Please note this is a draft version until the course is fully published.
AS
Unit 1 – PROD1 Materials Components and Application
Topic
Print Resources (Subheadings)
Page
Number
Electronic Resources
Chapter 1 Materials, Components and Application
Specification Reference 3.1.1 Section A: Materials and Components
Learning Objectives
become familiar with the range of materials and components available
be able to identify materials and their main characteristics
give reasons why material(s) and components have been used for particular applications
Chapter 1 Electronic Resources:
On your marks: Materials, components and application
Revision quiz: Plastics
Revision quiz: Metals and woods
Revision quiz: Smart and modern materials
Answers: Examination-style questions
Answers: Product analysis exercises (student book)
Answers: Product analysis exercises (online)
Images
Plastics
Elastomers
Plastics
- Introduction to plastics
- What are plastics?
- Why are plastics so popular?
- Sources of plastics
- The main types of plastics (polymers)
- General properties of plastics
- Improving the properties of plastics: additives
- Applications for thermoplastics
- Biodegradable plastics
- Processing plastics
- Applications for thermosetting polymers
- Thermoplastic and thermosetting materials
1-14
Case study: Polythene
Webquest: Thermoplastics
Elastomers
- Thermoplastic elastomers (TPE)
- Liquid silicon rubber (LSR)
- Other thermoplastic and thermosetting materials
- Identifying plastics’ processes
14-19
Webquest: Thermosetting
plastics
20-28
Webquest: What are composites
and what are their applications?
Product analysis exercise: Car
body kit
Product analysis exercise:
Biodegradable polymers
Animation: Injection moulding
Animation: Blow moulding
Animation: Rotational moulding
Animation: Plastics extrusion
Case study 1: Plastics:
- Plastics used in detergent packaging: bottled
detergents
Product analysis exercise 1: Thermoplastics
- Plastic drinks bottle
Composite materials
Composite materials
- Types of composite material
- Common fibre-reinforced composites
- Particle-based composite materials
- Sheet-based composites
© Nelson Thornes 2008
2
- Products where traditional materials have been
replaced by composites
Case study 2: Composite materials
- Carbon fibres in bicycles
Product analysis exercise 2: Glass-reinforced
plastics
Product analysis exercise:
Carbon-fibre product – artificial
leg
Metals
Metals
- Types of metal
- Sources of metals
- Availability of metals
- The structure of metals
- Ferrous metals: iron and steel
- Iron and carbon
29-31
Non-ferrous metals
Non-ferrous metals
31-32
Alloys and alloying
Alloys and alloying
- Benefits of alloying
- Alloying steels
- Work hardening and heat-treating metals
- Processing metals
- Wasting processes (relating to metals)
- Casting processes
- Forging
Product analysis exercise 3: Alloys
- Pipe fittings, taps and valves
Product analysis exercise 4: Non-ferrous metals
- Aluminium drinks can
32-53
Webquest:Metals
Case Study: Stainless steel
Case Study: Mocha express
coffee jug
Product analysis exercise:Pressformed product – Sweet tin
Product analysis exercise: Sand
cast product – Wood burning
stove
Product analysis exercise:
Pressure die casting – Utility
knife
Animation: Press Forming
Animation: Cupping & Deep
Drawing
Animation: Pressure die casting
Wood
Wood
- Sources of wood
- Types of wood
- The structure of wood
54-56
Veneers, laminates and
composites
Veneers, laminates and composites
- Veneers
- Laminates
- Wood-based composites (man-made boards)
57-60
Case Study: Formica
Case Study: Aalto
Product analysis exercise: Wood
based composite product
Case study 3: Wood
- Natural timber and manufactured boards
Webquest: Wood –
manufactured boards
Product analysis exercise 5: Wood and
manufactured boards
- Laminated dining chair
Glass
Glass
- Glass as a material
- Manufacturing with glass
- General properties of glass
- Glass versus polymers
61-64
Webquest: Glass
Ceramics
Ceramics
- Introduction to ceramics
- Engineering ceramics
- Manufacturing ceramic products
64-67
Webquest: Ceramics
Papers and boards
Papers and Boards
- Types of paper
- Paper properties and uses
- Manufacturing with papers and boards
- Cards and boards
67-69
Webquest: Papers and Boards
Case Study: Paper cup
