Cambridge O Level

* 2 9 8 3 0 4 2 3 4 7 *

DESIGN & TECHNOLOGY 6043/32

Paper 3 Resistant Materials October/November 2021

1 hour

You must answer on the question paper.

No additional materials are needed.

INSTRUCTIONS
● Section A: answer all questions.
● Section B: answer one question.
● Use a black or dark blue pen. You may use an HB pencil for any diagrams or graphs.
● Write your name, centre number and candidate number in the boxes at the top of the page.
● Answer in the space provided.
● Do not use an erasable pen or correction fluid.
● Do not write on any bar codes.
● You may use a calculator.

INFORMATION
● The total mark for this paper is 50.
● The number of marks for each question or part question is shown in brackets [ ].
● All dimensions are in millimetres.

This document has 20 pages. Any blank pages are indicated.

DC (SLM) 220784
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Section A

Answer all questions in this section.

1 Safety precautions need to be taken when carrying out different processes in a workshop.
Complete Table 1.1 by stating one safety precaution that would need to be taken for each process.

Table 1.1

Process Safety precaution taken

Using a pillar drill to drill sheet metal

Using a disc sander to sand a

hardwood block
[2]

2 Circle from the list of materials below one metal that can be hardened.

lead zinc high carbon steel cast iron [1]

3 Fig. 3.1 shows two pieces of hardwood that are to be joined by means of a KD (Knock-Down)
fitting.

Fig. 3.1

Add sketches and notes to Fig. 3.1 to show how a suitable KD (Knock-Down) fitting could be used
to join the hardwood together. [3]

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4 Fig. 4.1 shows two tools, A and B, that are used to remove nails from wood.

A B

Fig. 4.1

(a) Name each tool:

A ...............................................................................................................................................

B ...............................................................................................................................................
[2]

(b) Fig. 4.2 shows tool A removing a nail from wood.

scrap wood

Fig. 4.2

State the purpose of the scrap wood shown in Fig. 4.2.

............................................................................................................................................. [1]

5 Fig. 5.1 shows an item of equipment used to hold components when drilling holes.

handle

Fig. 5.1

(a) Give the correct name for the item of equipment shown in Fig. 5.1.

............................................................................................................................................. [1]

(b) State the name of a centre lathe process that could have been carried out to the handle to
improve grip.

............................................................................................................................................. [1]
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6 Fig. 6.1 shows a hardwood bracket. The bracket has been fabricated using hardwood.

160

Fig. 6.1

(a) State what is meant by the term ‘fabricated’.

............................................................................................................................................. [1]

(b) The bracket could be made from aluminium.

State a manufacturing process that could be used to produce the bracket from one piece of
aluminium.

............................................................................................................................................. [1]

7 Fig. 7.1 shows an incomplete design for a bending jig used when bending acrylic sheet.

X
adjustable board

hinge

fixed board

Fig. 7.1

Add to Fig. 7.1 to show how the adjustable board could be held securely in any position between
X and Y so that acrylic sheet could be bent to the required shape. [3]

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8 Fig. 8.1 shows a leaflet holder made from 3 mm thick acrylic.

200

0
15

Fig. 8.1

Complete Table 8.1 by describing what each of the tools or items of equipment could be used for
when making the leaflet holder.

Table 8.1

Tool/item of equipment What they are used for

Chinagraph pencil

Scroll saw

Hand file

Buffing machine
[4]

9 Complete the statement below by adding the correct term from the list.

moisture temperature weight light

Shape Memory Alloy (SMA) is a smart material that reacts to ................................................... [1]

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10 Fig. 10.1 shows the underside of a table top.

The table top is made by gluing together three hardwood boards.

positions for screws

slot

batten to hold
50 hardwood boards
0

end grain

Fig. 10.1

(a) Give one reason why the table top is made by gluing together three hardwood boards rather
than one board.

............................................................................................................................................. [1]

(b) Explain why the boards have been glued together with the end grains arranged as shown in
Fig. 10.1.

...................................................................................................................................................

...................................................................................................................................................

............................................................................................................................................. [2]

(c) Fig. 10.1 shows a batten that is used to hold the three hardwood boards.
The batten will be screwed to the underside of the table top.
Give one reason why the screw holes are slotted.

............................................................................................................................................. [1]

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Section B

Answer one question from this section.

11 Fig. 11.1 shows an incomplete design for a step stool made from oak.

platform 20 mm thick

through housing joint area A

step 20 mm thick

leg 60 × 20

Fig. 11.1

(a) Give two properties of oak that make it suitable for the step stool.

1 .................................................................................................................................................

2 .................................................................................................................................................
[2]

(b) The legs will be cut from one length of 60 × 20 oak.

Use sketches and notes to show how a sliding bevel could be used when marking out one
leg.

[2]

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(c) Fig. 11.2 shows part of one leg.

Fig. 11.2

(i) Draw on Fig. 11.2 to show a through housing joint that could be used to join the step to
the leg. [3]

(ii) Fig. 11.3 shows a portable power tool that could be used to cut the through housing
joints.

Fig. 11.3

Name the portable power tool. .................................................................................... [1]

(iii) State one safety precaution, other than wearing PPE (Personal Protection Equipment),
that must be taken when using portable power tools.

..................................................................................................................................... [1]

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(d) The platform shown in Fig. 11.1 will be joined to the tops of the legs using dowels.
Fig. 11.4 shows the tops of two legs.

20

70

Fig. 11.4

Draw on Fig. 11.4 to show:

• the diameter of dowel pegs used
• the number of dowel pegs required
• the spacing between the dowel pegs. [3]

(e) Area A shown in Fig. 11.1 is weak and needs to be strengthened.

