Aqa 8552W W MS Nov20

GCSE
DESIGN AND TECHNOLOGY

8552/W
Unit 1 Written Paper
Mark scheme
June 2020
Version: 1.0 Final
*206G8552/W/MS*
MARK SCHEME – GCSE DESIGN AND TECHNOLOGY – 8552/W – JUNE 2020
Mark schemes are prepared by the Lead Assessment Writer and considered, together with the relevant
questions, by a panel of subject teachers. This mark scheme includes any amendments made at the
standardisation events which all associates participate in and is the scheme which was used by them in
this examination. The standardisation process ensures that the mark scheme covers the students’
responses to questions and that every associate understands and applies it in the same correct way.
As preparation for standardisation each associate analyses a number of students’ scripts. Alternative
answers not already covered by the mark scheme are discussed and legislated for. If, after the
standardisation process, associates encounter unusual answers which have not been raised they are
required to refer these to the Lead Examiner.
It must be stressed that a mark scheme is a working document, in many cases further developed and
expanded on the basis of students’ reactions to a particular paper. Assumptions about future mark
schemes on the basis of one year’s document should be avoided; whilst the guiding principles of
assessment remain constant, details will change, depending on the content of a particular examination
paper.
Further copies of this mark scheme are available from aqa.org.uk
Copyright information
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Copyright © 2020 AQA and its licensors. All rights reserved.
2
Level of response marking instructions

Level of response mark schemes are broken down into levels, each of which has a descriptor. The
descriptor for the level shows the average performance for the level. There are marks in each level.
Before you apply the mark scheme to a student’s answer read through the answer and annotate it (as
instructed) to show the qualities that are being looked for. You can then apply the mark scheme.
Step 1 Determine a level

Start at the lowest level of the mark scheme and use it as a ladder to see whether the answer meets the
descriptor for that level. The descriptor for the level indicates the different qualities that might be seen in
the student’s answer for that level. If it meets the lowest level then go to the next one and decide if it
meets this level, and so on, until you have a match between the level descriptor and the answer. With
practice and familiarity you will find that for better answers you will be able to quickly skip through the
lower levels of the mark scheme.
When assigning a level you should look at the overall quality of the answer and not look to pick holes in
small and specific parts of the answer where the student has not performed quite as well as the rest. If
the answer covers different aspects of different levels of the mark scheme you should use a best fit
approach for defining the level and then use the variability of the response to help decide the mark within
the level, ie if the response is predominantly level 3 with a small amount of level 4 material it would be
placed in level 3 but be awarded a mark near the top of the level because of the level 4 content.
Step 2 Determine a mark

Once you have assigned a level you need to decide on the mark. The descriptors on how to allocate
marks can help with this. The exemplar materials used during standardisation will help. There will be an
answer in the standardising materials which will correspond with each level of the mark scheme. This
answer will have been awarded a mark by the Lead Examiner. You can compare the student’s answer
with the example to determine if it is the same standard, better or worse than the example. You can then
use this to allocate a mark for the answer based on the Lead Examiner’s mark on the example.
You may well need to read back through the answer as you apply the mark scheme to clarify points and
assure yourself that the level and the mark are appropriate.
Indicative content in the mark scheme is provided as a guide for examiners. It is not intended to be
exhaustive and you must credit other valid points. Students do not have to cover all of the points
mentioned in the Indicative content to reach the highest level of the mark scheme.
An answer which contains nothing of relevance to the question must be awarded no marks.
3
Glossary for maths
If a student uses a method which is not explicitly covered by the mark scheme the same principles of
marking should be applied. Credit should be given to any valid methods. Examiners should seek advice
from their senior examiner if in any doubt.
[a, b] Accept values between a and b inclusive.
For 𝝅 Accept values in the range [3.14, 3.142]
Their Accept an answer from the candidate if it has been inaccurately calculated
but is subsequently used in a further stage of the question.
Questions which do not ask students to show working
As a general principle, a correct response is awarded full marks.
4
Total
Qu Part Marking Guidance AO
marks
1 A Biomass 1 mark AO4
2 B To have a short lifespan 1 mark AO4
3 C To switch equipment on or off 1 mark AO4
4 B Photochromic pigment 1 mark AO4
5 D Woven fabric 1 mark AO4
6 A Due to improvements in new materials 1 mark AO4
7 An increased use of robotics has led to a reduction in manual 1 mark AO4

A
jobs
8 D Turbine 1 mark AO4
9 D Pulley 1 mark AO4
10 A Can be drawn into a long length 1 mark AO4
5
Total
marks
11 1 Name one alloy. 1 mark AO4
1 mark for a correct specific named alloy.
Indicative content:
Brass
Bronze
Duralumin
Pewter
Steel (accept any specifically named steel eg die steel (tool steel),
high speed steel (HSS), stainless steel)
Accept all other valid responses.
11 2 Explain why metals are alloyed. 2 marks AO4
2 marks Two correct simple points of explanation or one

point explained in detail possible using a specific
example of use.
1 mark One correct simple point of explanation.
0 marks No attempt or nothing worthy of credit.
Indicative content:
• Where a mixture of at least 2 metals are combined to give

enhanced properties
• To produce a tough corrosion resistant material eg stainless steel
• Titanium can be alloyed with other metals like aluminium and
vanadium for increased strength, better corrosion resistance and
easier workability
• Alloying metals can improve working properties and improve
aesthetics
Possible reference to examples of use to enhance explanation:
• Stainless steel – cutlery to make hard wearing and corrosion

resistant
• Brass – copper and zinc for brass musical instruments due to
workability into different forms and profiles
6
Total
marks
12 1 Composite materials such as foil and polymer lined boards are used 2 marks AO4
in food and drink packaging.
Give one advantage and one disadvantage of using composite

materials for packaging.
1 mark for one correct advantage and one correct disadvantage.
Indicative content:
Advantages:
• Improve resistance to water absorption