Printing
Printing
- Printing processes
- Electrostatic printing processes
70-75
‘Smart’ and ‘modern’
materials
‘Smart’ and ‘modern’ materials
- Introduction to ‘smart’ materials
- Thermochromic pigments
- Thermocolour film
- Thermometers
- Batteries
- Phosporescent pigments
76-87
Product analysis exercise:
Shape memory alloys
3
- Shape memory alloys
- Piezoelectric devices
- Smart grease
- Smart fluids
- Electroluminescent wires
- Glowsticks
- Smart textiles
- Quantum tunnelling composites
- Electronic smart glass
- Modern materials
- Fibre optics
- Liquid crystal displays
- Engineering timbers
- Kevlar
- Carbon fibre
- Metals
- Polymorph
- Precious metal clays
- Microfibres
- Dichroic glass
- Man-made boards
Product analysis exercise 6: Tefal ‘red spot’ pans
Chapter 2 Hand and commercial processing
Specification Reference 3.1.3 Section C: Processes and Manufacture
Learning Objectives
understand how materials and components are processed to create the product from the design
understand further processes related to joining, the deterioration of materials, finishes and finishing processes, and
testing materials
understand the general nature of manufacturing systems used to produce commercial products
Chapter 2 Electronic Resources:
On your marks:
Revision quiz: Joining techniques
Revision quiz: Finishes and properties
Answers: Examination-style questions
Answers: Product analysis exercises (student book)
Answers: Product analysis exercises (online)
Images
Joining processes
Joining processes
- Introduction
- Choosing a joining method
- Summary of joining process
88-90
Joining metals
Joining metals
- Processes involving forming
- Processes involving heat
91-98
Joining wood
Joining wood
- Self-assembly furniture
- Wood adhesives
99-101
Joining polymers
Joining polymers
- Mechanical means
- Adhesives
- Ultrasonic welding
- Plastic welding
- Integral fixings
101-103
Joining ceramics
Joining ceramics
- Adhesives
103-105
Webquest: Hand and
commercial processing
Animation: Spot welding
Webquest: Adhesives
Animation: KD fitting – barrel nut
Case study: The Dyson DC01 vacuum cleaner
Product analysis exercise 1: Joining processes
- Aluminium bicycle frame
Product analysis exercise 2: Joining processes
- Stainless steel saucepan
Corrosion, decay and
degradation
Corrosion, decay and degradation
- Corrosion of metals
- Decay of woods
- Degradation of plastics
105-108
Webquest: Corrosion, decay and
degradation
4
Product analysis exercise 3: Corrosion, decay and
degradation
Finishes and finishing
processes
Finishes and finishing processes
- Introduction
- Why include a finishing process?
- Finishing materials
- Finishing processes for metals
- Finishing processes for woods
Product analysis exercise 4: Finishes and
finishing processes
- Applied barriers
108-116
Case Study: Teflon
Properties and materials
testing
Properties and materials testing
- General properties of materials
- Materials’ properties and structures
- Materials’ properties and products
- Definition of materials’ properties
- Materials testing
117-123
Webquest: Properties and
materials testing
Chapter 3 Design, environment and ergonomics
Specification Reference 3.1.2 Section B: Design and Market Influences
Learning objectives
understand the environmental and sustainability issues that influence Product Design
practise analytical skills and develop an understanding of how products can be designed to meet human needs
appreciate how products are designed to meet safety criteria
understand some of the human and social values in Product Design, such as designing for disabled people and other
groups.
Chapter 3 Electronic Resources:
On your marks:
Revision quiz: Design and market influences
Answers: Examination-style questions
Answers: Product analysis exercises (student book)
Answers: Product analysis exercises (online)
Images
Environmental and
sustainability issues
Environmental and sustainability issues
- Why sustainable design?
- The role of designers and manufacturers
- The three Rs
- Eco-design improvements to a mobile phone
124-125
Webquest: Environmental and
sustainability issues
Case Study: Sustainable and
ethical toys
Ergonomics and
anthropometrics
Ergonomics and anthropometrics
- Ergonomics
- How does ergonomics influnce design?
