AQA A Level · Design and Technology: Product Design 7552

Forming, redistribution and addition processes: Practice Questions

5 multiple-choice questions marked as you go, and 5 written questions with worked solutions. All on Forming, redistribution and addition processes.

10 questions24 marksFree, no account

Question 1

1 mark

Which of the following processes is specifically used to produce three-dimensional polymer products by rotating a closed mold in an oven?

Question 2

1 mark

Which specific welding process uses a non-consumable electrode and a separate filler rod, typically used for high-quality joints in non-ferrous metals like aluminium or stainless steel?

Question 3

1 mark

A manufacturer needs to produce a complex, high-precision metal component with an intricate internal geometry that cannot be easily machined. Which casting process, often referred to as 'lost wax' casting, is most suitable for achieving high dimensional accuracy and a superior surface finish?

Question 4

1 mark

In metal redistribution processes, which method involves forcing a metal sheet into a female die using a male punch to create deep, cup-shaped components where the depth often exceeds the diameter?

Question 5

1 mark

Which addition process involves the use of a chemical reaction, often triggered by a catalyst or UV light, to bond two acrylic (PMMA) surfaces together by effectively 'welding' them with a liquid solvent?

Question 6

2 marks

Identify one common addition process used to join metal components permanently using a filler rod and a fuel gas mixture.

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Question 7

4 marks

Explain why rotational moulding is specifically suited for the production of large, hollow polymer products like water tanks compared to injection moulding.

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Question 8

5 marks

Compare the redistribution process of investment casting with sand casting in terms of the required surface finish and dimensional accuracy for complex engine components.

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Question 9

3 marks

A high-volume manufacturer is selecting a process to produce 50,000 intricate, 3D aluminium alloy housings for a new handheld device.

(a) State the most suitable industrial casting process for this scale of production and explain one reason for its suitability.
(b) Compare this process with sand casting in terms of surface finish and dimensional accuracy.

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Question 10

5 marks

An engineering firm is manufacturing a large batch of complex mild steel components. They are deciding between milling and laser cutting for the initial shaping stage.

(a) Explain why laser cutting might be preferred over traditional milling for producing complex 2D profiles in 3mm thick sheet steel.
(b) Describe how the 'wasting' process differs fundamentally between these two methods.
(c) Identify one limitation of using laser cutting for materials with high thermal conductivity, such as copper alloys.

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