Unit 2 AExemplar

Centre
Number: 68870 Spring Term 2010

Ma#hew Lane – Double Award GCSE Engineering
Design and make a DIY tool that will be given as a
free gi8 with the first edi:on of a new DIY Magazine.
The device must be useful to DIY enthusiasts and
should be safe and easy to be used for a range of
ac:vi:es.

I have produced a brainstorm of all my products possible target
audiences, locations of use, tools and activities. I have presented
them in a mind map diagram, using a program called eMindmaps.

Where and What?
Used for :ghtening general
Essen:al for camping. equipment. Aimed at
BoEle openers are general market, DIY and
always useful. camping.
Hook can be used to pull

things i.e tent pegs out from
Useful when no knives the ground. Could come in
are available. Essen:al use for DIY and Camping.
for general use, DIY
and camping.
Useful to cut small

wooden objects. Such
as small s:cks etc.
Good for camping.

Images of Exis;ng Products
  Good variety of tools which  Large variety of tools could be hard   Plas:c housing provides an
would desirable to the general to extract use. aErac:ve look, and is rela:vely
purpose market.  Case could be made more cheap to manufacture
  AErac:ve Metal Finish, ergonomic for the human hand to – Plas:c should be a good op:on
stored within plas:c housing. hold whilst the tool is in use. for my mul:-‐tool case.
 Tools ‘Lock’ into their
posi:on when fully erect.
  AErac:ve metal finish.  Not a large amount of tools on the  Metal housing gives the tool an
 Tools ‘Lock’ into their mul:-‐tool – Therefore not suited as aErac:ve and robust look
posi:on when fully erect. a general all ac:vity mul:-‐tool and – Metal should be considered for
  Two good length knife tools.
would therefore not appeal to a my mul:-‐tool case.
large market.  More costly, and harder to
 Blades safely encased when
  Very small – Could be easily manufacture than a plas:c
not in use.
misplaced housing.
  Mul:-‐tools need large
amounts of tools

Images of Exis;ng
Products
 Large amount of tools.  Large amount of tools could be  Large variety of tools are
 It has many different size hard to extract for use. desirable in an ‘all in one’ mul:-‐
spanners and Allen keys which  Large amount of tools could make tool.
will appeal to the mechanical the mul:-‐tool uncomfortable to  If too many tools aren’t totally
market. hold, whilst using – tools not in use hidden, it could make the tool
 It encloses a portable torch. could poke/dig into the human hand uncomfortable to hold
 Has serrated & sharp edge  Case/Handle could be made more  Ergonomics need to be taken
tools. ergonomic for the human hand. into account when designing my
product.
 Very good variety of tools  Large amount of tools could be  My case/handle will be made
which is desirable to the hard to extract for use. ergonomic for the human hand.
general purpose and camping  The tool size is rela:vely small for  I should consider different
market. the amount of tools on it. colours and shapes on my case/
  Tools are a usable size. handle, so that it makes my
  Robust looking plas:c case, product stand out/unique.
with an interes:ng colour.
 Cut out on casing allows
tools to be extracted more
easily.

The metal tool hides within the plas:c case. Also has an The metal tool slides out from the plas:c case. Tool seems to be a
compass and a magnifier glass. It has an ergonomically shaped stainless steal material. The tool clicks into the case, therefore it is
case. Case is made of plas:c. Blue plas:c gives the tool a safely enclosed when it is not in use.
professional finish. Can easily fit into a trousers pocket, so it is
mobile.
The product also has a detachable part which seems to have There seem to be many tools, including a screw driver, serrated
different screw driver heads. This would allow you to :ghten edge, buEerfly can opener, can opener, a 4 posi:on wrench and
different types of screws. This could be very desirable to a DIY wire stripers. Some tools are integrated into each other to take up
enthusiast. less space. Could be a desirable product to the DIY market.

Ergonomics is the designing of products that must be fiEed around the
human body so that it can fulfil safe movements and postures. These
products need to be suited and designed so that they fit with the shapes
and angles of the human body.
If ergonomics are not taken into account when designing products for
human use, the human body could be prone to being in dangerous
postures which can result in the user’s body being affected by repe::ve
strain injuries, which in turn can result in long-‐term disability.
It is essen:al when designing products, that ergonomics are considered!