- Anthropometrics
Product analysis exercise 1: Ergnomics
- Mobile phone
Product analysis exercise 2: Ergonomics and
anthropometrics
- Personal stereo
126-128
Webquest: Ergonomics and
anthropometrics
Product analysis exercise:
Overmoulded product
5
Inclusive design
Inclusive design
- Adapted products
- Designing for other groups in society
129-130
Consumer safety
Consumer safety
- The British Standards Institution (BSI)
- Safety features in a garden hedge trimmer
130-132
Case Study: Ball point pen
Page
Number
Electronic Resources
Unit 2 – PROD2 Learning Through Designing and Making
Specification Reference 3.2 Unit 2: Learning Through Designing and Making
Teacher notes
Introduction to coursework unit
Exemplar coursework: Project approach ‘Water carrier for dogs’
Exemplar coursework: Portfolio approach
Student guidance notes: Frequently asked questions
Student guidance notes: Investigation and clarification of problems
Student guidance notes: Development of design proposal
Student guidance notes: Making / modelling
Student guidance notes: Evaluation and testing
Student guidance notes: Communication and presentation
A2
Unit 3 – PROD3 Design and Manufacture
Topic
Print Resources (Subheadings)
Chapter 4 Design and manufacture
Specification Reference 3.3.1 Section A: Materials and Components
Learning objectives:
build on the work done in Chapters 1 & 2 by appreciating why particular materials have been chosen for a product
become familiar with industrial and commercial testing of materials and products
Chapter 4 Electronic Resources:
On your marks:
Revision quiz: Choosing the correct material - polymers
Answers: Examination-style questions
Answers: Product analysis exercises (online)
Images
Materials and components
Materials and components
Case study 1: Materials and components
- Toothbrush
Case study 2: Materials and components
- Domestic 13-amp power plug
133-137
Webquest:Materials and
components
Case Study: Stratocaster guitar
Case Study: Coca-cola bottle
Product analysis exercise:
Selecting materials – Patio
6
heater
Product analysis exercise:
Selection of polymers for
manufacture
Product analysis exercise:
Applied finishes – Aesthetics v
preservation
Industrial materials testing
Industrial materials testing
- Industrial testing
- Destructive testing
137-144
- Non-destructive testing
Case study 3: Steels and alloys used in industry
Chapter 5 Design and market influences
Specification Reference 3.3.2 Section B: Design and Market Influences
Learning objectives:
understand how the design and innovation process starts, the key stages involved in design and manufacture and the
individual roles in the design process
understand market research, social and economical factors and their influence on the success of Product Design
appreciate human factors such as ergonomics, anthropometrics and human consumer needs
understand the constraints influencing design and manufacture such as legislation, safety and environmental factors
understand how design and manufacture have been influenced by advancements in technology
understand the influence of contemporary styles and historical practices.
Chapter 5 Electronic Resources:
On your marks:
Revision quiz: Design & designers
Revision quiz: Safety and human needs & factors
Revision quiz: Technological innovation
Answers: Examination-style questions
Answers: Product analysis exercises (student book)
Answers: Product analysis exercises (online)
Images
Roles in the design
process
Roles in the design process
- The client
- The designer
- Inventors
- The designer-maker
- Makers
- Users
145-148
Webquest: Design and market
influences (roles in the design
process)
Webquest: Marketing functions
The marketing function
- The relationship between the user, designers
and makers
- The marketing mix
Design methods
Design methods
- How designing starts
148-149
Design activity within
organisations
Design activity within organisations
149
The design process
The design process
- Identification of the problem
- The brief
- The specification
- Analysis
- Research
- Market research
- User-centred research techniques
- Generation of ideas
149-153
Development
Development
- Manufacture
153-154
Testing and evaluation
Testing and evaluation
- How are ideas formed?
154-156
Patents
Patents
- Protecting designs (patents and intellectual
156-158
Webquest: Patents
7
properties)
Communication and
representation of design
ideas
Communication and representation of design
ideas
- Mood boards
- 2-D/3-D sketching
- Rendering
- Orthographic projection
- Modelling
- Mock-ups
- Prototypes
- Presentation boards
158-159
Sustainability and
environmental concerns
Sustainability and environmental concerns
- Introduction
- Environmental legislation and regulation
- Green design, ecodesign, sustainable design
and sustainable innovation: what’s the difference?