• Improve insulation properties
• Improve ability to preserve contents
• Improve strength and stability of the container
Disadvantages:
• Not always recycled by some local collection services hence may

be incinerated or end up in land fill
• Do not degrade easily if littered
• Difficult to separate different materials from each other for
recycling at the end of a containers life
12 2 Table 1 shows the number of food and drink containers successfully 2 marks AO4
recycled by a manufacturer in 2010 and 2017.
What is the percentage increase in recycling of composite food and

drink containers between 2010 and 2017?
1 mark For recognising a 14 billion tonne increase in

containers recycled ie 46-32 billion tonnes
1 mark 14 ÷ 32 × 100 = 43.75%
Accept 43.8%
Alternative method
1 mark 46 ÷ 32 = 1.4375
1 mark Answer 43.75%
Accept 43.8%
7
Total
marks
13 Figure 4 shows a system diagram for an alarm. 3 marks AO4
Complete the diagram by naming one component that could be

used in each block.
Suitable inputs Suitable processes Suitable outputs
• Light sensors • Microcontrollers • Buzzers

• Temperature • Timers • Speakers
sensors • Decision making • Lamps
• Pressure sensors
• Switches Accept trade Accept specific
• Pressure pad names for specific components:
components and:
Accept any • Bell
switch/sensor • PIC chip • LED
used to activate or • Genie chips • Siren
deactivate system, • Picaxe • App notification
eg: • Arduino on phone
• Crumble
• PIR sensor • Genie
• Sensor + • Counter
qualification • Transistor
• Motion sensor • Microprocessor
• SPST switch • Transistor
• Key switch • Time delay
• Reed switch • Monostable
• Key pad • Astable
8
Total
marks
14 Name one specific commercial manufacturing process and describe 4 marks AO4 1a
what it is used for. AO4 1b
Name of process
Using notes and/or sketches describe the process you have named
above.
1 mark for a correctly named specific process
1 mark for a simple descriptive point

2 marks for a detailed response with two credit-worthy points made
Indicative content:
Papers and Offset lithography Printing design and information

boards Screen printing on paper and card.
Digital printing
Die cutting Cutting out of nets.

Making perforations.
Creasing of card.
Timber Routing Production of grooves, rebates
based and joints.
materials
Turning Turning cylindrical objects and
shapes.
Lamination Bonding layers of veneers or

laminas together to create a
large flat board or a complex
curved shape using a former.
Machine Cutting square or rectangular

morticing holes in a piece of timber to
create joints. (Also note that
mortices often have round ends
so must be considered if in
answer).
Metal Milling Horizontal or vertical milling of
based a flat surface, groove, rebate or
materials hole.
Casting
9
Redistribution of metal in
molten form to fill a mould or
Welding cavity.
Redistribution of at least 2
pieces of metal along and
edge/spot/seam to create a
Brazing permanent joint.
Use of solder to join two or

more pieces of metal together
Sintering without physically melting them.
The compression of powdered

metals in a die using heat and
extreme pressure to create a
solid product in final shape.
Polymers Injection The heating and injection of
moulding molten polymer into a mould to
produce a 3D shape.
Extrusion Where molten polymer is

extruded through a die to
produce a consistent shaped
profile.
Vacuum forming Heating of sheet polymer so

that it softens and can be
shaped in a mould by
extracting the air between the
material and the form.
Calendaring Manufacture of thin

thermoplastic film.
Rotational Used to manufacture hollow 3D

moulding products using an enclosed
mould containing thermoplastic
polymer in powder form.
Blow moulding Polymer in tube form is

extruded (parison), the end
sealed and hot air blown in to
forcing the polymer out into a
mould to create a hollow
shape.
Textile Weaving Fabrics are woven on looms to
based produce large rolls of cloth in
materials either plain or repeating
patterns.
Dying
10
Fibres are dyed commercially

before weaving to establish a
fibre colour dying can be done
by batch dying in a tank or
continuous dying using various
tanks and rollers to move the
fabric along.
Printing
Roller printing, screen printing
and digital printing all transfer
images to the fabric.
Machine sewing
Specialist sewing techniques
like the overlock stitch can be
used to create a tough and
durable edge, hem or seam.
Electrical Pick and place Used to select and position
and assembly individual components in pre-
mechanical determined positions quickly
systems and consistently on a PCB.
Flow soldering/ Used in surface mounting of

Reflow soldering electrical components.
Components are located on a
PCB on pre-soldered pads.
PCB is then placed in a reflow
oven where the solder melts
connecting the component to
the PCB.
Wave soldering Circuit boards have pre drilled

holes with components located
in position. PCB board then
moves on a conveyer belt over
a molten solder wave, bonding
the components to the PCB as
the solder cools.
PCB manufacture Different to photoresist PCB