Anthropometrics is the designing of products, with the considera:on
of the sizes and weights of human hands, legs, head etc.
We can work out the sizes of the human limbs by measuring a sample
of people, and then using these results to help designers with their
anthropometrically suited designs.
If we apply all the informa:on we know about the human body, we can
makes anthropometrically designed products ‘fit’ the human user, so
that the product can be as effec:ve as possible for its purpose.

  The mul:-‐tool will be aimed at the DIY, general purpose and camping market.
  It must be robust enough to take general day to day use and abuse.
  The product must be finished to a high quality and standard.
  It needs to sit ergonomically well in the users hand and to be
anthropometrically suited to the human body.
  It must have a suitable protec:ve case to house the mul:-‐tool.
  The tools must sit safely within the case, when not in use.
  The mul:-‐tool must be visually aErac:ve and should include
interes:ng shapes/angles.
  The tool must be able to be used for many func:ons and ac:vi:es.
  The mul:-‐tool will require to have many useful & essen:al tools.
  It needs to be compact, so that it can be stored in a trousers pocket.
  It needs to be built and constructed for a low price, so that it can come
free with a magazine.

These are my original hand drawn sketches for my metal mul:-‐tool. I
created many designs and ideas on paper for my metal mul:-‐tool. I
then scanned them into the computer using a scanner. Later, I then
choose what shapes and tools were best suited to my mul:-‐tool them
and them took the designs/ideas forward and con:nued to develop
them, un:l I reproduced them on a computer using CAD So8ware.

- Continued

I produced many hand drawn
designs, for possible tool and cases
shapes and enclosing ideas. All my
hand drawn ideas are shown in the
following pages.

Out of all my hand drawn designs, this was my
favourite, as it has a unique way of enclosing the tool. It
also has the most posi:ve feedback when I showed the
designs to fellow class mates.

I have produced a first idea/sketch CAD design of my Top view of Mul8-‐tool
chosen mul:-‐tool design. I have created the design using
a CAD program called ‘Google SketchUp’. Using my
original hand drawn designs, I wanted to con:nue to
develop the design and to make an accurate concept of
what tools and cases could be suitable for the mul:-‐tool.
I planned to keep my original method of enclosing the
metal tool and the range of mul:-‐purpose tools were on
it.
Mul8-‐tool hidden within plas8c handle/case (Closed)

‘Xray’ view of Mul8-‐tool

Handle/case cut so
Handle/case cut so that it fits around that it fits around
the human hand (Ergonomic) the human fingers
Bo#le Opener 6 Posi;on (Ergonomic)
Wrench
Serrated Edge
Screw driver
This is my original CAD

design model for my mul;-‐
tool. The purpose of this
design was to show how my
final tool could look like.
Plas;c handle
Since then I have made
& casing modifica;ons to my design,
Bu#erfly Saw Edge
Nut fastening Plas;c, which is shown on a more
Hook Wrench
Sharp Edge Metal, Plas;c ‘Sandwich’. recent version of this CAD
design.
Shown below is a procedure chart that I have produced showing the stages of crea8ng my 1st CAD drawing on Google SketchUp.
A rectangle was first created , and then Both rounded rectangles were made into A rectangle was then made on top
the corners were rounded using the curve a component, and then they were raised of the handles, and the metal
tool, and then delete the excess area. I by 3mm using the pull/push tool to create mul:-‐tool’s complex shapes were
duplicated this shape, so that i had two the boEom handles. cut out and removed.
rounded rectangles.
Finally all parts materials were specified. Both boEom handles (which are iden:cal When all the areas were cut out for the
For all plas:c parts, a blue plas:c was components) were duplicated and moved tools, it was raised by 3mm using the
chosen. For the metal, a gray metal to above the metal mul:-‐tool part. The pull/push tool to create the metal-‐mul:
material was chosen. move/copy tool was used to do this. tool.
I used my hand drawn sketches, to create a CAD drawing using a
program called 2D design. When these drawings were done, I
then used the metal mul:-‐tool drawing as a template to cut out Handle/case cut so that it fits around
all of the holes and to transform it from a thin metal bar into a the human hand (Ergonomic)
tool, with many func:ons.
Serrated Edge Bo#le Opener

Screw driver
Hook
Sharp
Edge Handle/case cut so that it fits around
the human hand (Ergonomic)
6 Posi;on Spacer – To separate plas;c
Bu#erfly Wrench layers, to allow the metal to
Saw Edge
Wrench enclose in the case.
We needed to test our designs to see if our concepts and designs are actually possible
to create and to see if they fulfil their purpose. Models play important roles in
engineering. They are needed to find any faults in the opera:ons of a product. They are
essen:al to the final design processes! By making models we can alter designs and find
errors in the design which can be modified so that the product can be made more
ergonomic or anthropometric suited to a human user.
We made our first models out of Card/Cardboard. We used a pencil and ruler to mark
out the dimensions on the material. Then we used a scalpel and a cueng board to cut
the material, into the desired sizes.
Problems
1. Handle/case is too large for the metal mul:-‐tool piece.

