GCSE Design and Technology₈₅₅₂

Functionality: application of use, ease of working.

Aesthetics: surface finish, texture and colour.

Environmental factors: recyclable or reused materials.

Availability: ease of sourcing and purchase.

Cost: bulk buying.

Social factors: social responsibility.

Cultural factors: sensitive to cultural influences.

Ethical factors: purchased from ethical sources such as FSC.

Calculation of material costs.

Selection and use of materials considering end of life disposal.

Tension, compression, bending, torsion and shear.

Changing the magnitude and direction of forces.

How materials can be reinforced, stiffened or made more flexible: eg lamination, bending, folding, webbing, fabric interfacing.

Deforestation, mining, drilling and farming.

Mileage of product from raw material source, manufacture, distribution, user location and final disposal.

That carbon is produced during the manufacture of products.

Selecting appropriate materials.

Understanding of how to choose appropriate energy sources.

Reduce, refuse, re-use, repair, recycle and rethink.

Safe working conditions; reducing oceanic/atmospheric pollution and reducing the detrimental (negative) impact on others.

Ethical factors and the social footprint of materials used in products.

Primary sources of materials and the main processes involved in converting into workable forms for at least one material area.

• Paper and board (how cellulose fibres are derived from wood and grasses and converted into paper).
• Timber based materials (seasoning, conversion and creation of manufactured timbers).
• Metal based materials (extraction and refining).
• Polymers (refining crude oil, fractional distillation and cracking).
• Textile based materials (obtaining raw material from animal, chemical and vegetable sources, processing and spinning).

Life cycle assessment and recycling ie the basic principles in carrying out a life cycle assessment of a material.

Students must know and understand how different properties of materials and components are used in commercial products, how properties influence use and how properties affect performance.

Students must know and understand the physical and mechanical properties relevant to commercial products in their chosen area as follows.

• Papers and boards (flyers/leaflets and card based food packaging).
• Timber based materials (traditional timber children’s toys and flat pack furniture).
• Metal based materials (cooking utensils and hand tools).
• Polymers (polymer seating and electrical fittings).
• Textile based materials (sportswear and furnishings).
• Electronic and mechanical systems (motor vehicles and domestic appliances).

How physical and working properties are selected related and used in commercial products when designing and making.

• Additives to prevent moisture transfer (paper and boards).
• Seasoning to reduce moisture content of timbers (timber based materials).
• Annealing to soften material to improve malleability (metal based materials).
• Stabilisers to resist UV degradation (polymers).
• Flame retardants reduce combustion and fire hazards (textile based materials).
• Photosensitive PCB board in PCB manufacture and anodizing aluminium to improve surface hardness (electronic and mechanical systems).

• Papers and boards (how to cut, crease, score, fold and perforate card).
• Timber based materials (how to cut, drill, chisel, sand and plane).
• Metal based materials (how to cut, drill, turn, mill, cast, braze and weld).
• Polymers (how to cut, drill, cast, deform, print and weld).
• Textile based materials (how to sew, pleat, gather, quilt and pipe).
• Electronic and mechanical systems (how to cut, drill and solder).

Commercially available types and sizes of materials and components.

• sheet, roll and ply
• sold by size eg A3, thickness, weight and colour
• standard components eg fasteners, seals and bindings
• cartridge paper and corrugated card.

• planks, boards and standard moldings
• sold by length, width, thickness and diameter
• standard components eg woodscrews, hinges, KD fittings.

• sheet, rod, bar and tube
• sold by length, width, thickness and diameter
• standard components eg rivets, machine screws, nuts, and bolts.

• sheet, rod, powder, granules, foam and films
• sold by length, width, gauge and diameter
• standard components eg screws, nuts and bolts, hinges.

• yarns and fabrics
• sold by roll size, width, weight and ply
• standard components eg zips, press studs, velcro.

• sold by quantity, volt and current rating
• standard components eg E12 resistor series, dual in line IC packages (DIL), microcontrollers (PIC).

Calculation of material quantities and sizes.

Calculate surface area and volume eg material requirements for a specific use.

Efficient material use, pattern spacing, nesting and minimising waste.

How products are produced in different volumes.

• prototype
• batch
• mass
• continuous.

How to use measurement/reference points, templates, jigs and patterns where suitable.

Scaling of drawings, working to datums.

Material quantities required.

A range of tools, equipment and processes that can be used to shape, fabricate, construct and assemble high quality prototypes, as appropriate to the materials and/or components being used including:

• die cutting
• perforation
• turning
• sawing
• milling
• drilling
• cutting and shearing

• brazing
• welding
• lamination
• soldering
• 3D printing
• batik
• sewing
• bonding
• printing

• vacuum forming
• creasing
• pressing
• drape forming
• bending
• folding
• blow moulding
• casting
• injection moulding
• extrusion.

The manufacture to minimum and maximum measurements.

Extracting information on tolerances and using it to control quality and make a prototype.

• Papers and boards (offset lithography and die cutting).
• Timber based materials (routing and turning).
• Metal based materials (milling and casting).
• Polymers (injection molding and extrusion).
• Textile based materials (weaving, dying and printing).
• Electrical and mechanical systems (pick and place assembly and flow soldering).

The application and use of quality control to include measurable and quantitative systems used during manufacture

• Papers and boards (registration marks).
• Timber based materials (dimensional accuracy using go/no go fixture).
• Metal based materials (dimensional accuracy using a depth stop).
• Polymers (dimensional accuracy by selecting correct laser settings).
• Textile based materials (dimensional accuracy checking a repeating print against an original sample).
• Electrical and mechanical systems (UV exposure, developing and etching times in PCB manufacture).

The preparation and application of treatments and finishes to enhance functional and aesthetic properties.

• Papers and boards (printing, embossing and UV varnishing).
• Timber based materials (painting, varnishing and tanalising).
• Metal based materials (dip coating, powder coating and galvanizing).
• Polymers (polishing, printing and vinyl decals).
• Textile based materials (printing, dyes and stain protection).
• Electronic and mechanical systems (PCB lacquering, and lubrication).

Surface treatments to inhibit corrosion and oxidation.