Etching manufacture done in school by
spraying the etch directly onto
a developed PCB board.
PCB lacquering Application of a polymer layer

to protect PCB from corrosion,
dust and dirt.
Accept other valid responses.
11
Total
marks
15 Explain why each factor below would need to be considered by a 2x2 AO4
manufacturer when sourcing materials/components. marks
A maximum of 2 marks explaining why each factor needs to be

considered when selecting materials or components
2 marks Two simple points of explanation given or one

clarified in greater detail
1 mark A simple correct point of explanation given
Indicative content:
The guidance provided is illustrative and not exhaustive. Credit any

worthy points made in support of the band descriptors above.
Bulk buying Economies of scale – buying in bulk

will allow for reduced
material/components costs and these
can be passed on to the customer for a
more competitive price. Manufactures
will secure discounts that can be
passed on to the customer.
Stock forms – buying exactly the
quantity of materials required for a
product or range of products knowing
they can be used without waste
Standard components – bought in
bulk to secure discounts and reduce
final product cost
Ethical factors Finite v renewable – avoid
unnecessary consumption of finite
resources that will run out. Use
sustainable materials where possible.
Provenance – where do the materials
come from? Are they from an ethical
source eg Forest Stewardship council
(FSC) or Fairtrade.
Working conditions – the promotion
and support of people and communities
in developing countries to ensure they
are not exploited, having a detrimental
impact on education, health and
general well-being.
12
Total
marks
16 1 The products/components shown below are manufactured from 3 marks AO4

different materials.
Choose one product/component and complete Table 2 below.
One mark for each of:
• Specific main material

• Stock form
• Appropriate finishing technique
Indicative content:
Content is illustrative and other correct responses should be

rewarded.
Product: Metal can opener

Appropriate
Specific main Stock form used in
finishing
material used manufacture
technique
Steel Sheet Polymer over-
Stainless steel Strip moulding
Bar Left as finished/
polished finish
Powered coated
Product: Card shoe box

Appropriate
finishing
technique
Solid white board Sheet Offset lithography
Corrugated Printing
cardboard
Product: Textile shopping bag with logo

Appropriate
finishing
technique
Cotton drill Roll Dying
Denim Screen printing
Hessian Digital printing
Calico Stain resist finish
Water resist finish
13
Product: Wooden toy

Appropriate
finishing
technique
Beech Plank Cellulose
Pine Board Lacquer
MDF Varnish
Plywood Oil
Product: Polymer gears

Appropriate
finishing
technique
Most gears are Granules Pigment added
made from Nylon during injection
and Polyacetal Also accept named moulding
Also accept: gear stock forms eg
Polyphenylene spur, bevel, helical, Left as finished in
sulfide (PPS) worm, bevel, mould
Thermoplastic hypoid, crown gear
polyester, long fibre
reinforced plastic
and liquid crystal
polymers (LCP).
16 2 A number of calendars are being made. 2 marks AO4
Given the sizes provided in Figure 5 and Figure 6, how many

calendar pages can be made from one sheet?
Indicative content:
1 mark Correct calculation

280 × 4 = 1120 mm
210 × 4 = 840
OR
1187 ÷ 280 = 4.2 (so 4 sheets one way)

And 841 ÷ 210 = 4 the other way
OR
(1187 x 841) ÷ (280 x 210) = 16.9773 = 16 pages

max
OR
14
998267 ÷ 58800 = 16.9773 = 16 pages max.

1 mark Calculation that pages will fit in a 4 × 4 arrangement
allowing 16 pages to be made from each sheet
16 3 What percentage of material is waste after cutting the pages 3 marks AO4
calculated in Question 16.2?
Give your answer to two decimal places.
1 mark Step 1:
Total sheet area = 1187 × 841 = 998 267
Total area of their answer from 16.2 = their 16 × 280 ×
201 = 940 800
1 mark Step 2:
Total waste = 57 467 mm2 – their 940 800 = their 57 467
1 mark Step 3:
Percentage waste = their 57 467 ÷ 998 267 × 100 =
their 5.7567% = their 5.76%
Alternative method 1
1 mark Step 1:
Vertical waste portion their 67 × 841 = 56 347 mm2
Horizontal waste portion = their 1 × their 1120 = 1200
mm2
1 mark Step 2:
Total waste = their 57 467 mm2
Total sheet area = 998 267 mm2
1 mark Step 3:
Percentage waste = their 57 467 ÷ 998 267 × 100 =
their 5.7567% = their 5.76%
Alternative method 2
1 mark Step 1:
Vertical waste portion their 67 × their 840 = their XXX
mm2
Horizontal waste portion = their 1 × 1187 = their 1200
mm2
15
1 mark Step 2:
Total waste = XXX mm2
Total sheet area = 998 267 mm2
1 mark Step 3:
Percentage waste = their XXX ÷ 998 267 × 100 = their
5.7567% = their 5.76%
Total
marks
17 Responsible design should consider social issues in the design and 8 marks AO4
manufacture of products.
Analyse and evaluate the types of pollution caused by the

manufacture, use and disposal of products.
Give examples in your answer.
7–8 marks A fully detailed analysis and evaluation of oceanic

and/or atmospheric pollution and the impact it can
have on the environment. Several good examples
to support response.
5–6 marks A good analysis of both oceanic and/or
atmospheric pollution and the impact on the
environment. Some evaluative points given in
response to analysis information presented. Good
example(s) to support response.
4–3 marks Basic analysis of oceanic and/or atmospheric
pollution. Expect an imbalance in response
between the two types of pollution requiring
consideration in the question. One or no evaluative
point. Simplistic or vague attempt to include
examples in response.
1–2 marks One or two limited points considering oceanic
and/or atmospheric pollution. Very limited analysis,
evaluation and no examples.
Indicative content:

Analysis – identification of component characteristics of each type of

pollution
16
Evaluation – judgment on impact of each type of pollution on the

environment
Oceanic pollution • Pesticides and fertilisers being

washed from the land by rain and
carried by rivers into the sea.
• Chemicals and toxic materials like
mercury and lead find their way into
oceans. These then can enter to
food chain and poison water
supplies.
• Plastic which does not degrade is
carried by rivers into the sea creating
large pools of rubbish in the deep
oceans where sea currents
converge.
• Pollution of the seas from oil spills
during extraction and tanker
accidents.
• Oil and sewage pollution whilst better
than in previous years, can still
contaminate and pollute ecosystems
and marine life eg coastlines.
• Micro beads – no longer legal to use
in cosmetics as from January 2018 in
the UK (also banned in Europe and
North America). Big problem due to
size of less than 1 mm diameter is
that they cannot be removed by
water treatment making it all the way
into the oceans to the detriment of
sea life and ecosystems.
Atmospheric pollution • Acid rain – the combination of
nitrogen oxide and sulphur dioxide
combine and fall as acid rain which
when carried by prevailing winds fall
raising acidity levels in lakes killing
fish and marine life and also raising
acidity in the soil destroying plant
based life.
• Carbon monoxide contributes
extensively to greenhouse gasses
and raising the global temperature.
• Carbon dioxide emissions form
vehicles using fossil fuels is known to
lower air quality affecting the heath of
the young, elderly and those with
chronic breathing issues.
• Particulates – when released into the
atmosphere they can cause ‘global
dimming’ restricting light to the
surface of the earth.
17
• Lower air quality – impact on human

health particularly the young, old,
people with asthma, heart and lung
problems. Net impact on increase
health care costs and mortality rates.
Affected groups are told to stay
indoors on days identified as ones
with poor air quality.
18
Total
marks
18 Explain why the two methods below are used to manufacture 2x3 AO4
products in different volumes. marks
Give specific examples of products in your answer.
Maximum of 3 marks for each production method.
3 marks Two simple/One detailed point of explanation and

specific example (s) to further clarify response.
2 marks One detailed/Two simple points or one simple point
of explanation and a specific example to further
clarify response.
1 marks One simple point of explanation or appropriate
specific example to clarify response.
0 marks Nothing worthy of credit.
Indicative content:

Mass
• Used to produce products in tens of thousands/ large production

runs eg TVs, fridges, microwave ovens.
• Highly suited to products that can be made using automated
manufacturing techniques requiring minimal human involvement
eg packaging and leaflets.
• Where a large number of identical products are known to be
needed, making it worthwhile setting up a dedicated production
line.
• Used where efficient material use is paramount to ensure a cost
effective product with minimal waste/ zero defects to keep product
costs low eg mobile phones.
Batch
• Suited to small quantities of a product or slight variations of a

product eg perishable goods like food, chemicals (adhesives &
paint), home furnishings (wallpaper and tiles) some medical
supplies etc.
• Batches can be in single figures or several hundred depending on
what the product is eg set of dining chairs, bridesmaid dresses
• Extensive use of jigs, templates and moulds to assure consistency
across a batch.
• Opportunities for CAD/CAM to allow flexibility in manufacturing
different batches of products.
19
• Quick change over between one batch of products and another

without time consuming human involvement eg manufacture from
a CAD file.
• Economies of scale as some materials/ components can be
sourced/purchased in bulk.
20
Total
marks
19 Choose one of the companies from Table 3. 6 marks AO4
Outline the design features and/or manufacturing techniques that

have made your chosen company successful.
You should refer to specific products in your answer.
5–6 marks Thorough description of a wide range of design

features and/or manufacturing techniques provided
for one company. Two or more clear examples
provided to support response.
3–4 marks A good description with consideration of some
design features and/or manufacturing techniques
provided for one company.
1–2 marks Limited description identifying generic products
associated with one company rather than design
features and/or manufacturing techniques.
0 marks Nothing worthy of credit/ a company not in the
question has been discussed
Indicative content:

Alessi
Unique products produced with a distinctive design flavour.
Heavy focus on kitchen products and products for the household.
Products make extensive use of stainless steel mixed with brightly
coloured polymers.
Artistic design
A focus on high quality – hand
crafted objects made with the help of machines
Fun design imprinted with characterful features
Products designed to be aesthetic as well as functional with varying
degrees of success:
• Whistling bird kettle 1985 by Michael Graves
• Juicy Salif 1990 by Philippe Starck
• Anna G corkscrew 1994 by Alessandro Mendini
• Condiment set 1978 by Ettore Sottsass
Apple
Computers, portable music and phones:
• Apple 2 and 3 PCs in the 1970s
• Apple Macintosh computers in 1980s
• Macintosh mouse 1984
21
• iMac G3 1998 designed by Jonathan Ive with cases in distinctive

and various colours to catch attention
• Mini desktops – the Power Mac cube 2000
• PowerBook 100 1991 – miniaturised parts of the desktop range to
create a lap top with integrated mouse
• iPod Generation 1 2001 with click wheel technology for ease of
track selection
• iPod shuffle 2005 – random track selection
• MacBook Pro 2006 with aluminium case. The benchmark for all
other manufacturers
• iPhone 2007 with touch screen technology. Apps from the Apple
shop
Braun
A company forever linked with the work of German industrial
designer Dieter Rams and his 10 principles for good design:
1. Innovative
2. Useful
3. Aesthetic
4. Understandable – good design that does not need an instruction
booklet!
5. Unobtrusive
6. Honest
7. Long lasting
8. Design down to the last detail
9. Environmentally friendly
10. As little design as possible
A range of electrical and electronic products designed with simple

lines, function in mind and intuitive design:
• Portable radios
• Digital bedside radio/alarm clocks
• Battery powered/electric shavers eg Braun sixtant razor 1962
• Hair and skin care products eg hairdryers
• Health products eg blood pressure monitors
Dyson
Electrical and electronic products using imagination and innovation
to create stylish products that are also highly functional
• DC01 – the first dual cyclone vacuum cleaner 1993.
• Washing machine CR01 2000 with twin opposing drum technology
for a quicker more thorough wash supposedly.
• Dyson digital motor 2004 – with high speed impeller. Used in later
iterations of cleaners for improved efficiency.
• Dyson ball vacuum cleaner DC15 2005 – for improved
manoeuvrability. Traditional cleaners have fixed wheel s and only
go in straight lines.
• First Hand held cleaner 2006 – DC16 using root cyclone
technology.
• Airblade AB01 2006 – hand dryer with airblade technology.
Works by scraping water off washed hands, hygienic and drying
hands in 10 seconds approx.
22
• Air multiplier fan AM012009 – no blades and multiplies air flow by

15 times.
• Dyson digital slim cordless vacuum cleaner 2018 – no cord
connectivity. Power provided by high output lithium ion batteries
effective for whole house cleaning.
Gap
Established in the late 1960s (American fashion) in response to
different fashion requirements for customers between childhood and
adulthood – the gap:
• Men – trousers, shirts, shorts
• Women – dresses, maternity
• Children – baby and kids
Empowering women – PACE (Personal Advancement and Career

Advancement) launched 2007. Used to support women in the
apparel industry where barriers to education have impacted on
progression and development into leadership and management in
the workplace and also personal and professional growth. Used as
appositive promotional point for gap product.
Products designed and marketed with sustainability in mind – great

durable products designed using new technology and product
innovation, reducing the impact on people and the planet of what we
wear.
By 2020 eliminate the use of wood derived fabrics sourced from

ancient and endangered forests.
By 2021 100% of cotton will be from sustainable cotton sources

including Better Cotton Initiative (BCI).
By 2020 80% of Athleta materials will be made from sustainable

fibres.
By 2020 25% of Athleta’s products will be made using techniques
that save water.
Primark
A focus on ‘fast fashion’ designed for rapid change beyond seasonal
but also social, especially for teenagers and young adults.
Clothes are marketed as cheaply as possible and this has led to

complaints about irresponsible design as some items are worn only
once.
Products made sell themselves ie little advertising.
Manufactured products don’t use expensive hangers, tags or labels

that add to the product cost.
Suppliers are asked to pack clothes like t-shirts so they are ready to
go on shelves straight away.
Designs and products go beyond just clothing.
23
• Homeware
• Sweets and confectionary
Under Armour
A primary focus on sportswear and footwear. Designed originally to
enhance performance by keeping athletes comfortable and cool.
Origins based in the identified need of sports tops that did not
become wet during exercise- led to the development of a synthetic
‘moisture wicking’ fibre that kept the participant dry
Has moved into the design and manufacture of casual clothing.

Examples of specific materials used in products like shorts, socks,
trainers, tops are:
• Heatgear – Original product. Regulates body temperature, keeps
you cool.
• Coldblack – reflects heat when it is hot
• Coolswitch – pulls heat away from the body during exercise
• Iso-chill – dissipates heat from the body to keep you cool.
Zara
A focus on ‘fast fashion designed for rapid change beyond seasonal
patterns, but also social change for particularly young girls and
teenage girls.
Prides itself on keeping up with fashion, high quality at reasonable

prices. Products sold based on customer trends
• Men’s clothing
• Women’s clothing
• Kids clothing (Zara kids)
Life label (Join life) – recycling scheme. Home pick up of unwanted

clothes. Clothes they go for recycling and /or reuse to finance social
projects.
Use of REFIRRA – a fibre made from recycled cotton and wool from
sustainable forests.
Working to ensure all products are sustainable throughout raw

materials used, design and production.
24
Total
marks
20 1,2,3 Figure 7 shows three different kettles. 12 marks AO4
Analyse and evaluate the kettles in terms of the three features

identified below.
You should not use an analysis or evaluation point more than once.
Award up to 4 marks for each of the three parts of the question.
3–4 marks Well described and justified analysis containing full

evaluation, drawing on conclusions having
considered both positive and negative factors.
1–2 marks Brief points mentioned but not fully explained.
Analysis present but limited evaluation/ conclusions
drawn. May have focused solely on either positive
or negative factors.
Indicative content:

NB Do not reward repeats ie where some candidate may try to

use the same response multiple times in 20.1/20.2/20.3
Ergonomics • Ergonomic handle on polymer kettle allowing

firm safe grip
• Polymer construction is an insulator and
prevents transfer of heat and burns
• Carrying handle is away (opposite side) from
steam outlet on polymer kettle unlike other two
when hot steam rises and may burn you
• Polymer could make use of thermochromic
pigment to indicate when contents are hot
• Whistling kettle gives audible sound when
water is boiling
• Polymer kettle has viewing window so user
can see if kettle needs re filling
• Awkward carrying position with handle over
the top of the main kettle body
• No viewing window on cast iron kettle
• Cast iron kettle lid may prove difficult to reseat
especially if hot and it has expanded
• Spout of cast iron kettle not as easy to control
flow due to shape
25
• Iron is a conductor so hot to the touch

including the handle
Functionality • No trailing flex with the iron stove top kettle –
less chance of being pulled off stove surface
• Hinged lid on polymer kettle for ease of
closure and resealing
• Docking unit means kettle flex an plug do not
go anywhere near water which would be a
possible risk of electric shock
• Light weight for elderly and less able body to
carry and manipulate
• Thermostatic trip when the water has boiled,
preventing kettle from boiling dry
• Cast iron kettle can be used over an open fire
or hearth
• Cast iron kettle is heavy and could be dropped
leading to scalding
• Risk of electric shock if kettle develops a fault
or water accesses the electrics
• Rising steam could burn users hand on the
cast iron kettle
• Difficult to gauge how much water you are
boiling, which may lead to heating too much
water
• Polymer kettle MUST be near an electrical
point
• Whistling kettle MUST be near a
gas/electric/inductive hob
Innovation • Viewing window so you can see exactly how
much water you are boiling
• Viewing window has water level marks to
indicate precise capacity
• Trip switch to turn polymer kettle off and save
electricity
• Polymer kettle acts as an insulator and will
keep the water hotter for longer requiring less
frequent boiling
• Use of lighter materials
• Use of materials that insulate and keep the
water warmer for longer
• The polymer and whistling kettle consider the
safety more effectively
• The polymer and whistling kettles consider
the ease of use more effectively than the cast
iron kettle
• The use of new materials has allowed for
kettle development to consider the aesthetics
of the product rather than just the function
• Modern kettles consider energy efficiency far
more than the cast iron style kettle
• Just plug into electricity supply
26
• Cast iron kettle will require more energy to

heat and energy will be lost more readily into
the surrounding environment from the hob
plate
• The polymer kettle MUST have a (240v)
electric supply to work
27
Total
marks
21 Describe the following two types of investigation. 2x3 AO4

marks
Give examples to show how they help when designing. These can
be examples of use
Primary research:
3 marks Correct definition of primary research and two or

more named examples of primary research
2 marks Correct definition for primary research and one
correct example of primary research
1 mark Simple definition point or one correct example of
primary research
Indicative content:

specific points made in support of the band descriptors above.
DO NOT credit vague responses like to identify needs and

wants.
Definition of • Involves the collection of research first-hand

primary • Information you have collected yourself
research: • Completed by the author of the research
• All forms of field research
Examples • Interviews – telephone, social media and face to
of primary face
research: • Questionnaires
• Material testing
• Product analysis
• Measuring – useful sizes
• Surveys
• Focus groups
Secondary research:
3 marks Excellent definition with clear understanding of

secondary research and two or more named
examples of secondary research.
2 marks Correct definition for secondary research and one
correct example of secondary research.
1 mark Simple definition point or one correct example of
secondary research.
28
Indicative content:

Definition of • Involves the use of data and research collected

secondary by another person or 3rd party
research: • Data and information presented by another
person
• Use of material someone else has initially
collated and put together
• Also known as desk research
Examples • Use of books, magazines, periodicals
of • Looking at the work of other designers and
secondary companies
research: • Published anthropometric and ergonomic data
• Materials/component catalogues
• TV programmes and social media outlets
• Consumer sources eg watchdog
Accept all valid responses.
22 1 A designer has been asked to design a prototype toy suitable for use 1 mark AO4
by a child between 3 and 5 years of age. They are using the data in
Table 4.
Complete the two missing values in Table 4 for popularity votes.
1 mark One mark for both missing popularity vote values if

correct. NO MARKS IF ONE LEFT BLANK OR
ONE OUT OF TWO INCORRECT
Indicative content:
Popularity votes
Type of toy Popularity votes
as a percentage
Role play 65 26%
Construction 40 16%
Letters and
85 34%
numbers
Jigsaws and
25 10%
puzzles
Soft toys 35 14%
Total 250 100%
29
22 2 Use your values from Question 22.1 to complete the bar chart below 3 marks AO4
and label the x axis.
1 mark Step 1 – 1 mark for x axis

