V. Ryan © 2002 - 2012
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
14. Sustainability Questions
16. Manmade Boards and Natural Woods Questions PLASTICS 1. Plastics, Fuels and Chemicals from Crude Oil 2. The Oil Refinery and Distillation Tower
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. Low Density Polyethylene Questions 18. LDPE and Extrusion Blow Moulding 19. Extrusion Blow Moulding - Question - 1 20. Extrusion Blow Moulding - Question - 2 20. 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
7. Alloys
10. Steel Bench - Examination Question 11. Steel Bench Construction - Examination Question 12. Ferrous and Non-Ferrous Metals Question 13. Metals and Properties Questions 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 COMPLIANT MATERIALS 1. Compliant Materials - Examination Questions GENERAL MATERIALS QUESTIONS 1. Materials, Metals and Polymers 1 2. Materials, Metals and Polymers 2 SMART 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
QUESTIONS - JOINTS
SCREWS AND 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 CHARLES RENNIE MACKINTOSH AND STORAGE 1. An Introduction to Charles Rennie Mackintosh 2. Analysis / Description of a Charles Mackintosh Chair 3. Mackintosh Decoration 4. The Furniture of Charles Rennie Mackintosh - Product Analysis 1 5. The Furniture of Charles Rennie Mackintosh - Product Analysis 2 6. Product Analysis - Mackintosh Oak Washstand 7. Product Comparison 8. The Mackintosh Desk 9. A Young Child's Toy Box based on Charles Rennie Mackintosh Design Characteristics 10. DVD Storage Unit based on Charles Rennie Mackintosh Design Characteristics 11. Storage Unit based on a Mackintosh White Desk and Chair 12. How to Develop a Specification by Analysing the Design Brief 13. Specification Question 14. Design One - Child's Toy Box - Mackintosh Style 15. Design Two - Storage Box - Mackintosh Style 16. Design Three - Jewellery Box - Mackintosh Style 17. Design Four - DVD Storage - Mackintosh Style 18. Design Five - Bits And Bobs Storage Box - Mackintosh Style 19. Designing a Mackintosh Storage Unit 20. Presenting a Design Idea 21. Developing your Idea 22. Part Two Examination Questions 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 
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