Knowledge Organiser: Engineering Design

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Page 1 of 25 Knowledge Organiser: Engineering Design Contents R105 Design Briefs, Design Specifications and User Requirements ....................................... 3 LO1 The Design Cycle ................................ 3 Basic Concepts ...................................... 3 Identification of Needs ......................... 3 Designing ............................................... 3 Optimising the Design ........................... 3 Validating the Design ............................ 3 LO2 Understanding Requirements ........... 4 User Needs ............................................ 4 Product Requirements .......................... 4 Manufacturing Considerations ............. 4 Production Costs ................................... 5 Regulations & Safeguards ..................... 5 LO3 Wider Influences on Design ............... 6 Market Pull and Technological Push ..... 6 Cultural and Fashion Trends .................. 6 Links to Successful Existing Products .... 6 Legislative Requirements ...................... 6 Sustainable Design................................. 7 How Materials and Technology Influence Designs................................... 7 Ethical Design ........................................ 7 R106 Product Analysis and Research ............ 8 Production Methods.................................. 8 One off Production ................................ 8 Batch Production ................................... 8 Mass Production .................................... 8 Manufacturing Aids ............................... 8 Manufacturing Processes .......................... 9 Moulding ............................................... 9 Punch Press ........................................... 9 Press Brake ............................................ 9 Forging ................................................. 10 Machining............................................ 10 CNC Machining .................................... 10 Thread Cutting .................................... 10 Surface Finishes....................................... 11 Paint .................................................... 11 Varnish / Lacquer ................................ 11 Anodising............................................. 11 Dip Coating .......................................... 11 Plating ................................................. 11 End of Product Life .................................. 12 Safe Disposal of Hazardous ................. 12 Materials ............................................. 12 Research Techniques .............................. 13 Primary / Secondary Research ............ 13 Types of Data ...................................... 13 Sample Size ......................................... 13 Comparison of Research Methods...... 14