1 mark Step 2 – 1 mark for correct size of letters and
numbers bar (ft their answer from 22.1)
1 mark Step 3 – 1 mark for correct size and placement of
soft toys bar (ft their answer from 22.1)
Indicative content:
x axis label:
Accept:
Popularity of different toys
Popularity votes
Not:
Popularity votes as a percentage
Note: The graph below shows the correctly completed missing

bars (in blue and pink) if a student has provided the correct
values in 22.1.
If a student has provided incorrect values for 22.1 but their bar
chart correctly matches their values, they should receive the
mark(s).
Completed graph:
Correctly completed missing bars shown in blue and pink below:
30
Total
marks
23 Give five detailed specification points to help with the designing of a 5 marks AO4
toy for use by 3 to 5 year-old-children.
1 mark One mark for each design specification point given

appropriate for a toy suitable for use by 3 to 5 year
old children.
Indicative content:

worthy points made in support of the band descriptor above.
1. It must amuse/entertain the child

2. Bright and colourful to engage the interest of the child
3. It must not contain any small parts that could be easily
swallowed
4. There should be no sharp edges that could cause cuts to the
child
5. There should be no pointed pieces that could stab/puncture the
skin
6. Any finish (paint) applied must not be toxic/harmful in
chewed/ingested
7. If the toy contains a battery it should be secured and not possible
for a child to remove – battery directive (labelling bit)
8. There must be no gaps where a child could put a finger and trap
it
9. Materials that are tough and durable need to be used to ensure it
does not break if dropped or thrown
10. Materials need to be easy to clean (sanitise) because the child
may chew it, drop food on it.
A credit worthy point must not be vague. Zero mark responses

would be:
• It must be strong
• It must not be too big
• It must be made from cheap materials
• Easy and simple to use
Total
marks
31
24 1 Figures 8 and 9 show a front and side view of a bug box used to 4 marks AO4 2c
encourage insects to visit a garden.
Complete a two-point perspective drawing of the bug box in the

space provided below.
1 mark A recognisable attempt at a 3-dimensional drawing

e.g. 3 connected elevations/sides to object.
1 mark Clear evidence of some perspective/
foreshortening.
1 mark Drawing is recognisable as the bug box in the
indicative content below (does not have to show
hook or overhang of roof).
1 mark Inclusion of hook or extension to the front edge of
the roof.
Indicative content:
Responses with bug box drawn above, on or below a horizontal

plane between two vanishing points (horizon line) are acceptable –
see images opposite:
32
33
24 2 Calculate the size of angle X in Figure 10 to the nearest whole 4 marks AO4
degree to ensure an accurate fit of the two roof pieces.
Show your working/construction.
Trig Method
1 mark 85 seen
1 mark Step 1 – correct use of tan formula:
Tan Y = opp/adj
1 mark Step 2 – correct substitution of correct size
of opposite and adjacent lengths:
Tan Y = 70/85
1 mark Step 3 –
Tan-1 0.8235294117 = 39.47 (degrees)
Subtraction of angle from 90 degrees to
give angle X:
90 – 39.47 = 51 degrees (Accept 50
degrees)
Alternative Trig Method

1 mark 85 seen
1 mark Step 1 – correct use of tan formula:
Tan X = opp/adj
1 mark Step 2 – correct substitution of correct size
of opposite and adjacent lengths:
Tan X = 85/70
1 mark Step 3 –
Tan-1 1.214285714 = 51 degrees (Accept
50 degrees)
Drawn/constructed method
1 mark 85 seen
1 mark Constructing a triangle with sides 85 mm ×
70 mm
1 mark Accuracy of drawing
1 mark Measuring interior angle with protractor to
arrive at 39 – 40 degrees and subtracting
that angle from 90° (Accept 50 – 51
degrees)
Alternative drawn/constructed method

1 mark 85 seen
1 mark Constructing a triangle with sides 85 mm ×
70 mm
34
1 mark Accuracy of drawing

1 mark Measuring their angle X (Accept 50 – 51
degrees)
See drawing below:
Total
marks
25 During manufacture it is important to use materials efficiently and 2x3 AO4

minimise waste. marks
Explain how each of the following improves material management.
3 marks Two or more correct explanation points clearly

made in detail.
2 marks Two or more simple explanation points lacking
depth and understanding or one correct explanation
point given in detail.
1 mark One simple correct point for technique is given
demonstrating limited understanding.
Indicative content:
35

Nesting of shapes and parts/lay planning
• A process for planning and working out the best way to maximise
the effective use of material and minimising waste as much as
possible.
• By placing similar shapes and parts next to each other to minimise
waste.
• Strategic way of planning material use and minimising waste.
• Looking for patterns in nesting eg inverting shapes being cut out if
they are triangular to save material by placing parts as close
together as possible.
• Tessellation is a process by which parts are placed together in
interlocking and repeating patterns to minimise waste.
• Consideration of standard forms and sizes of available material to
ensure materials are sourced in the most cost-efficient form to
minimise waste.
Cutting techniques
• Allow for the width of saw cuts eg 2mm with a dovetail saw to
ensure the process of cutting does not accidentally reduce the
size of material being cut out.
• Failure to consider material removed by saw cuts will make
shapes/parts being cut out possible too small (out of tolerance)
and having to be rejected ie material wasted.
• Seam allowance to allow for an effective join to be formed along
the edges of fabric materials to be joined.
• Use of different coloured lines for cut and score/crease lines in
paper and boards to ensure fold flaps and glue flaps are created
to ensure effective assembly.
• Use of red line for cut and black lines for engrave/raster lines on a
laser cutter to avoid errors in pre-cut checks.
Accept other responses.
36
Total
marks
26 Describe how materials can be formed when making a prototype. 3 marks AO4
3 marks A thorough understanding of what ‘forming’ is and