2. Handle/case does not fully rotate to hide the metal mul:-‐tool component due to the
handle being larger in width than the metal mul:-‐tool, thus the device can not properly
‘close’.
3. Handle/case corners need to be curved so that the plas:c slides against each other
easily.
Modifica;ons & Adjustments
1. Make the handle/case smaller so that it is in a similar propor:on of the size of the
metal mul:-‐tool.
2. Reducing the size of each handle/case, so that is a correct size and hides the metal
mul:-‐tool when ‘closed’.
3. Make the handle/case have curved corners, so that the corners of the plas:c do not
collide with each other.

The second model was also made out of cardboard, using the same methods used to create the 1st Model.
The problems from the previous model have been rec:fied by making the modifica:ons & adjustments required.
The handle/case has been made smaller so that it is a similar size to metal mul:-‐tool, and the corners of the handle/
case have been made rounded so they can slide easier past each other
The biggest change in the 2nd Model is that ergonomics and anthropometrics have also taken into account, unlike
the 1st model.
Problems
1.  Cut outs from case/handle could be made more ergonomic.
2. Handle/case rota:on ac:on could be further improved.
Modifica;ons & Adjustments
1. Cut outs -‐ Need to be adjusted by changing posi:ons and sizes of cut outs.
•  Finger Cut outs need to be moved further down the handle/case.
•  Where hand sits into the handle cut out (thumb – index finger spacing) -‐ Size and loca:on of cut out needs
to be adjusted:
•  Cut out needs to be moved further up the handle/case
•  Cut out needs to be made larger in depth and wider to accommodate the human hand beEer.
2. Further improve handle/case rota:on ac:on by keeping measurements of both handles the same. The drilled
holes on the metal need to be an equal distance apart, so that both handles can fully rotate to ‘close’.

For the third model, I used the 2D designs I showed earlier of my mul:-‐tool to cut out a Card Model using
a CAM machine. In this case it was laser cuEer. The laser cuEer uses lasers to cut materials into shape.
The other op:on was to cut the material using a scalpel. When cueng out by hand, human error can
occur, which cannot happen when using the CAM machine. Using the CAM machine is more accurate &
precise than cueng the card out by hand, therefore giving a beEer, more accurate model.
In this model, I have been able to adjust the cut outs on the handle/case so that it is more ergonomic for
the human hand. Using a computer to design the tool, I have the advantage of being able to see a
visualisa:on of what the cut out components would look like if it were to be printed, improving the
design.
Another advantage of designing the tool on the computer is that I plan to cut my handle/case out using a
CAM machine. This means that I can use the designs I've used to create this card model to create the final
versions, which will be in plas:c.
Problems
No major problems – All previous errors have been adjusted or changed.

Along with our mul:-‐tool, a torch needed to be developed. For this product, we had to design, create and construct the
light’s electronic circuit and it’s casing.
The lights electronic circuit was designed using Yenka Electronics. When I had the necessary electronic components, such
as the printer circuit board (PCB), LED, baEery, baEery holder, switch and resistor, the electronic circuit was then created
by soldering the necessary components to the PCB board, using solder and a soldering iron. The electronic light was now
completed and a method of housing the electronic components were needed.
A case for the light was also required, to house the electronic components. I designed the light’s case on a CAD program
called 2D Design. When the design was complete it was sent to the C.A.M (Computer aided modelling) machine, which is
the laser cuEer. When all plas:c parts were completely manufactured, they were then assembled together, and then
electronic light was secured into the case so that the light’s switch is able to be turned on and off from outside the case.
Another plas:c component was also designed which aEaches to the boEom of the light’s casing, so that the light can fit
securely on the metal mul:-‐tool when it is closed. This piece of plas:c is moulded so that it fits into the space which is
cut to make the case/handle more ergonomic, therefore when the metal mul:-‐tool is shut the LED light can fit securely 2D Design of Top Face
in the mul:-‐tools case. of the PlasCc Case
The completed LED Light Case -‐ Assembled All the LED Light Components The completed LED Light Electronic Board