Transcript of Knowledge Organiser: Engineering Design

Page 1 of 25

Knowledge Organiser: Engineering Design

Contents

R105 Design Briefs, Design Specifications and

User Requirements ....................................... 3

LO1 The Design Cycle ................................ 3

Basic Concepts ...................................... 3

Identification of Needs ......................... 3

Designing ............................................... 3

Optimising the Design ........................... 3

Validating the Design ............................ 3

LO2 Understanding Requirements ........... 4

User Needs ............................................ 4

Product Requirements .......................... 4

Manufacturing Considerations ............. 4

Production Costs ................................... 5

Regulations & Safeguards ..................... 5

LO3 Wider Influences on Design ............... 6

Market Pull and Technological Push ..... 6

Cultural and Fashion Trends .................. 6

Links to Successful Existing Products .... 6

Legislative Requirements ...................... 6

Sustainable Design................................. 7

How Materials and Technology

Influence Designs................................... 7

Ethical Design ........................................ 7

R106 Product Analysis and Research ............ 8

Production Methods .................................. 8

One off Production ................................ 8

Batch Production ................................... 8

Mass Production .................................... 8

Manufacturing Aids ............................... 8

Manufacturing Processes .......................... 9

Moulding ............................................... 9

Punch Press ........................................... 9

Press Brake ............................................ 9

Forging ................................................. 10

Machining ............................................ 10

CNC Machining .................................... 10

Thread Cutting .................................... 10

Surface Finishes ....................................... 11

Paint .................................................... 11

Varnish / Lacquer ................................ 11

Anodising ............................................. 11

Dip Coating .......................................... 11

Plating ................................................. 11

End of Product Life .................................. 12

Safe Disposal of Hazardous ................. 12

Materials ............................................. 12

Research Techniques .............................. 13

Primary / Secondary Research ............ 13

Types of Data ...................................... 13

Sample Size ......................................... 13

Comparison of Research Methods ...... 14

Page 2 of 25

Summarising Research ............................ 15

Charts .................................................. 15

Diagrams ............................................. 15

Tables .................................................. 15

Digital Evidence ................................... 15

Sketches .............................................. 15

Annotations ......................................... 15

R107 Developing and Presenting Engineering

Designs ........................................................ 16

LO1 Be able to generate design proposals

using a range of techniques .................... 16

Hand drawn 2D & 3D sketches ........... 16

Annotation and Labelling .................... 16

Use of ICT software to produce, modify

and enrich design proposals ............... 16

Common sketching styles ................... 17

LO2 Know how to develop designs using

engineering drawing techniques and

annotation ............................................... 18

Why designs are developed ................ 18

Communicating the Final Design ......... 18

3D Styles of Engineering Drawing ....... 19

2D Styles of Engineering Drawing ....... 20

LO3 Be able to use Computer Aided Design

(CAD) software ........................................ 21

LO3 Techniques to produce and

communicate design proposals ............... 21

R108 3D Design Realisation ......................... 22

LO1: Know How to Plan the Making of a

Prototype ................................................. 22

Suitable manufacturing processes must

be selected: ......................................... 22

Production must be planned: .............. 22

Resources must be chosen and

obtained: ............................................. 22

LO2: Understand Safe Working Practices

Used When Making A Prototype ............. 23

Key Words............................................ 23

Common Workshop Hazards .............. 23

Risk assessment .................................. 23

Working safely .................................... 23

LO3: Be Able to Produce A Prototype ..... 24

Students must explain: ....................... 24

A good explanation will include: ......... 24

Students are assessed on the use of

preparation and assembly methods ... 24

Recording key stages in making the

prototype ............................................ 24

LO4: Be Able to Evaluate the Success of a

Prototype ................................................ 25

What goes into an evaluation? ........... 25

Evaluating a Prototype ........................ 25

Evaluating Your Own Performance ..... 25

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R105 Design Briefs, Design Specifications and User Requirements

LO1 The Design Cycle

Basic Concepts

The process of designing follows a standard

method.

The design process is not always liner; a

‘finished’ product is often analysed and re-

designed into an improve d version.

Identification of Needs

Before designing can start, the designer must

work out what the requirements for the

design are.

A design brief is written by the client.

A design brief is a summary of what will be

designed.

Further research is done to work out the

specific requirements for the design.

Requirements are shown in a design

specification.

A design specification must be agreed

between the client and designer.

Designing

The designer creates a range of ideas to

solve the brief.

Designs are evaluated by using the design

specification.

The best designs are developed further.

Optimising the Design

One or more designed are prototyped.

A prototype is a real-life version of the

design.

A prototype may not be complete.

A prototype is not usually made using mass

production methods, even if the final

version would be mass produced.

Validating the Design

The prototype is used to test the design.

The prototype is evaluated.

The evaluation decides what is good about

the design and what should be improved.

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LO2 Understanding Requirements

The design specification needs to consider a

wide range of requirements for the design.

Each of the areas listed below should be

considered.

This is like ACCESS FM which is sometimes

used in lower year groups but with a lot

more detail.

User Needs

These are the things that are important to

the person who will use the design.

Aesthetics – looks.

Ergonomics - how easy it is to interact with.

Anthropometrics - how well it fits the

human body.

Benefits and features - how it will help the

user.

Product safety.

Product Requirements

These are the technical requirements for the

design.

Function – what it will do.

Features – distinctive parts of the design.

Performance – how effectively it must

perform.

Working environment – where it will be

used.

Limitations to the design – e.g. size, weight

etc.

Lifecycle – How long it must last and what

will happen to it at the end of its life.

Manufacturing Considerations

These are the technical requirements for the

manufacturing and maintenance.

Materials availability – Selecting a material

which is available at the right price.

Design for disassembly - at the end of the

products life.

Manufacturing tolerances – how accurately

it must be made.

Sustainability – minimising environmental

impact.

Maintenance – so that the product can be

looked after and repaired.

Scale of manufacture – prototype to start

with but then, the design must be suitable

for one of:

One-off production.

Batch production.

Mass production.