Use sketches and notes to show how additional materials and constructions could be used to
make area A stronger and more rigid.

[3]

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(f) The step stool will be given an oiled finish rather than a painted finish.

(i) Give two advantages of an oiled finish rather than a painted finish for the step stool.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]

(ii) The step will be glasspapered, ready to take the oiled finish, before it is glued to the
legs.
Give two benefits of glasspapering the step before it is glued to the legs.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]

(g) A hand-hold will be joined to the step stool to provide support for the user.
Add sketches and notes to Fig. 11.5 to show a design for a hand-hold that would provide
support at a height of 1 metre above the platform.

Include the following details:

• the method of joining the hand-hold securely to the step stool
• two important sizes
• how the hand-hold is made comfortable to grip.

platform 20 mm thick

leg 60 × 20

step 20 mm thick

Fig. 11.5
[6]

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12 Fig. 12.1 shows parts of an incomplete model car.

body shell
2 mm thick polystyrene

chassis 200 × 140

1 mm thick aluminium

wheel support 30 × 30

Ø6 holes

Fig. 12.1

(a) Give two advantages of using CAD rather than traditional drawing methods to design the
body shell of the model car.

1 ................................................................................................................................................

2 ................................................................................................................................................
[2]

(b) Give two benefits of using aluminium for the chassis of the model car.

1 ................................................................................................................................................

2 ................................................................................................................................................
[2]

(c) The body shell will be produced by vacuum forming.

(i) State two features of the mould used to produce a quality body shell.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]

(ii) Give two reasons why it is important to heat the polystyrene to the correct temperature
when vacuum forming the body shell.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]

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(iii) A flow chart showing the stages of vacuum forming the body shell of the model car is
shown below.
Complete the flow chart by adding the missing stages needed from the list below.

Turn off vacuum Start/end

Is shape fully formed?
Lower mould
Turn on vacuum Process
Remove vacuum formed body shell
Is plastic soft enough? Decision
Raise mould

place mould
in machine

clamp plastic
sheet in place leave to cool

heat
plastic sheet

No Yes

Yes No

[5]

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(d) The chassis will be cut from a sheet of 1 mm thick aluminium shown below.

waste

200
30
30
200

(i) Name two hand tools that could be used to cut out the development (net) of the chassis.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]

(ii) Describe how the cut edges could be made safe to handle.

...........................................................................................................................................

..................................................................................................................................... [2]

(iii) Use sketches and notes to show how the wheel supports could be bent to shape.
Name the tools and equipment used.

[3]

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(e) Fig. 12.2 shows one of the wheels that will be fitted to the model car.

Ø5 hole

wheel Ø40 × 8 thick

Fig. 12.2

(i) Name the process used to manufacture the plastic wheel.

..................................................................................................................................... [1]

(ii) The body shell fits over the chassis and is held securely when axles are inserted and the
wheels are attached.
Use sketches and notes to show how wheels could be fitted to the model car and allowed
to rotate freely.

[4]

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13 Fig. 13.1 shows an incomplete design for a jewellery stand made from mahogany and brass.

Ø30 mahogany bar

brass cap
Ø15 brass tube

base: 15 mm thick mahogany

60

20
0
0
10

Fig. 13.1

(a) The Ø30 mahogany bars will be produced on a woodturning lathe by means of between-
centres turning.
Fig. 13.2 shows the length of mahogany marked out and prepared, ready to be set up on a
woodturning lathe.

waste

0
22

marked out corners removed

Fig. 13.2

(i) Give one reason why the corners of the mahogany have been removed.

..................................................................................................................................... [1]

(ii) When setting up the mahogany on a woodturning lathe state one check that would be
carried out before switching on the machine.

...........................................................................................................................................

..................................................................................................................................... [1]

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(iii) Name one tool that could be used to check that the mahogany has been turned to the
correct diameter.

..................................................................................................................................... [1]

(iv) Name one lathe tool that could be used to remove the waste to make the length of
mahogany round.

..................................................................................................................................... [1]

(b) Fig. 13.3 shows an engineers vice that will be used to hold each of the Ø15 brass tubes while
they are sawn to the required length.

Fig. 13.3

Describe one precaution that could be taken to prevent the brass tubes from being damaged
when held in the engineers vice.

...................................................................................................................................................

............................................................................................................................................. [2]

(c) Fig. 13.4 shows a brass cap that is fixed over the end of the mahogany bars.

Fig. 13.4

(i) State the purpose of the brass caps.

..................................................................................................................................... [1]

(ii) The brass caps are pre-manufactured components that have been purchased.
Give two advantages of using pre-manufactured components rather than making the
components in a school workshop.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]
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(d) The sides of the base, made from mahogany, will be joined by means of mitre joints.
Fig. 13.5 shows a mitre joint marked out on the end of one side.

waste

0
10
15

Fig. 13.5

(i) Name two tools that could be used to mark out the mitre joint.

1 ........................................................................................................................................

2 ........................................................................................................................................
[2]

(ii) Use sketches and notes to show how the waste could be removed to produce the mitre
joint. Name the tools and equipment used.

[4]

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(e) Fig. 13.6 shows the base of the jewellery stand.

15 mm thick mahogany

60
20
0

0
10

Fig. 13.6

Use sketches and notes to show a design for a drawer that would fit into the base.
Include the constructions and sizes of materials used.

[6]

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(f) Fig. 13.7 shows 1 mm thick brass sheet from which a handle for the drawer will be produced.

0
17
30

Fig. 13.7

Use sketches and notes to show a design for a handle that will be attached to the front of the
drawer. The design can use all or part of the brass sheet.
Include details of any cutting and shaping processes used to produce the handle.

[4]

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