Oxford Cambridge and RSA
Monday 2 June 2025 – Morning
A Level in Design and Technology:
Design Engineering
H404/01 Principles of Design Engineering
Time allowed: 1 hour 30 minutes
* 1 8 4 4 7 4 5 9 2 2 *
You can use:
• a ruler (cm/mm)
• a scientific calculator
• geometrical instruments
* H 4 0 4 0 1 *
Please write clearly in black ink. Do not write in the barcodes.
Centre number Candidate number
First name(s)
Last name
INSTRUCTIONS
• Use black ink. You can use an HB pencil, but only for graphs and diagrams.
• Write your answer to each question in the space provided. You can use extra paper if
you need to, but you must clearly show your candidate number, the centre number and
the question numbers.
• Answer all the questions.
• Where appropriate, your answer should be supported with working. Marks might be
given for using a correct method, even if your answer is wrong.
INFORMATION
• The total mark for this paper is 80.
• The marks for each question are shown in brackets [ ].
• Quality of extended response will be assessed in questions marked with an asterisk (*).
• This document has 24 pages.
ADVICE
• Read each question carefully before you start your answer.
© OCR 2025 [603/1131/9] OCR is an exempt Charity
DC (WW/FC) 354310/2 Turn over
for more: tyrionpapers.com
, 2
1 Fig. 1.1 shows an electric toothbrush.
Fig. 1.1
removable head thermosetting
polymer soft-grip
section of casing
thermo softening
polymer casing
control button
rechargeable
battery inside
battery indicator light
cordless charging port mode indicator light
(a)
(i) Identify three functional reasons why the electric toothbrush has a removable head.
1 .......................................................................................................................................................
..........................................................................................................................................................
2 .......................................................................................................................................................
..........................................................................................................................................................
3 .......................................................................................................................................................
..........................................................................................................................................................
[3]
(ii) Identify two properties of a thermo softening polymer that make it suitable for the casing of the
electric toothbrush.
Justify each of your answers.
1 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
2 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
[4]
© OCR 2025
for more: tyrionpapers.com
, 3
(iii) The manufacturer chose to include a soft-grip section on the casing of the electric toothbrush.
The soft-grip material is a thermoplastic elastomer (TPE) which is a type of thermosetting
polymer.
Describe two challenges to the manufacturer of including a soft-grip section on the casing of the
electric toothbrush.
1 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
2 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
[4]
© OCR 2025 Turn over
for more: tyrionpapers.com
, 4
Fig. 1.2 shows an electric toothbrush on a charging base. The base is used to charge the battery
inside the electric toothbrush.
Fig. 1.2
plugged into
mains power
supply
charging base
(b)
(i) The electric toothbrush contains a 3.7 V rechargeable battery.
A current of 0.1 A is passed through the battery when it is charging.
Calculate the power in watts (W) put into the battery during charging. Show your working. [2]
Power .............................................. W
(ii) The efficiency of the charging system for the electric toothbrush is 74%.
Use your answer from part (b)(i) to calculate the power drawn from the mains power supply
during the charging process. Give your answer in W and show your working. [2]
Power .............................................. W
© OCR 2025
for more: tyrionpapers.com
Monday 2 June 2025 – Morning
A Level in Design and Technology:
Design Engineering
H404/01 Principles of Design Engineering
Time allowed: 1 hour 30 minutes
* 1 8 4 4 7 4 5 9 2 2 *
You can use:
• a ruler (cm/mm)
• a scientific calculator
• geometrical instruments
* H 4 0 4 0 1 *
Please write clearly in black ink. Do not write in the barcodes.
Centre number Candidate number
First name(s)
Last name
INSTRUCTIONS
• Use black ink. You can use an HB pencil, but only for graphs and diagrams.
• Write your answer to each question in the space provided. You can use extra paper if
you need to, but you must clearly show your candidate number, the centre number and
the question numbers.
• Answer all the questions.
• Where appropriate, your answer should be supported with working. Marks might be
given for using a correct method, even if your answer is wrong.
INFORMATION
• The total mark for this paper is 80.
• The marks for each question are shown in brackets [ ].
• Quality of extended response will be assessed in questions marked with an asterisk (*).
• This document has 24 pages.
ADVICE
• Read each question carefully before you start your answer.
© OCR 2025 [603/1131/9] OCR is an exempt Charity
DC (WW/FC) 354310/2 Turn over
for more: tyrionpapers.com
, 2
1 Fig. 1.1 shows an electric toothbrush.
Fig. 1.1
removable head thermosetting
polymer soft-grip
section of casing
thermo softening
polymer casing
control button
rechargeable
battery inside
battery indicator light
cordless charging port mode indicator light
(a)
(i) Identify three functional reasons why the electric toothbrush has a removable head.
1 .......................................................................................................................................................
..........................................................................................................................................................
2 .......................................................................................................................................................
..........................................................................................................................................................
3 .......................................................................................................................................................
..........................................................................................................................................................
[3]
(ii) Identify two properties of a thermo softening polymer that make it suitable for the casing of the
electric toothbrush.
Justify each of your answers.
1 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
2 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
[4]
© OCR 2025
for more: tyrionpapers.com
, 3
(iii) The manufacturer chose to include a soft-grip section on the casing of the electric toothbrush.
The soft-grip material is a thermoplastic elastomer (TPE) which is a type of thermosetting
polymer.
Describe two challenges to the manufacturer of including a soft-grip section on the casing of the
electric toothbrush.
1 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
2 .......................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
[4]
© OCR 2025 Turn over
for more: tyrionpapers.com
, 4
Fig. 1.2 shows an electric toothbrush on a charging base. The base is used to charge the battery
inside the electric toothbrush.
Fig. 1.2
plugged into
mains power
supply
charging base
(b)
(i) The electric toothbrush contains a 3.7 V rechargeable battery.
A current of 0.1 A is passed through the battery when it is charging.
Calculate the power in watts (W) put into the battery during charging. Show your working. [2]
Power .............................................. W
(ii) The efficiency of the charging system for the electric toothbrush is 74%.
Use your answer from part (b)(i) to calculate the power drawn from the mains power supply
during the charging process. Give your answer in W and show your working. [2]
Power .............................................. W
© OCR 2025
for more: tyrionpapers.com