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Ease of manufacture

Making manufacture quicker, cheaper and

more reliable by:

Using standard components that are used in

other designs.

Using pre-manufactured components which

suppliers keep in stock and are inexpensive.

Production Costs

Considering how much the product will cost

to manufacture.

Labour

Materials

Overheads – lighting, rent etc.

Regulations & Safeguards

The designer must check that the law allows

their design to be manufactured.

Copyright - artwork cannot be copied

without permission.

Patents - the way in which something works

may ‘belong’ to someone else and cannot be

copied without permission.

Registered Designs – The shape of

something may ‘belong’ to someone else

and cannot be copied without permission.

European Conformity – Products sold in the

European Economic Area must comply with

a variety of laws.

British Standards – The client may want the

design to meet the tough British Standards

as well as European standards.

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LO3 Wider Influences on Design

Market Pull and Technological Push

This is to do with why new designs are

created.

Market pull is when a design is made because

people have an existing need.

Reusable water bottles are an example of

market pull.

Technological push is when a design is created

to use a new development or invention.

Touchscreens are an example of technological

push1.

1 Mr Miles thinks that the reality is that there are no successful products which are a result of just

Cultural and Fashion Trends

Some designs are more fashionable than

others and become more commercially

successful.

Trainers and headphones are often good

examples.

Links to Successful Existing

Products

Successful products often influence new

designs.

The development of Apple’s AirPods has

resulted in several cheaper copies of that idea

by other manufacturers.

technological push and he is more than happy to discuss this idea with you!

Legislative Requirements

Designs must be legal to manufacture and sell.

Some products can only be made with a

licence e.g. firearms and fireworks.

Some may be illegal if used as intended e.g.

‘hoverboards’.

Some products must meet specific laws.

Bicycles must have certain safety features.

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Sustainable Design

Consumption of materials and power is said to

be sustainable if we can continue to use it at

the current rate without it ever running out.

Using fuel usually creates pollution.

Consumption of Resources

Materials used in manufacture.

Use of fuel to make the electricity used in

manufacture.

Use of fuel to distribute the product.

Fuel used by the product in use e.g. electrical

and internal combustion engines.

Energy or land-fill ‘dumps’ used at the end of

the products’ life.

Life Cycle Analysis

The total impact of the design from the start of

manufacture to eventual disposal.

Environmental Pressures

Using up resources such as coal, gas, metal ore.

Pollution caused by burning fossil fuels such as

oil and coal.

Global warming caused by pollution.

Waste created such as plastics and nuclear

waste.

Destruction of natural environment e.g. by

mining and roads.

How Materials and Technology

Influence Designs

New materials are being created e.g. Kevlar

and carbon fibre.

New materials have better properties than

traditional materials.

New materials may allow designs to be

engineered for the first time e.g. electrically

powered drones.

Technological innovation is about new ways of

making or doing things.

Surface mount electronic components have

allowed electronics to become tiny.

Improved battery technology has made

electric cars possible.

Ethical Design

Designs should be created that have a positive

effect. For example:

Causing less pollution than older designs.

Using fewer resources than older designs.

Encourage cooperation between people.

Are not unnecessarily offensive to others.

Help people to learn.

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R106 Product Analysis and Research

Production Methods

One off Production Making just one of something.

Labour intensive.

High job satisfaction as worker usually makes whole product.

Uses inexpensive standard workshop machines.

The item produced is expensive because of the time used to make it.

Used for made-to-measure work or making a prototype.

Batch Production Making a fixed number of a product all at the same time.

Production

Making lots at once takes less time per item.

Uses manufacturing aids (jigs, templates and fixtures) to speed up production.

Less expensive per item than one-off production.

Used for small quantities of the same design e.g. cricket bats.

Mass Production Making large numbers of the same product.

Highly automated (robotic machines).

Makes use of assembly lines or production lines.

Low cost per product.

High set up cost.

Manufacturing Aids

These are used for batch production to improve accuracy and speed of production.

