CLICK HERE FOR INDEX PAGE

  
     

 

V. Ryan © 2002 - 2010

  
     
 

RESISTANT MATERIALS STUDENTS/PUPILS SHOULD ALSO STUDY THE 'EQUIPMENT AND PROCESSES' SECTION OF THIS WEBSITE

  
     
 

MATERIALS

  
 

 

  
  WOODS  
 

1. An Introduction to Materials

  
 

2. Natural Woods

  
 

3. Manmade Boards

  
 

4. What is a Sustainable Forest?

  
     
 

5. Natural Woods in Detail

  
     
  PLASTICS  
 

6. Plastics

  
 
  METALS  
 

7. Metals

  
  8. Alloys  
 

9. Galvanising Steel - 1

  
 

10. Galvanising Steel - 2

  
     
  COMPOSITE MATERIALS  
  11. Natural Woods  
  12. Concrete  
  13. Reinforced Concrete  
  14. Glass Reinforced Plastic  
  15. Carbon Fibre Reinforced Polymer (CFRP)  
  16. Plywood  
     
  SMART MATERIALS  
 

17. Smart Materials - Polymorph - Shaping by Hand

  
 

18. Smart Materials - Polymorph - Using a Mould

  
 

19. Smart Materials - Shape Memory Alloys - Page One

  
 

20. Smart Materials - Shape memory Alloys - Page Two

  
 

21. Modern Light Weight Modelling Materials

  
     
  MODEL / PROTOTYPE  -  MATERIALS AND MANUFACTURE  
     
  Making a Model - Introduction  
  Model Making - Tools and Equipment - 1  
  Model Making - Tools and Equipment - 2  
  Model Making - Tools and Equipment - 3  
  Model Making - Tools and Equipment - 4  
     
  Modelling Materials - 1  
  Modelling Materials - 2  
  Sample Models  
  Card Based Models  
  Architectural Models  
  Computer Generated Models  
  Computer Generated Systems Model (Spreadsheets)  
     
  PDF FILE - Modelling Questions - 1  
     
 

JOINTS

  
 

 

  
 

1. Cross Halving Joints

  
 

2.Tee Halving, Dovetail Halving and Half Lap Joints

  
 

3. Bridle Joints

  
     
 

4. The Mortise and Tenon Joint - The Basics

  
 

5. Mortise and Tenon Joints - 1

  
 

6. Mortise and Tenon Joints - 2

  

7. Double / Twin Mortise and Tenon Joints
 

8. How to Mark Out and Cut a Mortise and Tenon Joint - the Mortise

  
 

9. How to Mark Out and Cut a Mortise and Tenon Joint - the Tenon

  
 

 

  
 

10. Dovetail Joints

  
 

11. How to Mark Out and Cut Dovetail Joints - The Tail

  
 

12. How to Mark Out and Cut Dovetail Joints - The Pins

  
 

13. Finger Joints

  
 

14. How to Mark Out and Cut a Set of Finger Joints - Part One

  
 

15. How to Mark Out and Cut a Set of Finger Joints - Part Two

  
 

16. Lapped / Rebate / Shoulder Joints

  
 

17. How to Mark Out and Cut a Rebate / Shoulder / Lapped Joint

  
     
 

QUESTIONS - JOINTS

  
     
 

1. Finger /Dovetail Joints - Questions

  
 

2. Tools Required for Cutting Finger / Dovetail Joints

  
     
 

SCREWS AND GLUES

  
   
 

1. Types of Screws - 1
 

2. Types of Screws - 2
 

3. Types of Nail
 

4. General Glues for Woods
 

5. How to Apply Cascamite
 

6. Glues for Plastics

  
 

7. Lesson Starter - Glues

  
     
  HINGES  
     
  1. Types of Hinges  
     
  KNOCK DOWN FITTINGS  
     
  1. Knock-Down (K/D) Fittings  
  2. More Knock-Down (K/D) Fittings  
  3. The Table Plate  
     
  NUTS AND BOLTS  
     
  1. Bolts - Sheet 1  
  2. Bolts - Sheet 2  
     
  RIVETS  
     
  1. Pop Riveting  
  2. Cold Rivets - Types and General Use  
  3. Joining Plates with Rivets - 1  
  4. Joining Plates with Rivets - 2  
  5. Joining Plates with Rivets - 3  
     
