2025 CCEA GCSE Engineering and Manufacturing 0009 Practice Paper with Answers

(a) The bin body is a curved cylindrical shell formed from sheet metal, so press forming (pressing the flat blank between shaped tools/rollers) is the most suitable process. [2] (b) In press forming, the flat sheet-steel blank is placed between a shaped punch and die (or passed through forming rollers); force is applied, plastically deforming the sheet so that it permanently takes up the curved cylindrical shape of the tooling, without significantly changing its thickness. [3] (c) Advantages for a 5,000-unit run: once the tooling/press is set up, each part can be formed very quickly (short cycle time per unit), and because every part is formed by the same tool, all 5,000 bin bodies are highly consistent/repeatable in shape and dimensions. [2] (d) The plastic pedal cover, a small, identical, high-volume plastic component, is well suited to injection moulding. [2] (e) Injection moulding uses a mould that produces a fully finished, precise part in each short cycle, making it very efficient for producing thousands of identical small components with minimal manual finishing; vacuum forming is a slower, more manual process, generally used for lower-volume or larger, simpler shell-like shapes, and typically needs trimming afterwards, making it less efficient for 5,000 identical small covers. [3] Max 12 marks.

(a) [2] press forming (accept 'pressing'). (b) [1] shaped die/punch or rollers used; [1] force applied to the blank; [1] material plastically deforms/permanently takes the tool's shape. (c) [1] fast/short cycle time once tooling is made; [1] consistent/repeatable parts across the batch. (d) [2] injection moulding. (e) [1] produces fully finished parts each cycle with little/no manual finishing; [1] fast cycle time suited to high volume; [1] correct comparative point that vacuum forming is slower/more manual or suited to different (larger/simpler) shapes. Max 12 marks.

(a) BSI Kitemark: indicates the product has been independently tested by the British Standards Institution and shown to meet the requirements of the relevant British Standard. CE mark: indicates that the manufacturer declares the product meets the relevant European health, safety and environmental protection requirements. [4: 2 marks per standard — 1 for correct name, 1 for correct explanation] (b) The Factor of Safety is the ratio between the failure (maximum withstandable) load of a component and the maximum load it is expected to experience in normal use; it provides a safety margin to allow for factors such as material variability, unexpected loads, or wear, so the component is designed to be stronger than strictly necessary. [2] (c) \( \text{Factor of Safety} = \dfrac{\text{Failure load}}{\text{Maximum working load}} = \dfrac{900}{150} = 6 \). Answer: Factor of Safety = 6 (no units, as it is a ratio). [3]

(a) [1] BSI (Kitemark) named; [1] correct explanation (independently tested against a British Standard); [1] CE mark named; [1] correct explanation (manufacturer's declaration of meeting EU safety/health/environmental requirements). (b) [1] correct general idea (ratio of failure load to working/design load); [1] correct reference to providing a safety margin/allowance for uncertainty. (c) [1] correct formula (failure load ÷ working load); [1] correct substitution (900 ÷ 150); [1] correct answer (6, no unit — OFR applies). Max 9 marks.

(a) \( A = \pi r^2 = \pi \times (3\ mm)^2 = \pi \times 9 = 28.3\ mm^2 \) (3 s.f.). (b) \( \text{stress} = \dfrac{\text{force}}{\text{cross-sectional area}} = \dfrac{150\ N}{28.3\ mm^2} = 5.31\ N/mm^2 = 5.31\ MPa \) (since 1 N/mm² = 1 MPa). (c) \( \text{Young's modulus} = \dfrac{\text{stress}}{\text{strain}} \), rearranged: \( \text{strain} = \dfrac{\text{stress}}{E} = \dfrac{5.31 \times 10^{6}\ Pa}{200 \times 10^{9}\ Pa} = 2.65 \times 10^{-5} \). This is a very small strain, consistent with the pin operating well within the elastic region, far below the yield stress of mild steel (typically around 250 MPa). Answer: (a) 28.3 mm²; (b) 5.31 MPa; (c) strain ≈ 2.65 × 10⁻⁵.

(a) [1] correct formula (πr²) with radius correctly halved from diameter; [1] correct answer (28.3 mm², accept 28.2–28.3). (b) [1] correct formula (force ÷ area) with OFR from (a); [1] correct answer with correct unit (5.31 MPa, accept 5.3–5.4 MPa range from rounding). (c) [1] correct rearrangement of Young's modulus formula (strain = stress ÷ E); [1] correct unit conversion of stress (MPa) and E (GPa) to consistent units; [1] correct final answer (≈2.65 × 10⁻⁵, OFR from (b)). Max 7 marks.