- Technological devlopment in eco light bulbs
- The environmental impact of cars
160-168
Webquest: Environmental impact
of cars
Webquest: Sustainability and
environmental concerns
Product analysis exercise:
Recycled plastic products
Product analysis exercise: Power
Safer
Product analysis exercise 1: Design and the
environment
- Plastics in packaging
Product analysis exercise 2: Design and the
environment
- Pepsi can
Safety
Safety
- Risk assessments
- Safety legislation & manufacturing
- Risk asssessments
Case study 1: Safety in JCB manufacture
- Safety legislation and the user
Case study 2: Safety features in a domestic, 3-pin
electrical plug
169-173
Human needs and human
factors
Human needs and human factors
- Ergonomics and anthropometrics
Product analysis exercise 3: Computer
workstation
Product analysis exercise 4: Car interior
173-177
- Design for disabled people
Product analysis exercise 5: Design for disabled
people
Major developments in
technology
Major developments in technology
- Introduction
- Technological developments and the radio
- 1930s
- 1940s and 1950s
- 1960s
- 1970s
- 1970s to recent years
- The development of MP3
- Technological developments and the battery
- Technological developments and the TV
- Technological development in the telephone
- The impact of information and communication
technology (ICT)
- Intelligent systems and interlinked products
- ICT and the internet
- Radio Frequency Identification Tags (RFID)
- Fluidic self assembly (FSA)
- Nanotechnology
- Products using nanotechnology
Product analysis exercise 6: Major developments
in technology
- Mobile phones
- Technology push and market pull
178-193
Product and life cycles
and historical influences
Product life cycles and historical influences
- Introduction and launch
- Growth
- Maturity
- Decline
193-195
Case Study: The Mini
8
- Planned obsolescence
The work of past and
present designers
The work of past and present designers
- The machine age
- The product age
- Design movements
Case study 3: Clarice Cliffe (1899-1972)
- The work of past designers inspired by nature
195-205
Case Study: Mies van der Rohe
Case Study: Maclaren buggy
Case Study: Alessi
Case Study: Tizio lamp
Product analysis exercise 7: Historical influences
- Bauhaus chair
Product analysis exercise 8: Historical influences
- Super Lamp
Chapter 6 Processes and manufacture
Specification Reference 3.3.3 Section C: Processes and Manufacture
Learning objectives:
gain a thorough understanding of the factors affecting choice of process, along with the systems available that
support those processes. There are a range of example examination questions available on the web
be aware of the diversity of modern manufacturing systems including the use of ICT and robotics in manufacturing.
Chapter 6 Electronic Resources:
On your marks:
Revision quiz: Quality in product design
Revision quiz: Robotics in the car industry
Revision quiz: ICT in modern manufacturing systems
Answers: Examination-style questions
Answers: Product analysis exercises (student book)
Answers: Product analysis exercises (online)
Images
Selecting a process
Selecting a process
206-207
Modern manufacturing
systems
Modern manufacturing systems
- Introduction
- Quick response manufacturing (QRM)
- Electronic point of sale (EPOS)
- Just in time (JIT)
- Kanbans
- Sequencing
- Master production schedule (MPS)
- Telematics
- Flexible manufacturing systems (FMS)
207-211
Product analysis exercise: Oneoff/batch production –
Investment casting
ICT in manufacturing
ICT in manufacturing
- Introduction
- Scales of production
- One-offs
- Batch production
- Mass production (high-volume production)
- Continuous production
211-213
Product analysis exercise:
Scales of production – Jigs and
fixtures
Product analysis exercise:
Scales of production – High
volume products
ICT applications in product
design and manufacture
ICT applications in product design and
manufacture
- Computer-aided design (CAD)
213-220
Product analysis exercise:
CAD/CAM product – JCB
Case study: Josiah Wedgwood and Sons
- Virtual reality modelling (VR)
- Computer-integrated manufacture (CIM)
- Computer-aided engineering (CAE)
Product analysis exercise 1: ICT applications in
product design and manufacture
- CAD
- Computer-aided manufacturing
- Robotics
- Robot configurations
- Programming methods
- The benefits of using robots
- The drawbacks of using robots
Product analysis exercise 2: Computer-aided
manufacturing
9
Unit 4 – PROD4 Design and Making Practice
Specification Reference 3.4 Unit 4: Design and Making Practice
Teacher notes
Introduction to coursework unit
Exemplar coursework: Project approach ‘Music stand’
Student guidance notes: Frequently asked questions
Student guidance notes: Context and objectives
Student guidance notes: Plan of action and clarification of problem
Student guidance notes: Development of design proposal
Student guidance notes: Manufacture / modelling
Student guidance notes: Conclusions, evaluations and recommnedations
Student guidance notes: Communication and presentation