Activity: The design and manufacture of a USB pen using modern technology, through the application of
Autodesk software.
Project overview / Scheme of work
Project overview
As a short introduction project, this unit bears expectation that pupils will be relatively new to the use of the software for the purpose of modelling parts. It is
recommended that teachers first review this resource along side the scooter resource before commencing this design and make project.
The project concentrates on the design and manufacture of a USB flash pen drive using a range of sketching and software, alongside laser cutting and 3D printing
processes. Students will apply the tools in AutoCad and Autodesk Inventor to the challenging task of creating a small focused and detailed casing parts, before
manufacturing the product. Considerations of the manufacturing processes available will need to be made by pupils at an early stage of the project.
The students will spend time considering the user of the USB and develop focused ideas for that user, before producing a range of solutions using different software
techniques and strategies. Pupils will then move onto technical drawing techniques and link to commercial products, and develop STL and dxf files to use at later stages
of the project, before finalising the parts in CAM and completing the product assembly.
The project can be extended in the following ways:
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Modelling in foam and card before using software
Rendering designs using simple and complex rendering packages
Sketching using Sketchbook Pro
Designing complex fittings like clips
D&T concepts
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Developing a initial idea into a complex solution
CAD Modelling
CAM Manufacture
Designing for a user
1
Scheme of work
This scheme of work is flexible in its duration, especially when considering the time allowance for manufacturing and use of CAM available in your department. Students
can make their outcomes complex or simple depending on ability and time, and work from the exemplar work rather than copy existing solutions. The computer aided
design element and its application to a design and make task is the focus of the project, but the manufacture can be removed to provide a focused design only project.
Time spent developing the design in CAD can be reduced to increase manufacturing time. 3D printing or Laser cutting can be removed to make the project suitable for
your department’s provision. Students can explore manufacture through Autodesk portals for making including those in 123D Make and 123D Creature.
Lesson
1
Lesson objectives
Description of activity
Suggested preliminary activities.
It is expected that by following this plan; pupils/students already have:
 Have worked with a 3D software package already or have a
competency in CAD
 Have a basic knowledge of the CAM equipment you have
available in your department
 A basic knowledge of 3D sketching techniques for the
communication of design ideas.
Pupils/students could have:
 Access to an Apple device for using the App based versions of
software.
 Understand the design brief and 1. Introduction to the project including a brief outline of USB
technology and its history.
the context of the project.
2.
Learn about the use of a user profile to develop design ideas.
 Be able to design a range of
Develop a user profile for a specific user of a USB pen, including
solutions to meet the needs of a
wide ranging thoughts relating to the life of a user.
user.
3. Pupils develop a user profile.
4. Review of designing in 2D and 3D, including a teacher
demonstration of the techniques suitable for the age range. Pupils
look at existing designs to aid and support learning.
5. Sketching design ideas. Pupils are tasked with establishing a
range of sketches and ideas that could develop into a design for a
USB pen.
6. Review a summary of the learning in the lesson including the
tasks completed and questions relating to their outcome.
Homework
Resources
Research into existing
USB pens and document
groups (professional,
comedy, personalised,
etc)
PowerPoint Lesson 01
Example outcome
products
Example sketch
outcomes
2
2
 Be able to develop drawing and
annotation skills to
communicate a design for laser
cutting.
1. Teacher discusses different manufacturing techniques in relation
to 3D CAD design and links learning about processes to the
design on CAD.
2. Pupils learn and make notes on how to design for laser cutting by
reviewing the learning delivered in context by the teacher. Pupils
will need to know the differences and features of laser cut, 123D
Make and micro fastener designs.
3. Pupils develop a range of designs (4) which communicate laser
cutting as the process for manufacture.
4. Review and critique existing designs. Pupils review an existing
design page and outline what is missing. Pupils can add
annotation as needed.
5. Pupils design their laser cut USB pen using AutoCad or Autodesk
Inventor and 123D Make.
6. Review a summary of the learning in the lesson including the
tasks completed and questions relating to their outcome.
Write a short essay on
the impact of laser
cutters on the UK
industry.
PowerPoint Lesson 02
Example outcome
products
Example sketch
outcomes
3
 Be able to develop drawing and
annotation skills to
communicate a design for 3d
printing.
1. Pupils research wider topics about 3D printing to enhance their
knowledge of the manufacturing technique, using the prompts on
the PPT.
2. Pupils learn and make notes on how to design for 3D printing by
reviewing the learning delivered in context by the teacher. Pupils
will need to know the differences and features of simple and
complex 3D printed designs, including advanced ideas of fitting
magnets.
3. Pupils develop a range of designs (4) which communicate 3D
printing as the process for manufacture.
4. Pupils apply knowledge and use videos to support their modelling
of ideas using Autodesk Inventor.
5. Pupils save work to the Cloud to allow for sharing and working
from home (optional step)
6. Review a summary of the learning in the lesson including the
tasks completed and questions relating to their outcome.
Use the cloud to save,
upload and download
files from your student
profile.
PowerPoint Lesson 03
Example outcome
products
Example sketch
outcomes
Video resources
4
 Be able to produce industry
1. Teacher presents on technical drawings including the
Create an exploded view
PowerPoint Lesson 04
3
quality technical drawings
sufficient for GCSE coursework
submissions.
2.
3.
4.
5.
6.
requirements and the difference between first and third angle
projection of a solution.
Pupils learn about the formatting and application of technical
drawings using CAD models in Autodesk software. Pupils are
given time to finalise their designs in Inventor and AutoCad.
Pupils produce a technical drawing in Inventor and including the
balloons, parts list, and projected views with required overriding
dimensions.
Teacher reminds pupils about the format for applying 2 point
perspective. Pupils note the need to create an exploded view.
Pupils draw an exploded view and final 3D version of their design.
Review a summary of the learning in the lesson including the
tasks completed and questions relating to their outcome.
sketch of your USB pen
idea, and propose three
ways all different to close
and lock the two halves
together.
Example outcome
products
Example sketch
outcomes
Video resources
5
 Apply CAM to the production of
high quality parts suitable for
assembly and testing.
1. Pupils learn about 3D printing and why it is a dynamic technology
for use in schools, home and industry. Pupils learn how to
annotate a 3D printer that is open source, with the support of a
work sheet.
2. Pupils supported by technician 3D print their parts and build once
made. Pupils also laser cut parts and assemble using an
appropriate techniques.
3. Review a summary of the learning in the lesson including the
tasks completed and questions relating to their outcome.
Create a list of all the
CAM equipment in your
school and drawn
example products that
each can create.
PowerPoint Lesson 05
Example outcome
products
Example sketch
outcomes
Video resources
3D printer
Laser cutter
6
 Produce a product of high
quality.
 Be able to assembly a product
accurately.
 Be able to test and evaluate a
design and make activity.
1. Pupils produce a plan for the lesson and the manufacture of their
USB using a flow chart process. Teacher might want to support
this with a demonstration and example of their own.
2. Pupils finalise their product and test. Pupils save their work and
all files onto their USB and review its design for success.
3. Application of knowledge. Pupils are tasked with proving their
knowledge by designing a new USB pen that combines processes
rather than designing separately. Pupils draw and annotate their
designs suitable for submission and assessment by the teacher.
Test your USB at home
and document your
experience of using your
personalised product,
including the issues in its
design.
PowerPoint Lesson 06
Example outcome
products
Example sketch
outcomes
Video resources
3D printer
Laser cutter
4