Jig

A manufacturing aid which guides a tool into the work without need for marking out first.

Template

A pattern that is drawn around to make marking out quicker.

Fixture

A manufacturing aid which holds the work firmly in place whilst the worker works on it.

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Manufacturing Processes

Moulding

Moulding can create quite accurate complex

shapes. Little material is wasted.

Often several copies of a part are moulded on a

single runner.

When accuracy is important, the part will need

to be machined to an exact size after moulding.

Injection Moulding & Die Casting

This can made detailed parts with very little

waste quite accurately.

Called ‘Injection moulding’ for plastics.

Called ‘Die casting’ for metals

Hot material is injected (squirted) into a mould

called a die. Sometimes the mould is cooled by

water. When the material has solidified, the

part is removed, and waste trimmed off.

Investment casting

This is used with metals.

1. A wax model of the part is made.

2. The wax model is coated with ceramic

materials (clay).

3. The ceramic material is hardened, and

the wax melted out.

4. Molten metal is poured into the space

where the wax once was.

5. When the metal has hardened, the

ceramic material is removed.

6. The casting usually needs some

machining to an exact size.

Punch Press

This is used with sheet metals.

1. Sheet metal is placed between dies in a

powerful press.

2. The sheet material is pressed between

the dies.

3. The dies can be designed to punch (cut

out) or bend the material.

4. Often a part will move through several

stages, getting shaped further with each

stage.

Press Brake

This is used to fold metal sheet.

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Forging

Hot forging and cold forging can both be used

with metals. Hot forging can create very strong

shapes.

Hot Forging

1. Metal is heated to make it malleable.

2. The malleable metal is pressed between

a pair of shaped dies.

3. Sometimes a series of dies are used to

refine a part stage by stage.

4. The final forging usually needs trimming

and sometimes machining to exact

dimensions.

Machining

Sometimes, parts need to be made to a

tolerance of a fraction of a millimetre. This can

be hard or impossible to achieve by casting or

pressing.

Machining is used to remove material (usually

metals) very accurately.

Milling Machine

The work is moved under a rotating cutter to

create an accurate surface or slot.

Lathe

Cylindrical work is rotated, and a tool is moved

across the work to accurately remove material.

CNC Machining

It can be very time consuming to machine a

part by hand and mistakes are easy to make.

CNC machines do the same jobs but are

computer controlled.

CNC machines are more expensive.

CNC machines can work without an

operator. This makes production

cheaper.

Thread Cutting

Screw threads can be cut on a lathe as part of

machining or can be cut with a tap (internal

thread) or die (external thread).

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Surface Finishes

Paint Varnish / Lacquer Anodising Dip Coating Plating Covering with a protective and coloured layer.

Covering with a protective clear layer.

Creating a thick protective oxide layer on the surface of metals. Sometimes this is dyed for an attractive appearance.

Coating metals with a layer of thermoplastic polymer (plastic).

Coating an inexpensive metal with a different one to improve its surface. Often an inexpensive metal is coated with an expensive one.

Timber Metals Plastics (unusually)

Timber Metals

Aluminium and some other metals.

Metals Metals Plastics (unusually)

Parts dipped in paint.

Paint sprayed on.

Details may be hand painted with a brush.

Parts dipped in varnish / laquer

Sprayed on.

1. Treated in an electrified acid bath.

2. Oxide layer thickens. 3. Oxide can be dyed for a

better appearance.

Parts heated up then

dipped in a fluidized bed

of powdered

thermoplastic.

Plastic powder melts into

a smooth surface.

A metal part is suspended in an electroplating bath.

‘Donor’ matal also suspended.

Bath is filled with liquid.

Electricity causes some metal (ions) to move onto the part coating it.

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End of Product Life

Recycling Materials

Many materials can be recycled but often

aren’t.

By law, all electrical products must be

recycled.

A good designer will:

Use materials that can be easily recycled if renewable materials are not appropriate.

Make the materials in their design easy to take apart for recycling.