how it can be used in prototype construction in a
material area(s) studied by the candidate.
2 marks Basic understanding of ‘forming’ and how it is used
in prototype construction in a material area(s)
studied by the candidate.
1 mark Very limited understanding of ‘forming’ naming a
forming process or giving an example of where it
would be used in a prototype construction in a
material area(s) studied by the candidate.
Indicative content:

Note: responses may consider deforming of reforming. Both

processes involve a change in material shape without adding or
removing material.
Timber based materials
• Timber strips can be steamed to make them more pliable and

easier to bend.
• The timber fibres are softened and bent without tearing or rupture
eg stair hand rails, musical instruments.
• Thin strips of timber can be laminated using a suitable adhesive
using a former.
• Pressure is applied until the adhesive curs/set and a change in
shape is made.
Metal based materials
• Bars and tubes can be bent found a former to change shape from
a linear length.
• Metals can be heated (annealed) to make them easier to bend.
• Metals can be forged. Heating until red hot and shaped on an
anvil.
• Metals can be formed using casting processes where the metal is
heated until molten and poured into a cavity or mould to make 3d
products.
• Metals can be pressed using extreme pressure eg car body
panels.
Papers and boards
37
• Accurate folds can be produced using creasing bar on a paper or

board first.
• Scoring can be used to cut fibres weakening a piece of paper of
card making it easier.
• Perforations ‘push’ material apart (creating small holes) making it
easier to tear and separate material eg tissue box lid.
• Scoring, creasing and perforations are all forming processes
making it easier to perform a shape or direction change in a piece
of paper or card.
Polymers
• Simple bends can be created by heating a piece of thermoplastic

polymer in a straight line (using a line bender) where a bend is
needed.
• 3D shapes can be created using vacuum forming over a former by
heating a polymer sheet and creating a permanent form when it
cools.
• Plug and yoke method can be used to form a shape in polymer
sheet.
• Injection moulding of polymers to create profiles and 3D products.
• 3D printing to create a 3D prototype
Textiles
• Drape forming of felt based products like hats.

• Gathering – uses a sewing technique to increase the ‘fullness’ of a
material or prototype eg curtains.
• Pleating – similar to gathering, but where textiles are folded and
held by stitching along an edge.
38

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GCSE

DESIGN AND TECHNOLOGY

Further copies of this mark scheme are available from aqa.org.uk

Copyright © 2020 AQA and its licensors. All rights reserved.

Level of response marking instructions

Step 1 Determine a level

Step 2 Determine a mark

Glossary for maths

[a, b] Accept values between a and b inclusive.

For 𝝅 Accept values in the range [3.14, 3.142]

Questions which do not ask students to show working

As a general principle, a correct response is awarded full marks.

1 A Biomass 1 mark AO4

2 B To have a short lifespan 1 mark AO4

3 C To switch equipment on or off 1 mark AO4

4 B Photochromic pigment 1 mark AO4

5 D Woven fabric 1 mark AO4

6 A Due to improvements in new materials 1 mark AO4

7 An increased use of robotics has led to a reduction in manual 1 mark AO4

8 D Turbine 1 mark AO4

9 D Pulley 1 mark AO4

10 A Can be drawn into a long length 1 mark AO4

11 1 Name one alloy. 1 mark AO4

1 mark for a correct specific named alloy.

Accept all other valid responses.

11 2 Explain why metals are alloyed. 2 marks AO4

2 marks Two correct simple points of explanation or one

• Where a mixture of at least 2 metals are combined to give

Possible reference to examples of use to enhance explanation:

• Stainless steel – cutlery to make hard wearing and corrosion

Accept all other valid responses.

Give one advantage and one disadvantage of using composite

1 mark for one correct advantage and one correct disadvantage.

• Improve resistance to water absorption

• Not always recycled by some local collection services hence may

Accept all other valid responses.

What is the percentage increase in recycling of composite food and

1 mark For recognising a 14 billion tonne increase in

13 Figure 4 shows a system diagram for an alarm. 3 marks AO4

Complete the diagram by naming one component that could be

Suitable inputs Suitable processes Suitable outputs

• Light sensors • Microcontrollers • Buzzers

1 mark for a correctly named specific process

1 mark for a simple descriptive point

Papers and Offset lithography Printing design and information

Die cutting Cutting out of nets.

Lamination Bonding layers of veneers or

Machine Cutting square or rectangular

Use of solder to join two or

The compression of powdered

Extrusion Where molten polymer is

Vacuum forming Heating of sheet polymer so

Calendaring Manufacture of thin

Rotational Used to manufacture hollow 3D

Blow moulding Polymer in tube form is

Fibres are dyed commercially

Flow soldering/ Used in surface mounting of

Wave soldering Circuit boards have pre drilled

PCB manufacture Different to photoresist PCB