  PDF FILE - CLICK HERE FOR PRINTABLE EXERCISE REGARDING COLD RIVETING  
     
  6. Rivets and Movement  
     

 

     
  FITTINGS FOR SHAFTS AND WHEELS  
     
  1. Push Fittings  
  2. Split Pins  
  3. Lock Nuts  
  4.Combination Lock Nut and Split Pin.  
  5. Fittings for Metal Tube Frames - 1  
  6. Fittings for Metal Tube - 2  
  7. Examination Question  
     
  BRAZING  
     
  1. The Brazing Hearth  
  2. A Brazed Joint  
     
     
  INDUSTRIAL PRODUCTION  
     
  1. The Client /Customer  
  2. What is a Production Line?  
  3. Introduction to Industrial Production Techniques  
  4. Scales of Production - an Introduction  
  5. Single Item / Prototype Production - Example 1  
  6. Single Item / Prototype Production - Example 2  
  7. Batch Production - Example 1  
  8. Batch Production - Example 2  
  9. Batch Production Exercise  
  10. Continuous Production - Example 1  
  11. Continuous Production - Example 2  
  12. Production Methods - Lesson Starter  
  13. CIM - Computer Integrated Manufacture - 1  
  14. CIM - Computer Integrated Manufacture - 2  
  15. Remote Manufacturing  
  16. Continuous Improvement (CI) - Page 1  
  17. Continuous Improvement (CI) - Page 2  
  18. Flexible Manufacturing Systems - FMS - 1  
  19. Flexible Manufacturing Systems - FMS - 2  
  20. Detailed Example of Flexible Manufacturing - CD / DVD Manufacture  
  21. The Role of Market Research  
  22. How Market Research can be Carried Out  
  23. Design Idea to Design Concept (including Market Research)  
     
 
  24. Keeping a Manufacturing Logbook  
     
     
  QUALITY SYSTEMS  
     
  1. Quality Assurance  
  2. Quality Control  
  3. Quality Control Exercise  
     
  4. Product Analysis  
     
  5. Tolerances - 1  
  6. Tolerance - 2  
     
  MANUFACTURING PROCESS - REDUCING WASTE  
     
  1. Manufacturing Products and Reducing Waste  
  2. Manufacturing Products and Reducing Waste - Using Accurate Templates  
  3. Dealing with Waste - Reuse / Recycle  
  4. Training / Educating Staff about the Importance of Reducing Waste  
     
     
  PROPERTIES OF MATERIALS  
     
  1. Properties of Materials - 1  
2.Properties of Materials - 2
  3. Properties of Materials - Questions 1  
  4. Properties of Materials - Questions 2  
     
     
  EXAMINATION QUESTIONS  
     
  1. Exam Question 1  
  2. Exam Question 2  
  3. Exam Question 3  
  4. Exam Question 4  
  5. Exam Question 5  
  6. Exam Question 6  
     
  AS / A2 LEVEL QUESTIONS  
1. Question 1 - Traditional Chair
  2. Question 1 - Modern Plastic Chair  
  3. Question 1 - Contemporary Wood/Metal Chair  
  4. Plastics - Monomers and Polymers  
     
  EXAMINATION PREPARATION THEMES  

The aim of this sub-section is to set a design theme and context

 

THEME: OFFICE FURNITURE AND RELATED EQUIPMENT
 CONTEXT: TABLE and DESKTOP ORGANISATION

 

Pupils research the theme as they work through the resources/questions below. They should draw on all the skills and techniques developed through the Resistant Materials course.

 

*PLEASE NOTE: You may need to use the search facility on the index page of this site to find information when answering some of the questions*
     
  IMPORTANT - PDF FILE - CLICK HERE FOR PRINTABLE WORKSHEETS  
  (Use this section of the site for possible answers)  
     
  1. Desk Top Organisation - Rich Picture  
  2. Product Analysis - 1  
  3. Product Analysis Exercise  
  4. Design Requirements  
  5. The Design Specification - Desk Top Organiser  
  6. Desk Organiser - Ergonomics.  
  7. Additional Resources You May Need  
     
  MANUFACTURING TECHNIQUE ONE  
  1. Manufacturing a Simple Desk Top Organiser - The Base  
  2. Manufacturing a Simple Desk Top Organiser - The Tubes  
     