(a) 1. The folded steel pivot bracket is fixed to the base of the bin body. 2. The 6 mm steel pivot pin is inserted through the aligned holes in the bracket and the lever arm, forming the pivot. 3. The steel lever arm is mounted onto the pivot pin, positioned between the sides of the bracket. 4. The retaining clip is fitted onto the end of the pivot pin to stop the pin (and lever arm) sliding out sideways. 5. The moulded plastic foot pad is fitted/clipped to the front end of the lever arm, where the operator applies the effort. 6. The link rod is connected between the lever arm and the lid, so that rotation of the lever lifts the lid. [4: 1 mark for correct starting point and pivot assembly, 1 for correct positioning of the lever on the pin, 1 for correct retention (clip) step, 1 for correct final connection of foot pad and link rod to lever] (b) This is a second-class lever. The pivot (fulcrum) is at the back of the lever arm, the link rod (load) is attached partway along the arm, and the foot pad (effort) is at the far front end — so the load lies between the fulcrum and the effort, which is the defining feature of a second-class lever (as in a wheelbarrow). [4: 2 for correctly identifying second-class lever, 2 for correct justification referencing load position between fulcrum and effort] (c) 1. The operator presses down on the foot pad, applying the effort force at the far end of the lever arm. 2. The lever arm rotates about the fixed pivot pin in the bracket. 3. As the lever arm rotates, the point where the link rod is attached (closer to the pivot) moves upward. 4. This pulls the link rod upward, which lifts the lid open. [4: 1 mark per correctly ordered step] Max 12 marks.

(a) Up to 4 marks for a complete, logically ordered assembly sequence: [1] bracket fixed to bin body first; [1] pivot pin correctly placed through bracket (and lever); [1] retaining clip correctly identified as securing the pin/lever axially; [1] foot pad and link rod correctly shown fitted to the lever arm. (b) [2] correct identification of second-class lever; [2] correct justification (load positioned between fulcrum and effort). Award [1]-[2] only for an incorrect class with partially correct reasoning about relative positions. (c) [1] each for: effort applied at foot pad; lever rotates about the pivot; link-rod attachment point moves upward as arm rotates; lid is lifted via the link rod — in this logical order. Max 12 marks.

A strong answer should discuss several of the following, applied specifically to the EcoStep bin, with a balanced conclusion: Materials and components — new recyclable or bio-based polymers could replace some plastic components (e.g. the pedal cover), reducing reliance on virgin fossil-fuel-based plastic and making the bin easier to recycle at end of life; smart materials could also be explored, though cost may limit their use in a low-cost product like a pedal bin. Recycling — designing the bin using fewer different material types (or clearly separable/labelled parts) makes it easier to sort and recycle the bin itself once it reaches the end of its life, directly relevant given the bin's own purpose is to support household recycling. Environmental costs — CAD and simulation software allow the design to be optimised (e.g. minimising material thickness/waste in the press-formed bin body) before manufacture begins, reducing scrap material and the associated environmental cost of producing and disposing of wasted steel and plastic; CAM/CNC and robotic manufacturing can also improve precision and consistency, further reducing scrap rates across a 5,000-unit run. Reduced energy costs — automated and computer-integrated manufacturing (CIM) can optimise machine scheduling and reduce idle energy use in the factory, and more efficient forming/moulding equipment can lower the energy needed per unit produced. Maintenance and repair — if key components (such as the pivot pin, retaining clip or link rod) are standardised and 3D-printable, replacement spare parts could be produced on demand rather than the whole bin being discarded when a single part fails, extending the product's useful life and reducing the number of bins sent to landfill. A balanced discussion should also recognise limitations: introducing new technologies (e.g. 3D printers, robotics, new tooling for new materials) has its own upfront financial and environmental cost, may require staff retraining, and is not always justified for a simple, low-cost product manufactured in relatively modest volumes such as the EcoStep bin — so the overall environmental and economic case needs to be considered holistically rather than assuming every new technology is automatically beneficial.

Level 1 [1]-[3]: Basic, limited discussion; one or two relevant points made (e.g. recycling or CAD mentioned) with little development or application to the EcoStep bin specifically; weak use of specialist vocabulary. Level 2 [4]-[7]: Sound discussion covering several relevant areas (e.g. materials/recycling, and either environmental or energy costs, and/or maintenance/repair) with reasonable application to the EcoStep bin context; some evaluation present but not fully balanced or developed across all named aspects. Level 3 [8]-[10]: Comprehensive, well-developed discussion addressing materials and components, recycling, environmental costs, reduced energy costs, and maintenance and repair, all applied specifically and convincingly to the EcoStep bin; includes a balanced evaluation recognising both benefits and limitations/costs of adopting new technologies; confident use of specialist vocabulary and clear, well-structured, fluent written communication throughout.

