Materials Design & Technology
General Metals
Name: ______________________________
Irene McCormack Catholic College
Materials Design & Technology - General
Metals
Programme Outline
Week
1-3
Semester 1
Key Teaching Points
Overview of unit and assessment requirements
Safety
 correct use of PPE (personal protective equipment) where applicable
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
(Occupational Safety and Health) practices in workshops when working
with a variety of materials, tools and machines appropriate to situation
General Workshop safety practice.
Task 1A – G Clamp Design
Design fundamentals and skills
 using communication techniques
 sketching
 annotating
 sampling
 modelling
 sketches of personal product ideas with development of images to a final
solution
Teacher demonstrate basic freehand sketching techniques.
Students complete a series of freehand exercises.
Students to draw a freehand sketch of the G clamp for submission in folio.
3-9
Teacher guided drawing of G clamp using sketchup.
Students create
 Components Drawing with corresponding materials list
 Orthogonal drawing in 3rd angle projection.
All drawings are printed and placed in folio.
Use of technology
Skills and techniques
 name and correctly use common tools:
 measuring tools
 files and filing
 vice
 hacksaws and blades
 hammers
 hand tools for cutting
 pedestal drill/drill press
 fold and shape metals using anvil, jigs, bending machines or metal lathe
 demonstrate gas or electric methods of welding metals including metal
Irene McCormack Catholic College
Materials Design & Technology - General
Metals
preparation, set up, welding operations and testing
 demonstrate workshop clean-up procedures.
Task 1B Glamp Production
Students complete a production plan and identify steps in production.
Production is split into stations.
 Lathe operations to turn spindle to size and cut thread.
 Lathe operations to drill and cut thread using Tap in Vice.
 Marking out and cutting components for for G Clamp frame.
 Welding Bays – complete one practice weld prior to welding Clamp.
 Students to weld clamp together.
Students cycle around stations until completion of project.
Materials
 identify by appearance and name, metals used in the workshop
 identify differences in metals based on the basic aesthetic and physical
properties of colour and work characteristics
Students identify different types of metal by
1. Section - Round & Flat Bar
2. Properties – Bright and Black mild steel.
Students select appropriate materials – eg Bright Bar for thread cutting.
Week
11 - 13
Key Teaching Points
Task 2A Tool Box Design
Design fundamentals and skills
 Free hand sketching techniques to draw perspective drawing of Tool Box
 Identifying product use and establishing statement of intent.
 factors affecting design
 aesthetics
 function
 social requirements
Students write statement of intent and begin drawing Freehand concept sketch of
tool box and develop design solution
Drawing a development drawing to scale using sketch up.
Materials in context
 identify methods of reducing waste.
Students submit a scaled cutting plan that demonstrates most effective use of sheet
Irene McCormack Catholic College
Materials Design & Technology - General
Metals
14-18
metal.
Task 2B Tool Box Construction
Skills and techniques
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
Methods for marking out using, Odd leg Jenny, Scribe Ruler
Methods for cutting sheet metal using Guillotine, Bench shears, Tin Snips,
Aviation Snips
bending sheet metal using Pan Brake Bender, Magna Bend, plastic Mallet
Methods of Joining Sheet metal, Spot welding and Riveting.
Students construct Tool Box. Including Hasp and staple and handle.
19 – 20
Apply finish to tool box using spray equipment.
Safety requirements when handling and storing paint materials.
Set up and cleaning of spray equipment.
 evaluate:
 when investigating and devising
 product against initial design.
Students write an evaluation of their final product and outline their production
process. To be submitted with Task 2A – Design Folio.
Week
1 -3
Semester 2
Key Teaching Points
Task 3A – Table Design
Students are given an openended design brief with some basic parameters.
