CLICK HERE FOR INDEX PAGE

  
     
 

 
 

V. Ryan © 2002 - 2008

  
     
 

RESISTANT MATERIALS STUDENTS/PUPILS SHOULD ALSO STUDY THE 'EQUIPMENT AND PROCESSES' SECTION OF THIS WEBSITE

  
     
 

MATERIALS

  
 

 

  
 

1. An Introduction to Materials

  
 

2. Natural Woods

  
 

3. Manmade Boards

  
 

4. What is a Sustainable Forest?

  
     
 

5. Natural Woods in Detail

  
     
 

6. Plastics

  
     
 

7. Metals

  
 

8. Galvanising Steel - 1

  
 

9. Galvanising Steel - 2

  
     
 

10. Smart Materials - Polymorph - Shaping by Hand

  
 

11. Smart Materials - Polymorph - Using a Mould

  
 

12. Smart Materials - Shape Memory Alloys - Page One

  
 

13. Smart Materials - Shape memory Alloys - Page Two

  
 

14. Modern Light Weight Modelling Materials

  
 

 

  
 

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  
  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. Introduction to Industrial Production Techniques  
  3. Scales of Production - an Introduction  
  4. Single Item / Prototype Production - Example 1  
  5. Single Item / Prototype Production - Example 2  
  6. Batch Production - Example 1  
  7. Batch Production - Example 2  
  8. Batch Production Exercise  
  9. Continuous Production - Example 1  
  10. Continuous Production - Example 2  
  11. Production Methods - Lesson Starter  
  12. CIM - Computer Integrated Manufacture - 1  
  13. CIM - Computer Integrated Manufacture - 2  
  14. Remote Manufacturing  
  15. Continuous Improvement (CI) - Page 1  
  16. Continuous Improvement (CI) - Page 2  
  17. Flexible Manufacturing Systems - FMS - 1  
  18. Flexible Manufacturing Systems - FMS - 2  
  19. Detailed Example of Flexible Manufacturing - CD / DVD Manufacture  
     
  MODEL / PROTOTYPE 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)  
     
     
  QUALITY SYSTEMS  
     
  1. Quality Assurance  
  2. Quality Control  
  3. Quality Control Exercise  
     
  4. Tolerances - 1  
  5. Tolerance - 2  
     
  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  
     
  EXAMINATION PREPARATION THEMES  

The aim of this sub-section is to set a design theme and context

 

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*
     
  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*

 

  
     
  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  
     
 

3. 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