OCR GCSE Design and Technology manufacturing processes and techniques overview quiz quiz

Gluing two parts together

Injection moulding

Drilling a hole

Welding a joint

Welding two metal parts permanently

Gluing parts together with epoxy resin

Riveting two sheets permanently together

Screws or knock-down fittings

Deforming shapes the solid material (with force, maybe heat); reforming melts it and forms it in a mould

Deforming melts the material into a liquid first, while reforming simply bends the solid material

They are really the same process and the two words mean exactly the same thing in manufacturing

Reforming only ever applies to timber and can never be used with any plastics, metals or other materials

The metal mould is very cheap to make even when you only need a single bottle cap

It needs no mould or tooling at all, so there is nothing costly to set up first

Once the costly mould is made, each cap is fast, identical and very cheap

It is quite simply the only method that exists for making any plastic parts at all

Batch production

Mass production

Continuous production

One-off (bespoke)

A set quantity of the same product made together, then the line changes

A single unique product made individually to a customer's special order

Production that simply never stops at all, running both day and night

Huge quantities of identical products made continuously without any pause

From 49 mm up to 51 mm

49.5 mm to 50.5 mm

From 50 mm up to 50.5 mm

From 45 mm up to 55 mm

The one exact size that every single part must measure with no variation at all

The total cost of making a part, including the materials and the labour involved

The allowable difference between the largest and smallest acceptable size

The total time taken to make a part from start through to finished assembly

It deliberately makes each part a slightly different size so that no two of them are ever the same

It removes the need for any material at all, so the parts can be made out of nothing

It melts the material down so that the holes can be moulded into shape rather than drilled

It positions the holes identically every time, so parts are consistent and within tolerance

To protect it, improve its appearance, or change how the surface functions

To make the finished product noticeably heavier than it was before finishing

To remove unwanted material from it and waste away the surplus stock

To melt the whole product down so that it can be reformed into a new shape

Wood varnish brushed straight on

Powder coating or galvanising

A rub of beeswax over the surface

Leaving the steel completely bare

They must always be carefully painted by hand after moulding before they can ever be used

They cannot be given any colour at all and must always be left a dull grey

The moulded surface is smooth and coloured throughout, so no extra coating is needed

They rust away very easily and so need a protective coat to stop corrosion