Year 11 Product Design Revision Home Page

Topic 1 Materials and components

Topic 1.1 Woods

Aesthetic, functional and mechanical properties, application and advantages/disadvantages of the following woods when manufacturing products:

• oak
• mahogany
• beech
• ash
• pine.
• Structure, aesthetic, functional and mechanical properties, application and advantages/disadvantages of the following manufactured boards when manufacturing products:
• plywood
• chipboard
• medium density fibreboard (MDF)
• hardboard.

Topic 1.2 Metals

Aesthetic, functional and mechanical properties, application and advantages/disadvantages of the following ferrous and non-ferrous metals when manufacturing products:

• mild steel
• stainless steel
• carbon steel
• aluminium
• copper
• zinc
• brass.
• Composition of mild steel and brass.
• Understand and describe the following properties when selecting and using metals in product manufacture:
• ductility
• malleability
• hardness
• toughness
• elasticity
• strength in tension, compression and shear.

Topic 1.3 Polymers

Aesthetic, functional and mechanical properties, application and advantages/disadvantages of the following thermoplastics when manufacturing products:

• acrylic
• polyethene
• polyvinyl chloride
• high impact polystyrene
• Acrylonitrile-Butadiene-Styrene (ABS).

Structural, functional and mechanical properties, application and advantages/disadvantages of the following thermosetting plastics when manufacturing products:

• polyester resin
• urea formaldehyde.

Understand and describe the following properties when selecting and using polymers in product manufacture:

• plasticity
• durability.

Topic 1.4 Composites

Structural, functional and mechanical properties, application and advantages/disadvantages of the following composites when manufacturing products:

• carbon fibre
• glass reinforced plastics (GRP).

Topic 1.5 Modern and smart materials

Application and advantages/disadvantages of the following modern and smart materials when manufacturing products:

• shape memory alloys (SMA)
• photochromic paint
• reactive glass
• carbon nanotubes as additives to materials.

Topic 2 Tools and equipment

Topic 2.1 Marking out and measuring

Recognition, selection, use and advantages/disadvantages of the following tools and equipment when marking out and measuring during the manufacture of products:

• rules
• squares
• gauges
• scriber
• punches
• templates
• micrometer.

Topic 2.2 Wasting

Recognition, selection, application, use and advantages/disadvantages of the following tools when removing material during the manufacture of products:

• saws
• planes
• chisels
• files
• drills
• abrading tools.

Topic 3 Industrial and commercial processes

Topic 3.1 Scale of production

Characteristics, application and advantages/disadvantages of the following scales of production in the manufacture of products:

• one-off
• batch
• mass.

Topic 3.2 Materials processing and forming

Characteristics, preparation, processes, application and advantages/ disadvantages of the following methods when using materials and components:

• sand casting
• drilling
• turning (wood and metal)
• blow moulding
• injection moulding
• vacuum forming
• extrusion (plastic and metal)
• wood laminating.

Topic 3.3 Joining methods

Characteristics, recognition, preparation, processes, application and advantages/disadvantages of using the following temporary and permanent methods when joining materials and components:

• Temporary
• tapping and threading
• nuts, bolts and washers
• screws
• knock down fittings
• Permanent
• nails
• halving joint
• butt joint
• rebate joint
• housing joint
• mortise and tenon joint dowel joint
• soft soldering
• brazing
• welding
• rivets - snap and pop.

Topic 3.4 Adhesives

Preparation, application and advantages/disadvantages of using the following adhesives for joining materials:

• polyvinyl acetate (PVA)
• contact adhesive
• epoxy resin
• Tensol® cement.

Topic 3.5 Heat treatment

Characteristics, preparation, processes, application and advantages/ disadvantages of using the following heat treatments when altering the properties of metals:

• hardening and tempering
• annealing
• case hardening.

Topic 3.6 Finishing techniques

Processes, application and advantages/disadvantages of applying the following finishes to improve the performance, quality and appearance of manufactured products:

• varnish
• wax polish
• stain
• paint
• plastic dip-coating
• electroplating.

Topic 3.7 Manufacturing processes for batch production

Preparation, application and advantages/disadvantages of the following when manufacturing products and components:

• jigs
• patterns.

