3.1 Technical principles
Materials and their applications
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Students are expected to be able to name specific materials for a wide range of applications. They must also be able to provide detailed and justified explanations of why specific materials and combinations of materials are suitable for given applications, with reference to:
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Understand the appropriate use of materials including polymers, composites, woods and metals based on their physical and working characteristics such as:
Calculation of quantities of materials sizes and costs. |
Classification of materials
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Students should know and understand the classifications of the following materials and be able to name examples that belong to each category:
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Methods for investigating and testing materials
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Students should be able to describe how workshop and industrial tests are set up and what will be tested, measured and compared, including:
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Analysis of data obtained from testing. |
Performance characteristics of materials
Performance characteristics of papers and boards
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Students should be able to name different types of papers and boards. Students should be able to describe the performance characteristics of papers and boards, including:
Students should be able to explain why different papers and boards are suitable for different applications, including:
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Efficient use of materials in the construction of containers through 2D net design. Effective selection of materials to allow for recyclability, biodegradability and stability. |
Performance characteristics of polymer based sheet and film
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Students should be able to name different types of polymer based sheet and film. Students should be able to describe the performance characteristics of polymer based sheet and film, including:
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Students should be able to explain why different polymer based
sheet and film are suitable for different applications, including:
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Performance characteristics of woods
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Students should be aware of the different stock forms of timber, including:
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Students should be able to describe the performance characteristics of woods, including:
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Students should be familiar with the following woods and wood products:
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Performance characteristics of metals
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Students should be aware of the different stock forms of metals, including:
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Students should be able to describe the performance characteristics of metals, including:
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Students should be familiar with the following metals:
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Performance characteristics of polymers
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Students should be aware of the different stock forms of polymers, including:
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Students should be able to describe the performance characteristics of polymers, including:
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Students should be familiar with the following polymers:
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Elastomers
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Students should be able to explain the suitability of elastomers
for given applications making reference to relevant physical and/or mechanical
properties, including:
Students should understand how elastomers are used to enhance products, for example in producing grips for improved ergonomics. |
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Students should be familiar with the following elastomers:
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Biodegradable polymers
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Students should be able to explain the suitability of
biodegradable polymers for given application making reference to relevant physical
and/or mechanical properties, including:
Students should understand how biodegradable polymers degrade. |
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Students should be familiar with the following biodegradable polymers:
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Composites
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Students need to know and understand how materials are combined to make composites with enhanced properties. Students should be able to explain the suitability of composites for given application making reference to relevant physical and/or mechanical properties, including:
Students should be familiar with the following composites:
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Smart materials
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Students should know and understand the term smart material. Students should be able to explain the suitability of smart materials for given applications making reference to how the material responds to external stimuli, including:
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Students should be familiar with the following smart materials:
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Modern materials
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Students should know and understand the term modern material. |
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Students should be able to explain the suitability of modern materials for given applications. |
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Students should be familiar with the following modern materials:
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Enhancement of materials
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Students are expected to be able to describe enhancement methods for given materials and explain their suitability for specific product applications. |
Understand the appropriate use of materials, including polymers, composites, woods and based on their physical properties. |
Polymer enhancement
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The use of additives to enhance properties, including:
Students should be familiar with how additives are used in specific polymer products, eg patio furniture, food packaging and carrier bags. |
Wood enhancement
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The combining of natural timber with resins and lamination to give enhanced properties, eg increased strength and stability. Enhancing timber products with preservatives, finishes and coatings. |
Metal enhancement
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Students should be aware of heat treatment methods of enhancing
metals, including:
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Forming, redistribution and addition processes
Paper and board forming processes
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Students should be aware of the ways that paper and board can be shaped into different products such as packaging. Specific process to include:
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Polymer processes
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Students should be aware of how polymers can be formed into 3D products. They should be able to describe the different forming methods. |
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They should be able to explain the suitability of the different forming methods for a range of specific products and scales of production. Specific process to include:
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Metal processes
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Students should be aware of how metals can be shaped into 3D products. They should be able to describe the different forming methods. They should be able to explain the suitability of the different forming methods for a range of specific products and scales of production. Specific processes to include:
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Students should be aware of the different permanent and temporary joining methods for metals. They should be able to describe the different methods. They should be able to explain the suitability of the different joining methods for a range of specific products and scales of production. Including addition/fabrication processes:
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Students should be aware of the different wasting processes. They should be able to describe the different processes. They should be able to explain the suitability of the different wasting processes for a range of specific components and products. Specific processes to include:
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Wood processes
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Students should be aware of how timber can be joined to form different products. They should be able to describe the different methods. They should be able to explain the suitability of the different joining methods for a range of specific products and scales of production. Including:
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Students should be aware of how timber can be formed into 3D products. They should be able to describe the different processes. They should be able to explain the suitability of the different wasting processes for a range of specific products. Specific processes to include:
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The use of adhesives and fixings
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Jigs and fixtures
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Students should be aware of how jigs and fixtures can be used to aid the manufacture of products. They should be able to describe them and explain their suitability for accurate and repeated manufacture of products. |
Dimensions and angles in the design of jigs, fixtures and templates. |
The use of finishes
Paper and board finishing
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Students should be aware of the ways that paper and board can be finished to enhance their appearance or for improved function. Specific finishes to include:
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Ensure products are designed to take account of potential corrosion due to environmental factors. |
Paper and board printing processes
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Students should be aware of the different types of printing processes and their suitability for specific products and scales of production. Specific processes to include:
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Polymer finishing
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Students should be aware of the ways that polymers can be finished to enhance their aesthetics or for improved function. Students should be aware that some polymers are self-finishing and that this should be considered as a polymer finish. Specific finishes to include:
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Students should understand how pigments can be added to polymers
in the moulding process, including:
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Metal finishing
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Students should be aware of the ways that metals can be finished to enhance their appearance or prevent corrosion. Including applied finishes:
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Wood finishing
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Students should be aware of the ways that woods can be finished to enhance their appearance or prevent decay. Specific finishes to include:
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Modern industrial and commercial practice
Scales of production
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Students should be aware of, and be able to describe, the different scales of production giving example products and specific manufacturing methods. Specific scales of production to include:
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Efficient use of materials
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Students must develop an awareness of the relationship between material cost, form, and manufacturing processes, and the scale of production.
