Built from: SAMs (practice paper) · W24 (Jan 2024) · S24 (May 2024) · W25 (Jan 2025). Fully updated with official W24, S24, and W25 mark schemes. [cite: 3, 20]
⚠ W25 broke the pattern. Q1 was a roller coaster (not a bicycle). Q2 was a pillar drill + orthographic drawing (not a school project). Q3 was bicycle design with gear ratio, tolerance and instrument reading calculations. The exam is evolving — know everything, not just the old pattern.
All 4 papers — question by question
SAMs (practice)
Q1: Recumbent bicycle
Q2: Dustpan (riveting sketch)
Q3: Pillar drill + funfair circuit
Q4: Smart speakers
W24 — Jan 2024
Q1: Electric bicycle
Q2: Toolmakers' clamp (tapping)
Q3: Centre lathe + candy floss machine
Q4: Electric cars
S24 — May 2024
Q1: Tall bicycle
Q2: Dice paperweight (chamfer)
Q3: Milling machine + roller coasters
Q4: VR devices
W25 — Jan 2025 ⚠
Q1: Roller coaster (NOT bicycle!)
Q2: Pillar drill + bracket drawing
Q3: Bicycle design + calculations
Q4: Renewable energy
What's always in the exam — confirmed across all papers
Material properties (name + reason)
Surface finish reasons
Permanent vs temp joining
Tool identification [6 marks]
Sketch + annotate a process [6]
Safety precautions [3]
Workshop machine: name + process
Risks + control measures [6]
Engineering calculation
Environmental/disposal question
Q4: Adv + disadv discussion [10]
Gear ratio calculations
Tolerance max/min
Reading instruments
Drawing symbols + title block
CAD advantages
Screwdriver drive types
Internal + Odd-leg callipers
NDT explanation
Q4 topics — all confirmed
Topics that have appeared
- → Smart speakers (SAMs)
- → Electric cars (W24)
- → VR devices in manufacturing (S24)
- → Renewable energy (W25)
Likely future topics
- → 3D printing / additive manufacturing
- → Drones / autonomous vehicles
- → AI / robots in manufacturing
- → Smart home technology
- → Electric vehicles / batteries
For Q4: always write paragraphs not bullet lists. The S24/W25 mark schemes explicitly award up to 2 bonus marks for well written, extended prose[cite: 97, 108]. Always cover BOTH advantages AND disadvantages with specific engineering examples.
Formulas — must know
Ohm's Law: V = I × R | R = V ÷ I | I = V ÷ R
Gear ratio = teeth on driven gear ÷ teeth on drive gear
Tolerance: MAX = nominal + upper tolerance | MIN = nominal − lower tolerance
Area (rectangle) = length × width | Area (circle) = π r²
Volume = area × thickness/depth
Stock ordering: pieces per length = stock ÷ piece size (round DOWN) → lengths needed = pupils ÷ pieces per length (round UP)
Tolerance worked examples (W25)
25.0mm ± 0.5mm → MAX = 25.5mm | MIN = 24.5mm [cite: 88]
36.40mm ± 0.35mm → MAX = 36.75mm | MIN = 36.05mm [cite: 88]
7.8mm +0.4 / −0.0 → MAX = 8.2mm | MIN = 7.8mm (unilateral tolerance) [cite: 88]
Gear ratio worked examples (W25)
Drive gear = 30 teeth
Driven = 10 teeth: ratio = $10/30=1:3$ [cite: 67]
Driven = 15 teeth: fraction = $15/30 = \frac{1}{2}$ (must be in simplest form) [cite: 67]
Driven = 6 teeth: decimal = $6/30=0.2$ [cite: 67]
Material classifications
| Type | Examples | Key properties / notes |
|---|
| Ferrous metals | Mild steel, stainless steel, tool steel, cast iron | Contain iron · magnetic · can corrode (except stainless) |
| Non-ferrous metals | Aluminium, copper, brass, titanium | Non-magnetic · corrosion resistant · good conductors |
| Alloy | Steel (iron+carbon), aluminium alloy | Mixture of 2+ metals — improved properties over pure metals |
| Thermoplastics | Acrylic, nylon, HIPS, ABS, PVC | Soften when heated → can be reformed · recyclable |
| Thermosetting | Urea formaldehyde, epoxy resin, silicone, Bakelite | Set permanently when cured — cannot be re-melted |
| Composite | Carbon fibre (CFRP), Kevlar, GRP/fibreglass | High strength-to-weight · cannot be recycled · expensive · difficult to repair |
| Smart materials | Thermochromic ink, nitinol (shape memory alloy) | Change properties in response to a stimulus (heat, stress) |
Physical properties — definitions
| Property | Definition |
|---|
| Tensile strength | Resists being stretched / pulled apart without breaking |
| Compressive strength | Resists being crushed / compressed without deforming |
| Hardness | Resists surface scratching or deformation when impacted |
| Toughness | Absorbs impact / shock energy without fracturing |
| Malleability | Can be hammered / pressed into thin sheets without cracking |
| Ductility | Can be drawn into wire without fracturing |
| Elasticity | Returns to original shape after the deforming force is removed |
| Conductivity | Allows electricity or heat to pass through efficiently |
| Corrosion resistance | Resists damage from oxidation / chemical reactions (e.g. rust) |
Tools confirmed in real papers — Q2 tool identification [always 6 marks]
Mark scheme warnings: "bench vice" NOT just "vice" · "hand file" or "flat file" NOT just "file" · "digital calliper" and "vernier calliper" are DIFFERENT tools — don't mix up · Do NOT accept "Cross Head" for a Phillips screwdriver[cite: 30].