(a) 1. A microswitch is a small switch operated by a mechanical lever/plunger, commonly used to detect the position of a moving part. 2. A gear is a toothed mechanical component; meshed gears change the speed and/or direction of rotation transmitted between shafts. 3. A resistor limits (resists) current flow in a circuit, for example to protect an LED from excess current. [3] (b) BSI Kitemark: shows the product has been independently tested by the British Standards Institution and meets the relevant British Standard. CE mark: shows the manufacturer's own declaration that the product meets relevant European health, safety and environmental protection requirements. [3] Max 6 marks.

(a) [1] microswitch; [1] gear; [1] resistor. (b) [1] BSI (Kitemark) named with [correct explanation needed for full credit, otherwise 0]; combine as: [1] BSI named, [1] correct explanation of BSI; the third mark [1] CE mark named and explained together — accept: 1 mark per correctly named AND correctly explained standard, i.e. up to 3 marks split as needed across the two standards named. Max 6 marks.

(a) The GRP lever needs adequate strength (particularly bending/tensile strength, since the lever is loaded as it pivots) and sufficient stiffness (to avoid excessive flexing/deflection under the effort and load forces) to function reliably in place of the steel lever. [2] (b) A composite material is formed by combining two or more different materials so that the resulting material has improved properties compared with either material used alone. GRP (glass reinforced plastic) combines fine glass fibres (which provide high tensile strength and stiffness) embedded in a polymer resin matrix (which binds the fibres together, transfers load between them, and gives the material its shape); together they produce a material that is strong and stiff for its weight, unlike either the glass fibres or the resin alone. [3] (c) Advantage: GRP is considerably lighter than an equivalent-strength steel component, reducing the force needed to press the pedal, and it will not corrode/rust, unlike untreated steel. Disadvantage: GRP mouldings are typically more expensive to produce in relatively low volumes than a simple pressed/cut steel lever, and because it combines two bonded materials, GRP is more difficult to recycle at end of life than a single-material steel component. [2] Max 7 marks.

(a) [1] each for two valid mechanical properties (e.g. strength, stiffness, toughness — accept any two relevant, correctly justified properties). (b) [1] correct general definition of a composite (combination of two or more materials for improved properties); [1] correct identification of the reinforcement (glass fibres, providing strength/stiffness); [1] correct identification of the matrix (resin, binding fibres/transferring load). (c) [1] valid advantage (e.g. lighter weight, corrosion resistance); [1] valid disadvantage (e.g. higher cost at low volume, harder to recycle, potential for lower stiffness unless properly designed). Max 7 marks.

(a) Batch production is most appropriate: 5,000 units a year is too high a volume, and not varied enough, to be efficiently made as individual one-off items, but it is not so continuously high (or so unchanging in design) as to justify the investment in a dedicated assembly/mass-production line running constantly. Producing the bins in batches allows the manufacturer to use shared tooling and machines efficiently, while still being able to adapt the product or pause production between batches if needed (for example to incorporate design improvements). [3] (b) Direct cost = £4.20 + £2.10 + £0.30 = £6.60. Indirect cost = 25% × £6.60 = £1.65. Total cost = £6.60 + £1.65 = £8.25. [4] (c) CAD allows the design to be quickly modified and tested (e.g. checking that components fit) on screen before any physical tooling or material is committed, saving cost and material waste; CAD drawings/models can also be shared electronically and used directly to drive CAM/CNC manufacturing equipment, improving accuracy and reducing manual drawing errors. [2] Max 9 marks.

(a) [1] batch production correctly named; [2] valid, developed justification referencing the moderate/repeated volume (5,000/year) and/or flexibility compared with mass production. (b) [1] correct direct cost total (£6.60); [1] correct indirect cost method (25% of direct cost); [1] correct indirect cost value (£1.65); [1] correct final total (£8.25). OFR applies. (c) [1] each for two valid, distinct benefits of CAD (e.g. faster/cheaper design iteration, reduced material waste before production, direct link to CAM/CNC, easier sharing/collaboration, improved accuracy). Max 9 marks.

(a) The load (link rod, 50 mm from the pivot) lies between the fulcrum (pivot) and the effort (foot pad, 200 mm from the pivot), which is the defining arrangement of a second-class lever (as in a wheelbarrow). [2] (b) For equilibrium, moment of effort about the pivot = moment of load about the pivot: \( F_{effort} \times d_{effort} = F_{load} \times d_{load} \). \( F_{effort} \times 200 = 40 \times 50 \). \( F_{effort} = \dfrac{40 \times 50}{200} = \dfrac{2000}{200} = 10\ N \). [3] (c) As the lid closes, air is pushed out of the cylinder through the exhaust line; the unidirectional flow control valve only restricts flow in this outgoing (exhaust) direction, so the air can only escape slowly, which limits how quickly the piston (and lid) can move — slowing and cushioning the last part of the closing motion. Air is able to flow into the cylinder freely (unrestricted) on the return/opening stroke, so opening speed is unaffected. [3] (d) A soft-close damper prevents the lid slamming shut under its own weight/spring, which reduces noise, reduces wear/impact damage to the bin, and reduces the risk of a user trapping their fingers as the lid closes. [2] Max 10 marks.

