CLICK HERE
FOR INDEX PAGE
V. Ryan © 2002
- 2011
RESISTANT MATERIALS
STUDENTS/PUPILS SHOULD ALSO STUDY THE 'EQUIPMENT AND PROCESSES' SECTION OF
THIS WEBSITE
MATERIALS
1. An Introduction to
Materials
WOODS
1. World Distribution of Natural Woods
2. World Map - Distribution of Forests and Woodlands
3. The Preparation of Timber for Commercial Use - 1
4. The Preparation of Timber -Air Seasoning - 2
5. The Preparation of Timber - Kiln Seasoning - 3
6. Summary - Natural Wood - Raw Materials to
Manufacturing a Product
7. Initial Preparation of Timber
8. Preparation of Stock - Planing of Boards.
PDF FILE CLICK HERE FOR PRINTABLE WORKSHEET ON THE
PREPARATION OF TIMBER
9. Stock Forms - Woods
10. Veneer
11. Natural Woods
12. Manmade Boards
13. What is a Sustainable
Forest?
14. Natural Woods in
Detail
PLASTICS
1. Plastics, Fuels and Chemicals from
Crude Oil
2. The Oil Refinery and Distillation Tower
3. The Manufacture and
Nature of Plastics
4. Crude Oil to Fuels and Plastics -
Summary Diagram
5. Thermoplastic Elastomers (TPEs)
6. Properties of Thermoplastic Elastomers
(TPEs)
7. Examination Question - Thermoplastic
Elastomers
8. Renewable and Environmentally Friendly Polylactide
9. Polylactide - Life Cycle
10. Polylactide - Examination Question
11. Polyethylene Terephthalate or PET / PETE (Polyester)
12. Polyethylene Terephthalate or PET / PETE -
Examination Question
13. Vacuum Forming PETE Packaging - Examination
Question
14. Examination Question (Part One) - Injection Moulding
HIPS, HDPE, LDPE, PP, Acrylic (PMMA), ABS.
15. Examination Question (Part Two) - Injection
Moulding HIPS, HDPE, LDPE, PP, Acrylic (PMMA), ABS.
16. Examination Question - Polypropylene Packaging
17. Further Questions and Answers on Plastics
METALS
1. Iron Ore to Iron Ore Pellets
2. Where is Iron Ore Mined?
3. The Blast Furnace - Iron Production
4. Processes inside the Blast Furnace
5. Producing Steel through the Modern Converter Process
6. Metals
7. Alloys
8. Galvanising Steel -
1
9. Galvanising Steel -
2
10. Steel Bench - Examination Question
11. Steel Bench Construction - Examination Question
COMPOSITE MATERIALS
1. Natural Woods
2. Concrete
3. Reinforced Concrete
4. Glass Reinforced Plastic
5. Carbon Fibre Reinforced Polymer (CFRP)
6. Examination Question - Carbon Fibre (CFRP)
7. Plywood
8. Laminated Veneers and Steam Bending
9. Kevlar - General Introduction
10. What is Kevlar? Types of Kevlar - Advantages and
Disadvantages of Kevlar
PDF FILE Click here for Printable Worksheet on Kevlar
11. Kevlar and Modern Cars
12. Automotive use of Kevlar - Summary
SMART MATERIALS
1. Smart Materials -
Polymorph - Shaping by Hand
2. Smart Materials -
Polymorph - Using a Mould
3. Smart Materials - Shape
Memory Alloys - Page One
4. Smart Materials - Shape
memory Alloys - Page Two
5. Modern Light Weight Modelling Materials
6. Inks That Change After Contact With Water
7. Inks that change Colour with Temperature
8. Photochromic Inks
9. Photochromic Inks - Examination Question
10. Hydromorphic Polymers
11. Hydrocarbon Encapsulating Polymers
12. Aroma Pigments
13. Further Questions and Answers on Smart Materials
14. GENERAL MATERIALS - Questions and Answers
MATERIALS
- FINISHES
1. Materials - Finishes Questions / Answers
2. More Materials - Finishes Questions / Answers
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)
Model Making Examination Question
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. Series of Examination Questions
related to Mass Production in a School Workshop
14. CIM - Computer Integrated Manufacture
- 1
15. CIM - Computer Integrated Manufacture - 2
16. Remote Manufacturing
17. Continuous Improvement (CI) - Page 1
18. Continuous Improvement (CI) - Page 2
20. Flexible Manufacturing Systems - FMS -
1
21. Flexible Manufacturing Systems - FMS -
2
22. Detailed Example of Flexible
Manufacturing - CD / DVD Manufacture
23. The Role of Market Research
24. How Market Research can be Carried Out
25. Design Idea to Design Concept
(including Market Research)
26. ICT as
a Marketing Tool
27. Barcodes in Manufacturing,
Distribution and Supply
PDF FILE EXAMINATION QUESTION - ICT and Manufacturing,
Marketing and Supply - Examination Question
28. Information Communication Technology -
Developing and Modelling Ideas
29. Keeping a Manufacturing Logbook
QUALITY SYSTEMS
1. The British Standards Institute Kite Mark and the Conformite European
Symbol
2. Quality Assurance
3. Quality Control
PDF FILE CLICK HERE
FOR PRINTABLE WORKSHEET ON QUALITY CONTROL
4. Quality Control Exercise
5.