  MANUFACTURING TECHNIQUE TWO  
  3. Injection Moulding  
     
  MANUFACTURING TECHNIQUES THREE  
  4. Line Bending / Strip Heater  
     
  EXAMINATION STYLE QUESTIONS  
     
  1. Questions - 1  
  2. Questions - 2  
  3. Questions - 3  
  4. Questions - 4  
  5. Questions - 5  
  6. Questions - 6  
  7. Questions - 7  
     
  ADDING ACCESSORIES  
  1. Adding a Sellotape Dispenser  
  2. Sellotape Dispenser Examination Question 1  
  3.Sellotape Dispenser Examination Question 3  
  4. Sellotape Dispenser Examination Question - 4  
     
 

2. INDIVIDUAL RESEARCH THEME and EXAMINATION QUESTIONS

THEME: EDUCATIONAL TOYS
 CONTEXT: YOUNG CHILDREN LEARN THROUGH PLAY

 

Pupils research the theme as they work through the resources/questions below. They should draw on all the skills and techniques developed through the Resistant Materials course.

 

*PLEASE NOTE: You may need to use the search facility on the index page of this site to find information when answering some of the questions*

 

  
  PDF FILE - CLICK HERE FOR PRINTABLE WORKSHEETS RELATING TO THE QUESTIONS BELOW  
     
     
  1. Rich Picture - Educational Toys  
  2. Product Analysis  
  3. Product Analysis (Toy) - Exercise  
  4. Educational Toys and Devices  
  5. Design Requirements - Educational Toy  
  6. The Design Specification - Educational Toy  
  7. Design Problem - Educational Toy  
  8. Further Explanation of Key Words /Phrases  
  9. Design Brief - Educational Toy  
  10. Educational Toy and Ergonomic Considerations  
  11.Educational Toy / Ergonomic Walking Toy  
     
 

12. Symbols - Packaging- 1

  
  13. Symbols - Packaging - 2  
  14. More Symbols and Questions  
  15. Safety Symbols - Lessons Starter  
  16. Toy Lessons Starter  
     
  17. Educational Jigsaw - 1  
  18. Educational Jigsaw - 2  
  19. Educational Jigsaw - 3  
     
  20. A Mechanical Toy  
  21. Another Mechanical Toy  
     
  22. Try the Mechanisms Index Page - CAMS and CAM Toys  
     
  23. Questions - 1  
  24. Questions - 2  
  25. Questions - 3  
  26. Questions - 4  
  27. Questions - 5  
     
 

3. INDIVIDUAL RESEARCH THEME and EXAMINATION QUESTIONS

THEME: MEDIA STORAGE
 CONTEXT: STORING DVDs, CDs AND COMPUTER GAMES

 

Pupils research the theme as they work through the resources/questions below. They should draw on all the skills and techniques developed through the Resistant Materials course.

 

*PLEASE NOTE: You may need to use the search facility on the index page of this site to find information when answering some of the questions*

 

  
  1. Rich Picture - Media Storage  
  2. Product Analysis of a Typical Homemade DVD / CD Storage Unit  
  3. Product Analysis Exercise - DVD Storage Unit  
  4. Design Requirements  
  5. Design Specification - Media Storage  
  6. Design Problem - Media Storage  
  7. Design Brief - Media Storage  
  8. Ergonomics - Media Storage  
     
  9. Manufacturing a Basic DVD / CD Storage Unit - Single Item Manufacture - 1  
  10. Manufacturing a Basic DVD / CD Storage Unit - Single Item Manufacture - 2  
  11. Assembly - Single Item Manufacture - 3  
     
  12. Manufacturing a Basic DVD / CD Storage Unit - Batch Production  
  13. Plastics - Batch Production - Many Made  
  14. Production Flow Charts - Single Item and Batch Production  
     
  15. CIM - Computer Integrated Manufacture - 1  
  16. CIM - Computer Integrated Manufacture - 2  
     
  17. Manufacturing a Cabinet - DVD / CD Storage Unit - Material Pine  
  18. Flat Pack DVD / CD Storage Unit  
19. Free Gift - Glider - 1
20. Free Gift - Glider Manufacture
21. Modern Light Weight Modelling Materials
22. Making a Model Glider - By Hand
23. Flow Chart - Making a Model Glider By Hand
24. Examination Questions - 1
25. Examination Questions - 2
26. Examination Questions - 3
27. Examination Questions - 4
  28. Examination Questions - 5  
  29. Examination Questions - 6  
  30. Examination Questions - 7  
  31. Examination Questions - 8  
     
  SUGGESTED FURTHER REVISION  
     
 

4. INDIVIDUAL RESEARCH THEME and EXAMINATION QUESTIONS

THEME: EATING OUTDOORS
 CONTEXT: PICNIC FURNITURE

 

Pupils research the theme as they work through the resources/questions below. They should draw on all the skills and techniques developed through the Resistant Materials course.