Topic 3.8 Health and safety

• How to understand/describe safe working practices.
• How to identify workshop hazards and precautions.

Topic 4 Analysing products

Topic 4.1 Specification criteria

When analysing a product, students should take into account the following specification criteria:

• form - Why is the product shaped/styled as it is?
• function - What is the purpose of the product?
• user requirements - What qualities make the product attractive to potential users?
• performance requirements - What are the technical considerations that must be achieved within the product?
• material and component requirements - How should materials and components perform within the product?
• scale of production and cost - How does the design allow for scale of production and what are the considerations in determining cost?
• sustainability - How does the design allow for environmental considerations?

Topic 4.2 Materials and components

Students should identify the materials and/or components used in the manufacture of a product, including:

• the properties and qualities of the materials and/or components
• the advantages/disadvantages of the materials and/or components
• justification of the choice of materials and/or components.

Note: materials and components are those referenced in Topic 1.

Topic 4.3 Manufacturing processes

Students should identify the processes involved in the manufacture of products, including:

• the stages of the manufacturing process
• the advantages/disadvantages of the manufacturing process
• justification of the choice of manufacturing process.

Note: manufacturing processes are those referenced in Topic 3.

Topic 5 Designing products

Topic 5.1 Specification criteria

When designing a product, students should take into account the following specification criteria:

• form - How should the product be shaped/styled?
• function - What is the purpose of the product?
• user requirements - What qualities would make the product attractive to potential users?
• performance requirements - What are the technical considerations that must be achieved within the product?
• material and component requirements - How should materials and components perform within the product?
• scale of production and cost - How will the design allow for scale of production and what are the considerations in determining cost?
• sustainability - How will the design allow for environmental considerations?

Topic 5.2 Designing skills

When designing a product, students should be able to respond creatively to design briefs and specification criteria, including:

• clear communication of design intentions using notes and/or sketches annotation which relates to the original specification criteria.

Topic 5.3 Application of knowledge and understanding

When designing a product, students should be able to apply their knowledge and understanding of a wide range of materials and/or

• components and manufacturing processes to each design idea, including:
• the properties of materials and/or components
• the advantages/disadvantages of materials and/or components and manufacturing processes
• justification of the choice of materials and/or components and manufacturing processes.

Topic 6 Technology

Topic 6.1 Information and communication technology (ICT)

Characteristics, processes, application, effects on society and advantages/disadvantages of ICT in the design, development, marketing and sale of products including:

• electronic communications between designers, manufacturers, retailers and consumers using email
• electronic point of sale (EPOS) in the retail and manufacture of products
• internet marketing and sales.

Topic 6.2 Digital media and new technology

Characteristics, processes, application and advantages/disadvantages of the following digital media and new technology in relation to:

• transfer of data using Bluetooth® wireless personal area networks
• videoconferencing between designer/client.

Topic 6.3 Computer-aided design/computer-aided manufacturing (CAD/CAM) technology

Characteristics, processes, application and advantages/disadvantages of CAD/CAM in the design, development and manufacture of products:

• virtual modelling and testing
• laser cutting
• computer numerically controlled (CNC) milling and turning
• rapid prototyping.

Topic 7 Sustainability

Topic 7.1 Minimising waste production

Principles, application, advantages/disadvantages to society and the environment of minimising waste production throughout the product life cycle using the following 4 Rs:

• reduce materials and energy
• reuse materials and products where applicable
• recover energy from waste
• recycle materials and products or use recycled materials.

Topic 7.2 Renewable sources of energy

The characteristics, applications and advantages/disadvantages of using the following renewable sources of energy:

• wind energy using turbines and wind farms
• solar energy using solar cells and photovoltaic cells
• biomass converted into biofuels for transportation.

Topic 7.3 Climate change

The responsibilities of 'developed’ countries in minimising the impact of industrialisation on global warming and climate change including:

• reducing greenhouse gas emissions through the Kyoto Protocol.

Topic 8 Ethical design and manufacture

Topic 8.1 Moral, social and cultural issues

The strategy, characteristics, applications and advantages/disadvantages of the following value issues when designing and manufacturing products:

• built-in obsolescence in new products for a 'throwaway’ culture
• offshore manufacture of mass-produced products in developing
• countries by multinational companies
• tolerance of different cultures to avoid offence.