Quality Control and Quality Assurance - Examination Questions and Answers
6.
Products and Quality Standards - Examination Question
7. Product Analysis
8. Tolerances - 1
9. Tolerance - 2
PDF FILE CLICK HERE FOR
PRINTABLE WORKSHEET ON TOLERANCES
10.
Tolerance Examination Question
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
CONTEXT : MP3 DOCKING STATION FOR THE TEENAGE MARKET
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*
STILL UNDER CONSTRUCTION
1. MP3 Rich Picture
2. Existing MP3 Player Docking Stations
3. MP3 Docking Station - Product Analysis Question 1
4. MP3 Docking Station - Product Analysis Question 2
5. How to Develop a Specification by Analysing the Design Brief
6. MP3 Docking Station - Ideas
7. Alternative Way of Presenting Ideas
8. Evaluating an Idea for an MP3 Docking Station
9. Developing Your Chosen Design
10. Manufacturing your chosen MP3 Docking Station
11. Manufacturing an Alternative Design through
Injection Moulding
Further Examination Questions
1. Equipment and Tools - 1
Answers
2. Equipment and Tools - 2
Answers
3. Health and Safety - 1
4. Health and Safety Answer - 1
4. Health and Safety - 2
5. Health and Safety Answer - 2
6. Manufacturing a Product - 1
7. Manufacturing a Product -
Polyvinylchloride (PCV) - Answers
8. Manufacturing a Product - Pine - Answers
8. Sequence of Manufacture - QUESTION - Pine Desk
Tidy B
9. Sequence of Manufacture - ANSWER - Pine
Desk Tidy B
10. Manufacturing a Product - CAD and Injection
Moulding
11. Manufacturing a Product _ CAD and Injection
Moulding - ANSWER
12. Materials - 1
13. Materials - 2
14. Raw
Materials to Manufactured Products - Crude Oil to Polystyrene
15. Raw
Materials to Manufactured Product - Natural Wood to Guitar
16. Materials and Finishes
17.
Product Analysis
18. What is Anthropometrics and Ergonomics?
19. Ergonomics and Anthropometrics
(Feet)- 1
20. Ergonomics and Anthropometrics
- Child's Walking Toy - 2
21. Why Make a Model?
22. Life Cycle - 1
23. Environmental Impact - Product Life Cycle
24. Environment/Recycling - 1
25. Environment/Recycling - 2
26. Maintenance of Products - Kettles
27. Maintenance of Product - Drills
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
6. INDIVIDUAL RESEARCH THEME and EXAMINATION QUESTIONS
THEME: PORTABILITY
CONTEXT: Wheeled devices
that help with moving and transporting a range of different items
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 - Wheeled Devices
2. Folding Trolley - Product Analysis One
3. Folding Trolley - Product Analysis Two
4. Folding Trolley - Product Analysis
Three
5. Children's Building Block Trolley -
Product Analysis
6. Product Comparison - Portability and
Wheeled Devices
7. Materials Selection - Wood Based
Trolley
8. Materials Selection - Metal Based
Trolley
JOINTS AND FITTINGS FOR WOOD TROLLEYS
9. Wood Based Trolley - Joints and
Fixings
FITTINGS - FIXING WHEELS TO
TROLLEYS
10. Push
Fittings
11. Split
Pins
12. Lock
Nuts
13.Combination Lock Nut and Split Pin.
FITTINGS AND JOINTS - METAL TUBE
/ TROLLEYS
14. Fittings
for Metal Tube Frames - 1
15. Fittings
for Metal Tube - 2
16. Examination
Question
SCALES OF MANUFACTURE
17. Building Block (Wood Based) Trolley
- One Off / Batch Manufacture
18. Updated Building Block Trolley
19. A Metal Trolley - Selection of
Materials
20. Building a Steel/Aluminium Trolley
- One Off and Batch Manufacture
21. The Hydraulic Press - Pressing Steel
Sheet
ERGONOMICS AND SAFETY
22. Ergonomics of a Trolley
23. Health and Safety - Lifting and
Moving Weights
UNDER CONSTRUCTION - ESTIMATED TIME - ONE MORE WEEK