Materials that are easy to recycle

Thermoplastics

Metals

Glass

Reusing Parts

It is even better to reuse a part than to

recycle it.

A used part can be used to replace a broken

part.

A good designer will create designs that are

easy to disassemble and repair.

Example: Car alternators have bearings that

wear out, but the other parts are routinely

cleaned and re-used in a reconditioned part.

Safe Disposal of Hazardous

Materials

Some materials are damaging to the

environment.

Damage to the environment can include

polluting the water and poisoning the land

so nothing will grow.

Hazardous materials must be specially

recycled

Batteries

Batteries contain acids or alkalis and

poisonous metals.

Some batteries contain very reactive metals

which can catch fire or explode.

Designers must make sure batteries are

removable.

Consumers must recycle batteries.

Fluorescent Tube Lamps

Fluorescent tubes contain mercury which is a

very poisonous metal.

Designers must make sure fluorescent tubes

are removable.

Consumers must recycle fluorescent tubes.

Lead & Copper

Almost all wiring is copper.

Almost all circuit boards use lead in solder.

Copper and lead are poisonous.

A designer should make sure that their

product is easy to take apart at the end of its

life.

Consumers are required by law to recycle

their electrical goods safely.

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Research Techniques

Primary / Secondary Research

You should show that you can use both

approaches in your work.

Choose methods based on the information

you want to find out.

Primary Methods

This involves you doing the actual research:

Physical analysis of products

Questioning users

Surveying users

Secondary Methods

This is identifying relevant information that

has been compiled by others:

Web sites

Books & other literature

Manuals

Drawings & diagrams

Images

Secondary research must be referenced;

you need to show where you got the

information. Failure to do this may be

cheating.

Types of Data

Quantitative data is measurements. E.g. the

amount of memory in a phone or the

capacity of a battery.

Qualitative data is opinions, impressions

and points of view. E.g. how comfortable a

handle is or how attractive a bath tap is.

Sample Size

When we research products, we are usually

comparing them. We might also get

information from more than one person.

How many we compare is the sample size.

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Comparison of Research Methods

Method Type of Data Available Sample Size Example of Use

Pri

mar

y R

ese

arch

Physical analysis of products Examining and testing real life products. Usually they are compared using criteria.

Qualitative information about products according to criteria that you decide.

A few (as many examples as you can find).

Comparing bike saddles for comfort. Comparing phone chargers for speed of charging.

Questioning Users Users are interviewed usually with a pre-prepared set of questions.

Qualitative information about user needs according to criteria that you decide.

A few (as many people as you can interview).

Finding user needs for a refrigerator. Understanding the impact of someone’s disability.

Surveying Users Many users are asked straightforward questions and the results are then analysed e.g. using graphs.

Quantitative information from lots of people.

Many (as many as will complete your survey).

Asking 40 people how much they would pay for a school bag. Asking a class about their favourite leisure activities.

Seco

nd

ary

Res

ear

ch

Web sites Finding information you need on the internet needs care – be clear about what information you need and watch out for bias.

Images. Opinions (qualitative). Reviews (qualitative). Technical data (quantitative). Comparisons (quantitative). Prices (quantitative).

Several (as many as you can find on websites).

Finding out what sizes of paper different printers use. Researching different solutions to bike security.

Books & other literature Similar to web sites but books tend to be more accurate if they’re not out of date.

Magazines sometimes have qualitative reviews of products.

A few. Gaining opinions about current hair straighteners.

Manuals Manuals can show you technical details of a product.

Maintenance manuals can show how things work and how to repair them.

One product per manual usually.

Finding out how food mixers work.

Images, Drawings & Diagrams Images can help you judge aesthetic appeal and might give clues about ease of use etc.

The parts that make up a product. How a product is operated.

As many as you can find.

Making judgements about the aesthetic appeal of headphones. Identifying all the parts that make up a power drill.

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Summarising Research Once you have done your detailed research,

you should summarise it to show what you

have learned by comparing products.

There are several ways of summarising your

findings but in each on you should explain

what is shown in your own words.

