This question paper consists of 8 printed pages.
© OCR 2005 [T/100/3469] Registered Charity Number: 1066969
[Turn over

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You are required to answer two questions.
Answer the questions in the separate answer booklet.
1 Fig. 1 shows a self-assembly computer workstation.
Fig. 1
(a) (i) Name two manufactured boards that could be used for this type of self assembly
furniture. [2]
(ii)
(iii)
Describe, using annotated sketches, how one of these boards has been constructed to
provide its strength. [2]
Describe, using annotated sketches, two ways in which the edges of manufactured
boards could be finished after being cut. [4]
(b) (i) Describe, using annotated sketches, two KD (knock-down) fittings used to join pieces of
self assembly furniture. [4]
(ii)
Explain how anthropometric data would be used in the design of a home-based
computer workstation. [4]
(c)
Discuss the factors that have influenced the increased availability of self-assembly furniture.
[8]
2524/01 Jun05

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2 Fig. 2 shows a bicycle frame.
Fig. 2
(a) (i) Name two specific metals that are used in the manufacture of bicycle frames. [2]
(ii) Give two reasons why metal bicycle frames often have a spray painted finish. [2]
(iii)
Use annotated sketches to identify two different forces that act within the bicycle frame,
shown in Fig. 2, when it is in use. [4]
(b)
Fig. 2 shows a metal bicycle frame where the components have been brazed together.
(i)
(ii)
Describe, using annotated sketches, how the frame would be set up prior to joining, to
ensure a consistency of shape. [4]
Describe, using annotated sketches, the brazing process used in the assembly of one of
the joints in the bicycle frame. [4]
(c)
Discuss the influence of modern materials on the development of high performance sports
equipment. [8]
2524/01 Jun05 [Turn over

3 Fig. 3 shows a plastic packet used to retail sandwiches.
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Fig. 3
(a) (i) Name two thermoplastics that are suitable for sandwich packets. [2]
(ii) Give two reasons why thermoplastics are suitable for sandwich packets. [2]
(iii)
In use, the packet shown in Fig. 3, was found to be too flexible and the contents were
often damaged.
Describe, using annotated sketches, two ways of stiffening the plastic packet. [4]
The sandwich packets are vacuum formed using a high volume continuous flow production
method.
(b)
Describe, using annotated sketches, how the sandwich packets could be vacuum formed
using a high volume continuous flow method. [8]
Many items of packaging are made from non-renewable resources.
(c) Discuss the environmental implications of using non-renewable resources. [8]
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4 Fig. 4 shows a design for a point of sale display made from card. The display includes a pop-up
mechanism.
‘pop up’
mechanism
pot rises
pull
pull
pull
tab pulled
down
POS display
Fig. 4
(a) (i) Name two printing processes that could be used to print this point of sale display in
colour. [2]
(ii) Give two reasons why companies use point of sale displays. [2]
(iii)
Give four reasons, other than cost, why board is a suitable material to produce a point of
sale display. [4]
(b) Describe, using annotated sketches, the construction of the pop-up mechanism shown in Fig. 4.
Include details of:
• Jointing techniques
• Guides
• Stops
• Surface detail [8]
(c)
Discuss the implications of using ICT during the development of publicity for a new product.
[8]
2524/01 Jun05 [Turn over

5 Fig. 5 shows a box used for washing machine powder.
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plastic
handle
Fig. 5
(a)
The box in Fig. 5 is made from duplex board.
(i) Draw a labelled cross section of duplex board. [2]
(ii) Give two reasons why duplex board is a suitable material to produce the box. [2]
(iii) Draw and label two printer’s marks used for quality control during the manufacture. [4]
(b)
(c)
Sketch, to suitable proportions, a net of the box shown in Fig. 5. Include all manufacturing
details. [8]
Discuss the implications for the design of packaging to enable a reduction in the volume of
disposable waste. [8]
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6 Fig. 6 shows a cotton towelling dressing gown.
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Fig. 6
(a) (i) Give three reasons why a cotton towelling fabric is suitable for a dressing gown. [3]
(ii)
(iii)
Cotton towelling is a looped pile fabric. Describe, using annotated sketches, the structure
of a looped pile fabric. [3]
Name two finishes which would enhance the performance of the dressing gown fabric.
[2]
(b)
Describe, using a detailed flow chart supported by annotated sketches, the order of making
and attaching one pocket to the dressing gown. [8]
(c) Discuss the implications of using recycled materials in the manufacture of textile products. [8]
2524/01 Jun05 [Turn over

7 Fig. 7 shows a sleeping bag with a ‘stuffsack’ for storage.
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sleeping bag
‘stuff sack’
Fig. 7
(a) (i) Name two fibres that could be used to make the outer fabric of the sleeping bag. [2]
(ii)
List three performance characteristics needed by the outer fabric of the sleeping bag.
[3]
(iii) Explain what is meant by the term ‘tog’ rating. [2]
(iv) Give one reason tog ratings are important to the consumer. [1]
(b)
(c)
Describe, using a detailed flow chart supported by annotated sketches, the order of
manufacture of the stuff sack. Include all pattern pieces and components. [8]
Discuss the impact of technological developments in the manufacture of textile products
designed for outdoor use. [8]
2524/01 Jun05