The light which was made needed a case to enclose and house the electronic components. This would make the light more visually aErac:ve,
easier to hold and making the light more robust so it is less prone to breaking. I designed the light’s casing on a CAD program called 2D Design.
Using the program I made the template for all plas:c parts. A plas:c top for the case was needed, which has an area cut out of it in the centre to
allow the LED light to be easily turned on and off, as well as plas:c spacers which allow for the electronic components to fit within the case. A
plas:c boEom is also required, which has a slider on it that allows us to access the light’s baEery, if it needs to be replaced. The final plas:c part
is a piece of plas:c which aEaches on to the boEom of the light’s case (on the plas:c slider so that we can s:ll access the baEery). This plas:c is
cut in way which will allow it to fit around the mul:-‐tool’s ergonomic cut outs, which allows the LED light to be securely aEached to the mul:-‐
tool when it is closed.
All the plas:c case components have been made ergonomic so that they fit around the human hand, to allow it to be held comfortably in a
hand. The lights case looks very similar to the metal mul:-‐tool, which has nearly iden:cal designs on the top of the handle/case. Therefore, both
products, would work as a package.
Area cut out for LED
Case cut so Case cut so

that it fits that it fits
around the around the
human fingers human fingers
(Ergonomic) (Ergonomic)
Plas;c cut so that it fits
Area cut out for around the mul;-‐tool
Curved corners for case, to secure the LED
Light’s switch to be
be#er finish Light to the Mul;-‐tool
turned on/off
(When fully closed)

Below are all three circuit designs I considered when I was designing the electronic circuits on Yenka Electronics. I had to consider all the
circuits I designed and make a final decision on what light would be more appropriate for the light’s purpose.
First Design Second Design Third Design
For this design, I considered using more than one Unlike the first and third design, it only has one LED, For the third design, I considered using two LEDs.
LED in a parallel fashion. Pueng the LED’s in a therefore it would create less light, but would require Both LEDs are in a series fashion. This means that
parallel paEern instead of a series paEern is beEer less electrical energy, and should save baEery life. It the whole circuit would fail if one of the LED broke
because if an LED broke in a series circuit, the also has a on/off switch . because the circuit not be complete, due to the
whole circuit would fail due to the circuit not be broken component. Unlike the first and second
complete. Having the components in a Parallel I choose this design for the electronic light. I believe design, it has a push switch instead of a on/off
circuit allows the circuit to s:ll work if an LED having more than one LED is unnecessarily and an switch. Having a push switch is good for having a
broke, as the electronic current can con:nue on/off switch is essenCal, as a push switch has to be light on for a short amount of :me but can be
through an alterna:ve wire. It has an on/off conCnually held down, and would be annoying to annoying to use if you want to use the light for
switch, which is easier to use than an alterna:ve use, as you want a light to stay on. long periods of :me.
push switch. Advantages Advantages
Advantages Less LEDs would mean there would be less on the Having more LEDs would create a larger light.
Having more LEDs would create a larger light. baEery. Push switch are good to use for short amounts of
Disadvantages Disadvantages :me.
More LEDs would mean there would be drain on Less LEDs than designs 1&2 -‐ Less light due to one Disadvantages
the baEery. LED. Push switch can be annoying to use for long :mes.
This is my final 3D CAD design of my mul:-‐tool. It was created using the CAD program called Google Sketch Up. This CAD drawing has
modifica:ons made since the original CAD sketch up I created. The original CAD sketch was analysed and ideas which were plausible were
con:nued in the design ideas process. I wanted to keep the same mul:-‐purpose tools in the final product and I also wanted to further develop
the rota:ng handles idea, to fully enclose the metal mul:-‐tool when both handles rotate together, so it acts as a case. Another reason why I
wanted to con:nue the development of this idea was because its a new concept. During my research I did not find a product with the same tool
erec:ng func:on, therefore this product is an new innova:on in mul:-‐tool technology, and should aEract customers due to it being original.
The 3D CAD design shown below is how I hope for the final finished Nut fastening Plas;c, Plas;c
product to look like, with iden8cal tools and func8ons! Metal, Plas;c ‘Sandwich’ handle /case
e r rate d Edge
Bo#le Opener S
Screw driver
Hook
Handle/case cut so that it
6 Posi;on fits around the human
Sharp Bu#erfly fingers (Ergonomic)
Wrench
Edge Edge Wrench
Saw
Centre Number: 68870 Spring Term 2010
Introducing the brand new innova;ve Mul;-‐tool ML Ltd.