You should use a range of these in your

work but you do not have to use them all.

Charts

Good for comparing numerical data.

Diagrams

A diagram is a visual representation of

information. They can be used to

summarise:

Processes

Relationships

Tables

Tables are good for comparing information.

Digital Evidence

This can include:

Photos

Video#

Photos are particularly useful for showing

aesthetic information.

Sketches

Useful to help explain a mechanisms or

other design features.

Sketches must be annotated.

Annotations

Annotations are much more than labels. A

label is a statement of fact. Annotation

should include explanations.

Page 16 of 25

R107 Developing and Presenting Engineering Designs

LO1 Be able to generate design proposals using a range of techniques

Hand drawn 2D & 3D sketches

At the start of the design process the

designer aims to produce as many varied

design ideas as they possibly can.

Design ideas are imagined in the designer’s

brain.

Designers show their ideas by using drawn

sketches or quick ‘sketch’ models.

A variety of 2D and 3D drawing styles are

used.

Rendering a design in colour:

Makes the design look 3 dimensional.

Shows colour.

Can show the material it is made of.

Makes it more attractive.

Annotation and Labelling

Designs are always annotated:

To explain anything that is not

obvious from the drawing.

To explain the choice of materials.

To state manufacturing methods.

To explain the designers reasoning.

To comment on the positive aspects

of that design idea.

To note weaknesses and ideas for

improvement.

Use of ICT software to produce,

modify and enrich design

proposals

Sometimes quick virtual models all made

using software such as SketchUp.

Often paper designs are photographed or

scanned and imported into a computer

document.

ICT software can then be used to improve

the appearance of the design by:

Changing brightness and contrast.

Adding colour.

Adding annotation.

Arranging various designs on a single

page.

Presentation documents such as PowerPoint

can be used to show designs to clients to get

their feedback.

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Common sketching styles

Front elevation (2D)

Detailed view of the front

Cross section (2d)

Shows inside workings

Isometric sketch (3D)

A realistic view showing three sides at once

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LO2 Know how to develop designs using engineering drawing techniques and annotation

Why designs are developed

At the start of the design process, the

designer’s aim is to produce as many varied

designs as possible.

These designs are then evaluated and the

best one or best few are developed further.

The purpose of developing designs is to add

enough detail to allow them to be

manufactured and to make improvements

to the design based on evaluation of each

new version.

Designs are developed by:

Adding detail.

Gaining feedback from others.

Resolving problems.

Redesigning to allow for how they

will be manufactured.

The design of components will be

appropriate for the manufacturing process

chosen.

Communicating the Final Design

In the end one design is chosen and fully

completed.

The design is communicated using a

manufacturing specification.

The manufacturing specification contains all

the details needed for another person to

manufacture that product.

A manufacturing specification

will include:

Technical drawings of all the

components.

A parts list.

An assembly drawing showing how

the components fit together.

Standard engineering drawing techniques

are used so that all engineers can

understand them.

Engineering drawings are always accurately

drawn to scale and have dimensions shown.

An assembly drawing shows how all

components fit together.

Assembly drawings are usually 3D exploded

drawings or 2D cross-sectional drawings.

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3D Styles of Engineering Drawing

Exploded view

Shows all the components of an product or assembly.

Looks like it was ‘blown’ apart.

Shows how components fit together.

Is often used for an assembly drawing.

Isometric (3D)

A realistic view showing three sides at once

Used to show the complete component or product.

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2D Styles of Engineering Drawing

These will always be drawn accurately.

They are often drawn to scale.

Orthographic Projection

Detailed view from each side.

Always shows dimensions.

This example also shows a 3D isometric view.

Cross-section

Shows inside workings

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LO3 Be able to use Computer Aided Design (CAD) software

CAD stands for Computer Aided Design.

CAD software is expensive and takes time and skill to learn.

CAD has the following advantages:

Designs can be changed easily.

Designs can be worked on collaboratively with others even if

they're not in the same building.

Designs can be quickly emailed to manufacturing facilities.