(a) [1] second-class lever correctly identified; [1] correct justification (load between fulcrum and effort). (b) [1] correct moments equation set up (effort × its distance = load × its distance); [1] correct substitution of values; [1] correct final answer (10 N). OFR applies. (c) [1] correct identification that the valve restricts air leaving/exhausting from the cylinder; [1] correct explanation that this slows the piston/lid's closing movement; [1] correct point that flow into the cylinder (opening) is unrestricted. (d) [1] each for a valid benefit, up to 2 (e.g. reduces noise, reduces impact/wear, reduces risk of trapped fingers) — accept any two distinct valid points. Max 10 marks; OFR applies throughout part (b).

(a) Each pin uses 27 mm of stock (25 mm pin + 2 mm kerf): \( \dfrac{3000}{27} = 111.1 \), so 111 complete pins can be cut (with 3 mm of stock left over). (b) Total kerf wastage = number of pins × kerf per pin = \( 111 \times 2 = 222\ mm \). (c) Volume of a cylinder = area × length. Radius = 3 mm. \( A = \pi r^2 = 3.14 \times 3^2 = 3.14 \times 9 = 28.26\ mm^2 \). \( V = A \times L = 28.26 \times 25 = 706.5\ mm^3 \). (d) Converting to consistent SI units: volume \( = 706.5\ mm^3 = 706.5 \times 10^{-9}\ m^3 = 7.065 \times 10^{-7}\ m^3 \). \( \text{mass} = \text{density} \times \text{volume} = 7850 \times 7.065 \times 10^{-7} = 5.546 \times 10^{-3}\ kg = 5.55\ g \) (3 s.f.). Answer: (a) 111 pins; (b) 222 mm; (c) 706.5 mm³; (d) 5.55 g.

(a) [1] correct total length per pin used (27 mm); [1] correct division (3000 ÷ 27); [1] correct final integer answer (111 — must round down, not up). (b) [1] correct method (pins × kerf); [1] correct answer (222 mm). (c) [1] correct formula and substitution (π × r² × length, using r = 3 mm); [1] correct answer (706.5 mm³, accept 706–707). (d) [1] correct unit conversion of volume to m³; [1] correct method (density × volume); [1] correct final answer in grams (5.55 g, accept 5.5–5.6 g). Max 10 marks; OFR applies throughout.

(a) 3D printing (additive manufacturing): builds parts up layer by layer directly from a CAD model, so prototype pedal covers or replacement pivot pins could be produced quickly and cheaply without needing expensive dedicated tooling (such as an injection mould), which is a specific benefit when testing design changes or supplying occasional spare parts. Robotics: robotic arms can perform repetitive tasks (such as assembling the pivot pin, bracket and lever, or applying the powder coating) with high speed, precision and consistency, reducing labour costs and reducing the number of faulty/inconsistent assemblies compared with manual assembly. [4: 2 marks per technology — 1 for correctly naming it, 1 for a valid, specific benefit] (b) 3D printing only deposits material where it is needed to build the part, so, compared with processes that cut a shape out of a larger sheet or block (and waste the offcut), it produces significantly less material waste — directly reducing the environmental cost of raw material extraction and disposal of scrap. Robotics and computer-integrated manufacturing (CIM) improve the consistency and precision of each production step, which reduces the number of faulty or out-of-tolerance parts produced; because fewer parts need to be scrapped and remade, less material and less manufacturing energy is wasted overall, lowering the bin's overall environmental footprint. [4: 2 marks per point — 1 for the mechanism, 1 for the resulting environmental benefit] Max 8 marks.

(a) [1] first technology correctly named (e.g. 3D printing/additive manufacturing, robotics, CIM, CAM); [1] valid, specific benefit to the manufacturer; [1] second technology correctly named (different from the first); [1] valid, specific benefit to the manufacturer. (b) [1] first environmental mechanism correctly described (e.g. reduced material waste from additive manufacturing); [1] correctly linked to a resulting environmental benefit; [1] second environmental mechanism correctly described (e.g. reduced scrap/rework from improved consistency/CIM); [1] correctly linked to a resulting environmental benefit. Max 8 marks.