| Tool | Correct mark scheme name | Use | Paper |
|---|
| Scriber | Scriber | Mark/scratch lines onto metal surface during marking out | SAMs |
| Centre punch | Centre punch | Create dimple to locate drill bit accurately, prevent wandering | SAMs |
| Engineer's square | Engineer's square | Mark lines at 90° from a straight edge | SAMs |
| Bench vice | Bench vice (NOT "vice") | Securely hold workpiece for filing, hacksawing, marking | S24 |
| Hand file / flat file | Hand file / flat file (NOT "file") | Remove small amounts of material by hand; shape and deburr | S24 |
| Digital calliper | Digital calliper (NOT "vernier") | Measure internal, external, depth dimensions electronically | S24 |
| Vernier calliper | Vernier calliper | Measure internal, external, depth and step dimensions using a vernier scale | W24, W25 |
| Tailstock | Tailstock | Supports end of long material on lathe; holds Jacobs chuck for drilling | W24 |
| Jacobs chuck | Jacobs chuck | Holds drill bit on pillar drill or centre lathe | W24 |
| Odd-leg calliper | Odd-leg calliper / jenny calliper | Scribe/mark-out a parallel line from an edge at a specific distance [cite: 33] | W25 |
| Internal calliper | Internal calliper | Used to gauge/compare/check (not measure) internal dimensions [cite: 33] | W25 |
Machines — confirmed across all papers (Q3 or Q2)
| Machine | Primary use | Tools / bits used | Paper |
|---|
| Pillar drill | Drill accurate holes in materials | Twist drill, countersink, counterbore bits | SAMs, W25 |
| Centre lathe | Turn/reduce cylindrical components to size | R/H knife, facing, parting, knurling, chamfer, boring bar, roughing tool | W24 |
| Milling machine | Remove material from flat surfaces; produce slots, recesses, counterbores | Face mill, slot drill, end mill, shoulder cutter | S24 |
Screwdriver drive types (W25)
| Drive type | Appearance | Notes |
|---|
| Slotted / flat head | Single straight slot [cite: 30] | Oldest type; easy to slip out; less torque than cross-head |
| Phillips / Pozi drive | Plus (+) cross shape | DO NOT ACCEPT "Cross Head" in the exam[cite: 30]. |
Engineering drawing conventions (W25)
| Symbol / convention | Name | Use |
|---|
| Ø symbol | Diameter | Used to show the dimension value is a diameter (width not length) [cite: 55, 56] |
| Target symbol (circle with cross) | Datum | Used for a point of origin or reference for measurements [cite: 57, 58] |
| Chain-dot line (dash-dot) | Centre line | Marks the central axis of holes, cylinders, and symmetrical features [cite: 48] |
| Dashed line | Hidden detail line | Shows edges/features hidden from the viewer's current direction [cite: 47] |
Title block — information included (W25)
Information may include: Projection angle symbol · Scale of drawing · Drawing Number · Drawing title / product or part name · Author of Drawing · Date created or checked or modified · Department drawing was created in · Material selection · Finishes that could be applied · What units the dimensions are in[cite: 64].
PPE — Personal Protective Equipment (W25)
P = Personal P = Protective E = Equipment
Items for a pillar drill: Eye protection (Goggles / Safety glasses / face mask) · Work wear (Apron / overalls / lab coat) · Safety footwear (Safety boots / Steels)[cite: 30].
Note: Do NOT accept gloves[cite: 30].
Advantages of CAD (W25)
Can produce accurate models · Can be quicker to produce CAD models · Easier to amend, modify and change models · Can share models with others digitally · Several people can work on model at the same time from different locations · Offers 'Virtual tours' of the design · Non-destructive testing can be simulated · Digital CAD model files take up no physical space unlike physical models · Quick to duplicate designs · 3D models can easily be projected into 2D orthographic models for engineers to read[cite: 24].
Q4 — Renewable energy (W25) — key content
Wind, Solar & Geothermal
Wind: Low cost electricity, low operational cost, creates jobs. Disadv: Blades are non-recyclable, noisy, danger to wildlife[cite: 100].
Solar: Clean energy with minimal impact, good for economy. Disadv: Expensive to set-up, needs large space, weather dependent / doesn't work at night[cite: 100, 102].
Geothermal: Clean energy, no need to burn fuels. Disadv: Location specific, expensive to set-up, needs long connection distance to grids[cite: 102].
Biomass & Hydropower
Biomass: Versatile source, cheaper/cleaner than fossil fuels, good way to get rid of waste. Disadv: Generates CO2 when burned, lots of space needed for crops, can contribute to deforestation[cite: 103, 104].
Hydropower: Reliable, highly efficient, reservoirs build leisure industry. Disadv: Dams can displace communities/drown land, uses huge amounts of concrete (bad for environment), very expensive to build[cite: 104, 105, 106].