Working drawings can be created easily once the component

has been modelled in the software.

The software can work out facts such as the total weight when

made in a certain material.

Software can produce a photo realistic 3D image before the

product is even made.

CAD software links with rapid prototyping facilities such as 3D

printers.

LO3 Techniques to produce and communicate design proposals

The final design must be communicated to the client.

The client must accept and approve the final design.

Display boards can be used to present photographs of models,

working drawings and photo realistic images from CAD software.

PowerPoint can be used to allow a speaker to show this information in

a presentation.

Models do not necessarily function but can be useful to show clients

how will the final component or product will look and allow them to

handle it.

Models can be handmade, can be 3D printed, laser cut, or can be a

combination of both.

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R108 3D Design Realisation

LO1: Know How to Plan the Making of a Prototype The creator must decide how to interpret a

working drawing and the tools and

techniques that they will use to create a

prototype.

The creator must be able to interpret the

product specification that they are given.

Suitable manufacturing processes

must be selected:

Use of hand tools.

Use of rapid prototyping techniques

such as laser cutter or 3D printer.

Use of machine tools.

Production must be planned:

Gantt charts.

Tables.

Flow charts.

Resources must be chosen and

obtained:

Materials.

Component parts.

Tools and equipment.

Risk assessments.

Cutting lists are used to prepare and check

materials.

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LO2: Understand Safe Working Practices Used When Making A Prototype Potential hazards must be assessed, and

controls put in place in order to minimise

risk.

Key Words

A hazard is something that can cause harm.

A risk is the chances that the hazard will

cause harm.

Control measures are put in place to

minimise the risk of a person becoming

injured by the hazard.

Common Workshop Hazards

Cuts from tools or sharp edges of

materials.

Becoming entangled in a machine.

Breathing in dust or fumes.

Slips or trips.

Material ejected from a machine for

example from a polishing machine.

Live exposed electrical conductors.

E.g. in a damaged cable.

Risk assessment

There is a standard process for assessing

risk.

Risks are assessed on a standard risk

assessment form.

1. List process is to be undertaken.

2. List the hazards.

3. Decide on how each hazard could be

controlled.

Sometimes a scoring system is used:

1. The severity of a hazards is given a

score. The worse the injury, the

higher the score.

2. The likelihood of the injury is given a

score. The more likely it is to happen,

the higher the score.

3. Overall risk is calculated by

multiplying the severity score with

the likelihood score.

Working safely

Students must be seen to work safely by:

Creating risk assessments.

Wearing appropriate personal

protective equipment (PPE).

Use safe working procedures.

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LO3: Be Able to Produce A Prototype

Students must explain:

The materials that they have chosen

to use.

How they will use those materials at.

The methods they will use too create

each part.

Which tools they will use.

How they will assemble the parts

together.

A good explanation will include:

A written discussion of the options

available.

A choice being made.

Reasons why that choice was made.

Reasons why other options are

rejected.

Students are assessed on the use

of preparation and assembly

methods

Examples:

Jigs.

Formers.

Templates.

Patterns.

Moulds.

Adhesives.

Fixings.

Recording key stages in making

the prototype

Students must keep a record of how the

prototype was made.

The record must include evidence such as

photographs.

This could include:

Taking notes.

Creating a production diary.

Photographing every stage of

production.

Recording problems and how they

were solved.

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LO4: Be Able to Evaluate the Success of a Prototype

What goes into an evaluation?

And evaluation includes:

1. An explanation of the strengths.

2. An explanation of weaknesses.

3. Ideas for improvement.

Evaluating a Prototype

The prototype is evaluated against each

point in the product specification

individually.

Improvements to be considered:

features

function

materials

aesthetics

ergonomics

modelling and prototyping processes

alternative manufacturing techniques

Evaluating Your Own

Performance

Each student must evaluate how well they

worked in this unit.

This must include evaluation of:

Management of time and resources.

Planning and preparation.

Precision and accuracy achieved in

making processes.

Quality of the final prototype.