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Determining quantities of materials. |
The use of computer systems
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Students should be aware of how computer systems are used to plan and control manufacturing, reduce waste and respond quickly to changes in consumer demand. |
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Students should be able to explain specific industrial manufacturing systems and their use in the production of given products. Specific manufacturing systems to include:
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Students should be able to explain the use of computer controlled systems in production, distribution and storage. Students should be able to explain the use of standardised and bought-in components made by specialist manufacturers. |
Sub-assembly
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Students should be aware of, and able to explain, sub-assembly as a separate line of manufacture for certain parts of a product. |
Digital design and manufacture
Computer aided design (CAD)
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Students should be aware of, and be able to describe, the following:
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Use of datum points and geometry when setting out design drawings. The use of tolerances in dimensioning. |
Computer aided manufacture (CAM)
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Students should be aware of, and be able to describe, how CAM is used in the manufacture of products. Specific processes to include:
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Calculating speeds and times for machining. |
Virtual modelling
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Students should be aware of, and be able to describe, how virtual modelling/testing is used in industry prior to product production. Specific processes to include:
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Interpretation of data from CFD or FEA testing. |
Rapid prototyping processes
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Students should be aware of, and be able to describe, rapid prototyping processes, including 3D printing. Students should understand, and be able to explain, the benefits to designers and manufacturers. |
Calculating volumes of 3D printed products, calculating time/speed for 3D printing. |
Electronic data interchange
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Students should be aware of, and able to describe, the use of
electronic point of sales (EPOS) for marketing purposes and the collection of market
research data, including:
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Production, planning and control (PPC) networking
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Students should be aware of, and able to describe, the role of
PCC systems in the planning and control of all aspects of manufacturing, including:
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The requirements for product design and development
Product development and improvement
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Through the study and critical analysis of existing products, students should develop an understanding of the requirements of the following:
Students should develop the skills to critically assess products and develop new design proposals. Students should development their ability to work with a variety of materials, including two- and three-dimensional forms, to produce creative and original products which satisfy the demands of the target market, and consider accurate and efficient manufacture. When designing products Students should consider aesthetics, ergonomics and anthropometrics. |
Inclusive design
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Students should be aware of, and be able to explain, the development of products that are inclusive in their design so that they can be used by a wide range of users including the disabled, children and the elderly. |
Health and safety
Safe working practices
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Students should be aware of, and able to explain, health and safety procedures related to products and manufacturing, including:
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Understand why some materials, adhesives and finishes are hazards. |
Safety in products and services to the customer
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Students should be aware of, and able to explain, how designers
and manufacturers ensure products are safe for consumers to use, including:
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Protecting designs and intellectual property
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Students should be aware of, and able to explain, the importance
of the following to the designer:
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Students should be aware of, and able to explain, the concept of ‘open design’. Specifically referring to the development of products for the common good of society, including potential use. Students should be able to give examples of this in practice, eg humanitarian projects and file sharing for 3D printing. |
Design for manufacturing, maintenance, repair and disposal
Manufacture, repair, maintenance and disposal
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Students should be aware of, and able to explain, the need to
modify designs to make them more efficient to manufacture, including:
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Ease of manufacture
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Students should be aware of, and able to explain, the different
ways in which a product can be designed to allow for more efficient manufacture, including:
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Disassembly
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Students should be aware of, and able to explain, how a product can be designed and manufactured with disassembly in mind, including integral fixings and active disassembly using smart materials such as SMA and biodegradable parts. |
Feasibility studies
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Students should be aware of, and able to explain, the use of feasibility studies to assess the practicality for production of proposed designs, including the testing of prototypes with potential consumers. |
Interpret statistical analyses to determine user needs and preferences. Use data related to human scale and proportion to determine product scale and dimensions. |
Enterprise and marketing in the development of products
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Students should be aware of, and able to explain, the importance
of marketing and brand identity, including:
Students should be aware of, and able to explain, the collaborative working of designers in the development of new and innovative products, including virtual and face-to-face collaborative working systems. |
Interpretation of market research data, calculating costs and profit. |
Design communication
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Students should be aware of, and able to explain and demonstrate the skills, in a range of communication and presentation techniques for conveying proposals and intentions to clients, potential users and manufacturers, including:
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Scaling drawings. Use of datum points and geometry when setting out design drawings. Representation of data used to inform design decisions and evaluation of outcomes. Presentation of market data, user preferences and outcomes of market research. |