 

*PLEASE NOTE: You may need to use the search facility on the index page of this site to find information when answering some of the questions*

 

  
  1. Rich Picture - Picnic Furniture  
  2. Product One - Wood Based - Teak  
  3. Product Analysis - A typical Folding Picnic Table  
     
  4. Manufacture of Folding Table 1 - Single Item/One off Production Sheet 1  
  5. Manufacture of Folding Table 1 - Single Item/One off Production Sheet 2  
  6. Folding Table - Manufacture of Brass Fittings / Hinge  
     
  7. Manufacture of Product One - Batch Production - CNC 1  
  8. Manufacture of Product One - Batch Production - CNC2  
  9. Production Flow Chart - CAD/CAM - Batch Production  
     
  10. Product Two - HDPE and Steel/Aluminium  
  11. Product Analysis - HDPE and Steel/Aluminium  
  12. Manufacturing Techniques - HDPE Table  
     
  13. Product Three - Teak Folding Chair  
  14. Properties of Teak  
     
  15. Product Four- HDPE Chair.  
  16. Properties of HDPE  
     
  17. Permanent Steel and Teak Bench  
     
  18. Design Requirements - Picnic Furniture  
  19. Design Specification - Picnic Furniture  
  20. Design Problem - Picnic Furniture  
  21. Design Brief - Picnic Furniture  
  22. Ergonomics and Picnic Furniture  
  23. Eco-Friendly Symbols - Furniture  
  24. Bicycle Rack  
     
  EXAM TYPE QUESTIONS  
     
  1. Examination Questions 1  
  2. Examination Questions - 2  
  3. Examination Questions - 3  
  4. Examination Questions - 4  
  5. Examination Questions - 5  
  6. Market Research Examination Questions  
  7. Quality Systems Questions  
     
     
 

5. INDIVIDUAL RESEARCH THEME and EXAMINATION QUESTIONS

THEME: ENVIRONMENT
 CONTEXT: RECYCLING BINS

 

Pupils research the theme as they work through the resources/questions below. They should draw on all the skills and techniques developed through the Resistant Materials course.

 

*PLEASE NOTE: You may need to use the search facility on the index page of this site to find information when answering some of the questions*

  
     
  1. Rich Picture - Environment and Recycling Bins  
  2. Product Analysis Exercise - 1  
  3. Product Analysis Exercise - 2  
  4. Product Analysis Exercise - 3  
  5. Product Analysis - Exercise - 4  
     
  6. Design Requirements  
  7. Design Specification  
  8. Design Problem Exercise  
  9. Design Brief Exercise  
     
  10. Examination Question 1  
  11. Examination Question 2  
     
  12. Pedal Mechanism - 1  
  13. Pedal Mechanism - 2  
  14. PDF FILE - EXAM QUESTION BASED ON BOTH MECHANISMS  
  15. Further Question on Pedal Bin Mechanisms  
     
  16. Stages in the Manufacture of the Wire Mechanism  
  17. Manufacturing Processes - Steel _ Pedal Bin  
     
  18. Bins with Wheels  
  19. Further Wheel Fittings  
     
20. Materials for the Manufacture of Recycling bins - 1
  21. Properties - High Density Polyethylene (HDPE) and Mild Steel  
     
  22. Ergonomics and Recycle Bins  
  23. How to Work Out an Ergonomic Measurement  
     
  24. Recycling Symbol - Vinyl Cutter  
  25. Recycling Symbols - Bins  
     
  BATCH PRODUCTION  
  26. Shopping Bag Recycling Bin - CAD/CAM  
  27. Production Flow Chart - CAD/CAM - Batch Production - Recycle Bin  
     
  SINGLE ITEM PRODUCTION  
  28. Manufacturing the Wood Recycle Bin - Single Item  
  29. Flow Chart of Manufacture - Single Item - Recycle Bin  
  30. Wood Bin - Examination Question  
     
  31. Other Aspects of Revision