The mul;-‐tool is hardwearing as it is made from mild steel and 3mm Acrylic. There very li#le
this tool can do in everyday DIY work. Here are some of the things it can achieve:
Opening a Corn Beef Can CuSng a card box Tightening a Screw into Wood CuSng some Wood
(BuPerfly Opener) (Serrated Edge) (Screw Driver) (Saw Edge)
Fastening a Nut Pulling a Tent Peg from some Grass Opening a BoPle
(6 PosiCon Wrench) (BoPle Opener) (BoPle Opener)
This tool has evolved from many hand drawn
designs, to a fully func:oning product, storming
the DIY mul:-‐tool market!
Hand drawn design of the Metal Tool.
CAD Mock Up of the MulC-‐tool

I have produced a brainstorm of all my products possible target
audiences, locations of use, tools and activities. I have presented
them in a mind map diagram, using a program called eMindmaps.

For the third model, I used the 2D Design to design the parts. It was cut using the laser cuEer. The laser
cuEer uses lasers to cut materials into shape. The other op:on was to cut the material using a scalpel.
When cueng out by hand, human error can occur, which cannot happen when using the CAM machine.
Using the CAM machine is more accurate & precise than cueng the card out by hand, therefore giving a
beEer, more accurate model.
In this model, I have been able to adjust the cut outs on the handle/case so that it is more ergonomic for
the human hand. Using a computer to design the tool, I have the advantage of being able to see a
visualisa:on of what the cut out components would look like if it were to be printed, improving the
design.
Another advantage of designing the tool on the computer is that I plan to cut my handle/case out using a
CAM machine. This means that I can use the designs I've used to create this card model to create the final
versions, which will be in plas:c.
Problems
No major problems – All previous errors have been adjusted or changed.

I used my hand drawn sketches, to create a
CAD drawing using a program called 2D Handle/case cut so that it fits around
design. This helped my further develop my the human hand (Ergonomic)
tool!
Serrated Edge Bo#le Opener
Screw driver
Hook
Sharp
Edge Handle/case cut so that it fits around
the human hand (Ergonomic)
6 Posi;on Spacer – To separate plas;c
Bu#erfly Wrench layers, to allow the metal to
Saw Edge
Wrench enclose in the case.
This tool has evolved from many hand drawn design to CAD sketches. The design has
gone through many beneficial modifica:ons to finally become the completed
ML Mul;-‐Tool
Nut fastening Plas;c, Plas;c
Metal, Plas;c ‘Sandwich’ handle /case
e r rate d Edge
Bo#le Opener S
Screw driver
Hook
Handle/case cut so that it
6 Posi;on fits around the human
Sharp Bu#erfly fingers (Ergonomic)
Wrench
Edge Edge Wrench
Saw
The tool also incorporates a detachable LED light.

The LED Light, which
comes with the tool!
“With magneCc technology to

lock the tool into posiCon!”
Final CAD Design compared to the Final Product.

Unit 2 AExemplar

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Centre

Number: 68870 Spring Term 2010

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Hook can be used to pull

Useful to cut small

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Mul8-­‐tool hidden within plas8c handle/case (Closed)

Ma#hew Lane – Double Award GCSE Engineering

This is my original CAD

Serrated Edge Bo#le Opener

1. Handle/case is too large for the metal mul:-­‐tool piece.

Modiﬁca;ons & Adjustments

Ma#hew Lane – Double Award GCSE Engineering

Modiﬁca;ons & Adjustments

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Case cut so Case cut so

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Hand drawn design of the Metal Tool.

CAD Mock Up of the MulC-­‐tool

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

Ma#hew Lane – Double Award GCSE Engineering

“With magneCc technology to

Ma#hew Lane – Double Award GCSE Engineering

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Mul8-‐tool hidden within plas8c handle/case (Closed)

1. Handle/case is too large for the metal mul:-‐tool piece.

CAD Mock Up of the MulC-‐tool