Unit 1: Written Paper (8552)

GCSE Design and Technology

(100 marks)
 Use of mathematical modelling in design process

 To model/draw to scale
 To work out quantities of material needed
 To work out economic use of materials, nesting/tessellation and manage
waste
 To work out sizes and weights etc.
 To manage budgets
 To work out repeat pattern needs/waste
 To process tolerances
 CAD/CAM/CNC

What is CAD?
CAD means Computer Aided Design.
That is using computer software to draw shapes/designs. Tools used to design
include; edit, modify, save, delete, etc.
What is CAM?
CAM means Computer Aided Manufacture.
That is using computer-controlled machine (e.g. laser cutter) to produce shapes.
What is CNC?
CNC means Computer Numerically Control. Example of CNC machines include
laser cutter, miller, engraver, etc.
CAM Processes (e.g. 3D printer)
• Installation of appropriate polymer cartridge/materials /
• Preparing build bed for adhesion /
• Production/post processing of CAD file /
• Set-up 3D printer – nozzle size, temperature and resolution / rafting/support
provision / running file /
• Monitoring print for failure / QC
• Removal of material from bed /
• Clean-up of rafting/support /
• Post print finishing if required
What is ‘tessellation’ and ‘nesting’?
Tessellation or nesting is an arrangement of shapes closely fitted together in
a repeated pattern without gaps or overlapping.

This is done to minimise wastage of materials.

Materials and their properties

High impact polystyrene (HIPS) :

Malleable when heated – so that it can be formed to shape.
Tough– so that it can withstand knock/bumps in transportation or use / hold the weight of the contents.
Available in a variety of colours – attractive to users.
Stainless Steel:
Resistant to rust – meaning that it won’t corrode/rust.
Hard – meaning that it will keep its shape/edge in use.
Tough – meaning it will withstand knock and bumps in use.
Durable – Can withstand very high-water temperatures when being washed/sterilised.
Bleed proof paper:
Smooth surface – giving a high-quality finish.
Sized surface – so that the ink from the markers pens sits on the surface / giving a deeper/richer/less faded colour / marker
won’t go through the paper staining the worksurface/material underneath.
Non-absorbent – good for water and spirit based colours.
Beech
Fine and dense grain – to withstand pressure exerted when used or when dropped/thrown and durable/resists splitting /
holds paint and stains well
Natural pinkish – attractive aesthetics when unfinished.
Materials and their properties

Medium Density Fibreboard (MDF):

No natural defects/uniformly consistent material e.g. no knots.
Flat and rigid.
Comes in large sheets.
Easy to machine/mill/route to add features and pre-drilled locations for fittings.
Good compressive strength.
Cost effective to cover a large area.

High-Speed Steel (HSS):

It is very hard therefore it can cut through softer materials/metals
It can withstand high temperatures
Effective at high speed under load
Keeps its cutting edge well
Primary and Secondary data

Primary Sources of Information.

This involves collecting information yourself. First hand information.
1.Interviews.
2.Questionnaires.
3.Surveys.
4.Product Analysis.
Secondary Sources of Information.
This involves collecting information by another person or third person.
1.Websites.
2.Books/Magazines.
3.Newspapers.
4.Television and radio.
Design Fixation

What is ‘design fixation’?

Design fixation is a common condition where designers become stuck and can
only produce a range of similar designs and become blind to the alternatives. It
can be caused by playing safe / not taking risks.

How to avoid design fixation

•Avoid too much research / take a risk / go for the wacky idea.
•Use collaborative design to exchange ideas / peer review.
•Take an alternative/abstract approach such as working in a different.
medium/size of paper/use or don’t use CAD / scale up/down / any change is good.
•Acknowledge that ideas come only after many failures.
 What is Life Cycle Assessment (LCA)?

What is ‘Life Cycle Assessment (LCA)’?

A Life Cycle Assessment (LCA) is defined as the systematic analysis of the
potential environmental impacts of products or services during their entire life cycle.

Evaluate how the results could influence the way a product is manufactured.
•Extraction
•Production/manufacture
•Distribution/transportation
•Use
•End of life
 Tolerance

Tolerance is the measurement of the amount of error that is allowed for a given
task. Tolerance is used in quality checking to ensure products and systems
perform correctly to a given set of criteria.

Why do designers use tolerances?

•Physical checking of item for size/weight/resistance etc., to ensure it falls
between given minimum and maximum levels.
•Items are rejected/changed/adjusted if they fall outside acceptable levels. This
ensures all items are the same/within tolerance/have repetitive accuracy
•Changing tolerances can indicate wear/maintenance problems in a
manufacturing/tooling system. It can be used as a diagnostic tool for targeted
maintenance.
 Renewable and Non-Renewable energy

 Wind – Source: wind or wind turbine

 Solar – Source: sun
 Tidal – Source: Gravitational pull of the moon
 Biomass – Source: plant/animals
 Hydroelectric – Source: water/rivers/waterfall
 Geothermal – Source: heat
 Fossil fuels – Oil – Source: earth

- Gas – Source: earth

- Coal – Source: earth

NOTE: Non-renewable energy includes; Oil, gas, coal. (Fossil fuels)

 Forces on a body

Compression: Tension: Bending: Torsion: Shear:

Pushing force Pulling force Bending force Twisting force Cutting force
Input, process and output

Input Process Output

This is the information This is the brain of the This is what the device
that is fed to the device. device. The input does with the information.
information is sent to
the processor.

Examples (Components): Examples (Components): Examples (Components):

•Switches, •Electronics, •Light/LED
•Buttons, •Decision making, •Sound,
•Sensors, •Timer, •Alarm,
•Key pad, •Computer, •Siren,
•Transistor, •Bell,
•PIC Chip,
Types of cam
Types of motion

reciprocating oscillating rotary linear

Types of motion
Rotary Systems (Linkages)
Chain and sprocket Crank and Slider

Pulley and belt Gears

 Ferrous metals

Ferrous metals contain iron.

Steel – Iron and Carbon

Examples:
Mild steel
Stainless steel
Low Carbon Steel
High Carbon steel
What are alloys? Give examples and why?

An alloy is a mixture of two or more metals.

Examples:
Steel – Iron and Carbon
Brass – Copper and Zinc
Bronze – Copper and Tin
Pewter – Copper and Antimony

Why alloys?
To enhance the property of the metals. E.g. stainless steel cutlery is hard wearing and
corrosion resistant.
Mathematical Calculation