Design fundamentals and skills
 investigate:
 personal or others’ design needs and values
 design fundamentals
 aesthetics
 function
 safety
 cost
 factors affecting design
 aesthetics
 function
 social requirements
 environmental requirements
 existing ideas and products
 devise:
 design ideas using annotated sketches
 using communication techniques
 sketching
 annotation
 samples
Irene McCormack Catholic College
Materials Design & Technology - General
Metals








models
solution drawings or sketches with measurements or dimensions
production plan
materials list
materials costing
evaluate:
design concepts against design brief
finished product against initial design criteria.
Use the Technology process as basis of design folio
Students create a design brief building on the drawing skills learnt in previous tasks
and extend the content of their folio adding research of existing products and devising
a personal design solution.
Evaluating products based on aesthetics, Function, purpose…..
Students to identify the materials they intend to use joining methods etc.
Using freehand sketching to conceptualise design solutions and produce basic plan
drawings.
Skills and techniques
 use basic ICT skills
 use graphic communication skills appropriate to situation:
 isometric and pictorial hand sketches for project development
 dimensioned orthogonal drawing in 3rd angle for working drawing
 select appropriate materials and calculate the correct amount required for
completion of project
 perform basic calculations for costing of project materials
Materials
 identify and name common metal sections: bar and tube
4 – 10
Task 3B Table Construction
Students use technology skills to construct their table design.
Skills and techniques
 select and apply appropriate and accurate marking out tools and techniques, which
may include the use of a rule, square, combination squares, scriber, inside/outside
callipers
 apply skills using a range of tools and machinery (including the safe machine
operation) for:
 cutting, shaping and folding techniques
 welding equipment, both gas and electric
 pedestal grinder and/or buffing machine
 select correct hacksaw blades and use different techniques of cutting metals
 select and use the correct type and grade of hand file
 select and use the correct type and grade of abrasive cloth
Irene McCormack Catholic College
Materials Design & Technology - General
Metals
 preparing metals for surface finishing
 use correct processes to apply metal finishes:
 paint or lacquers
Demonstrate a range of bending and shaping techniques using Scroll formers and
hydraulic benders.
Methods of machine cutting including: Cold saw, Plasma cutter and grinder.
Teacher to work with students individually to complete projects according to design
folio.
Production management
 complete production processes:
 maintain time management
 follow planned sequential instructions for manufacturing
 materials list and costing
 evaluate ongoing processes
use communication techniques to record any changes to the production processes,
required to complete finished product
Students complete a production journal outlining a basic production procedure and time
management to be placed into folio with Task 3A.
Materials Research Assignment Response Task 1
Nature and properties of materials
 understand the differences between ferrous, non-ferrous and alloys
 identify common metals:
 mild steel
 stainless steel
 tool steel
 aluminium
 zinc
 alloys—brass and solder
 classify these common metals by appearance, hardness, weight and cost
 identify the basic physical and aesthetic properties related to function of at least two of
these metals
11 - 14
Task 4A – Free choice project.
Students chose form a list of suggested projects or create a design proposal for a
project based on a personal need.
Students create a Design folio that demonstrates all skills learnt through the year.
Design fundamentals and skills
 investigate:
 personal or others’ design needs and values
 design fundamentals
 aesthetics
 function
 safety
 cost
 factors affecting design
 aesthetics
Irene McCormack Catholic College
Materials Design & Technology - General
Metals
function
social requirements
 environmental requirements
 existing ideas and products


 devise:
 design ideas using annotated sketches
 using communication techniques
 sketching
 annotation
 samples
 models
 solution drawings or sketches with measurements or dimensions
 production plan
 materials list
 materials costing
 evaluate:
14 - 20
 design concepts against design brief
 finished product against initial design criteria
Task 4B Free Choice Construction.
With aid from the teacher students manage the production process of their final
project demonstrating a range of technology skills
Production management
 complete production processes:
 maintain time management
 follow planned sequential instructions for manufacturing
 materials list and costing
 evaluate ongoing processes
 use communication techniques to record any changes to the production processes,
required to complete finished product.