NCFE Level 1/2 Technical Award in Engineering

(603/2963/4)
Internal Synoptic Project
November 2021

Centre name: CORBY TECHNICAL SCHOOL

Centre number: 27141

Learner name: James Hughes

Learner number: 7064

Project Brief
• You are employed as an engineer at a company that specialises in
manufacturing a range of storage boxes. The Chief Engineer has
asked you to produce a prototype of a new storage box.
• The Chief Engineer has given you drawings and manufacturing
criteria of the storage box with all the relevant parts labelled. Use
these drawings and criteria where required throughout the project.
• You are required to produce a portfolio of evidence to accompany
your storage box.
• The portfolio should include:
• sketches, engineering drawings and/or computer aided
design (CAD) of your storage box using the criteria and
drawings provided
• a production plan
• evidence of testing the storage box in relation to the criteria
• an evaluation of the project, making reference to your learner
log where appropriate (to include a description of what you
would have done differently if other tools, materials and
techniques were available).

• Using your drawings and production plan, manufacture your

storage box. Use your storage box to produce the evidence
required by the Chief Engineer for review. You can manufacture
the storage box from any suitable and/or available materials.
• Produce drawings and photographs and/or video of your completed
storage box. The drawings and photographs/videos should show
that your storage box meets all the criteria given in the brief.
• During the manufacturing process, you should:
• demonstrate that you are able to carry out manufacturing
techniques
• provide evidence of how you demonstrated safe use of
appropriate tools and/or machinery when manufacturing your
storage box.

• Note: You must use the information and dimensions in the

drawings and criteria provided. All other dimensions are your
own choice.
Drawing
Introduction: On this page I have drawn the tray from the design brief dimensions using the 2D CAD drawing program
2D design. 
Drawing
Introduction: On this page I have drawn the toolbox from the design brief dimensions using the 2D CAD drawing
program 2D design. 
Drawing
Introduction: On this page I have drawn an isometric image of the Toolbox from the design brief dimensions using the
2D CAD drawing program 2D design. 
Drawing
Introduction: On this page I have drawn the tray from the design brief dimensions using the 3D CAD drawing program
solid works. 
Drawing
Introduction: On this page I have drawn the toolbox from the design brief dimensions using the 3D CAD drawing
program solid works.
Hardwoods​
Introduction: I will look at three hardwoods, and research their properties and applications. I will use the textbook to do this.
A hardwood tree is typically deciduous with broad leaves. The wood produced is close grained and is strong. Hardwood trees are typically slow growing.
Type​ Description​ Properties​ Applications​ Image
Oak​ Oak trees are large and produce a pale, yellow/brown Oak is durable and strong with Interior woodwork and high-
wood​ open grains. It can be expensive​ quality furniture. Windows, roofs
and Roof supports​

Ash​ Large trees that produce wood that is a lighter colour Ash is open grained, tough and Sports equipment, tool handles
than oak.​ strong. It is also flexible and easy and ladders. Ash is also used in
to work with.​ furniture.​

Balsa​ Very pale colour, the trees are typically tall with a wide Very easy to work with. Low Balsa - Spanish word for raft.​
canopy of leaves.​ density - lightweight​ Buoys, rafts surfboards. Models of
aircraft and buildings,
musical instruments.​

Conclusion: Key Points: Key Words:

I have found out that hardwoods are produced by • Hardwoods are produced by • Lightweight – A material that has a
deciduous trees and are typically strong. I don’t think deciduous trees low density and doesn't weigh
hardwoods will be suitable for this project. I will now • They are close grained and strong. much.
research softwoods. • They are typically more expensive • Flexibility – The ability of a material
than softwoods, as the trees take to bend without breaking
longer to grow.
Softwoods​
Introduction: I will look at three softwoods and research their Propeties and applications. 
Softwood trees are evergreen coniferous trees with needle like leaves. The trees grow quickly all year round and produce wide grain wood. These trees produce acorns.
Type​ Description​ Properties​ Applications​ Image
Scots pine​ The wood is white to yellow in Cheap, easy to work with. Straight, Furniture, wall panelling and
colour.​ fine grain. The wood is knotty flooring, joinery and shelves.​
and prone to twisting​

Cedar​ When weathered the wood takes Is strong, dense solid and robust.​ Lining drawers, chests and storage
on a light silvery grey closets.​
colour. Before that it is typically a
pinkish/reddish colour.​

Spruce​ The wood is a reddish brown.​ Strong and hard wearing – durable. Mast and spars for ships, aircraft
Low resistance to decay​ crates, boxes, general millwork
and ladders.​

Conclusion: Key Points: Key Words:

I have found out that softwoods are produced by • Softwoods are produced by
evergreen trees and are typically weaker than evergreen trees
hardwoods. I don’t think softwoods will be suitable for • They are wide grained.
this project. I will now research manufactured timbers. • They are typically cheaper than
hardwoods, as the trees can grow
much quicker.
• Aromatic – A material that repels
moths.
• Knot – A part of a wood that is
formed where branches grow. This
can cause the surrounding area to
be weaker than the surrounding
wood.
Manufactured Timbers
Introduction: I will look at three Manufactured timbers and research their properties and applications.
Manufactured timbers are wood that have been produced by humans. They are often made of waste wood pulp or sheets and a glue

Type Description Properties Applications Image

Plywood Thin layers of wood glued together at different
grain angles.
MDF Wood pulp (normally waste wood cuttings)
bonded together with formaldehyde – a resin.
Chipboard Made from waste wood chips that have been
glued together under high pressures.
Resistant to warping, high impact Commonly used in flooring and
strength, high chemical resistance roofing. Also used in boat building
and in packing cases.
Cheap, high compressive strength, Internal use. Kitchen and bath
dense, flat. Has no knots, easily worktops, flooring, furniture
machined, strong and durable. manufacture and joinery.
Cheap, high compressive strength.  Cheap, self-assembly furniture.
Kitchen tops, fire tops. Flooring
and shelving.

Conclusion: Key Points: Key Words:

I have found out that manufactured timbers are wood • Manufactured timbers are wood
that have been produced by humans. I don’t think made by humans, often from a
manufacture timbers will be suitable for this project. I waste wood shavings or pulp and a
will now research Thermosetting plastics. glue.
• Some of these materials can be
cheaper as they are made from
waste products.
• Wood Pulp – fibers of wood that
have been separated by a chemical
or mechanical process.
• Compressive Strength – The ability
of a material to resist compressing
and crushing forces.
Thermosetting plastic
Introduction: I will look at three thermosetting plastics and research their properties and applications.
Thermosetting polymers cannot be reformed by heating once set. Because of this they cannot be recycled.  They are often used where they may be exposed to heat, chemicals or solvents.

Type Properties Applications Image

Epoxy Resin Good heat resistance and hard wearing.  Two pack adhesives, laminates and
Epoxy resin is formed by mixing a reinforced plastic composites.
resin and hardener, triggering cross
linking
Urea formaldehyde High tensile strength, low water absorption, high Used in electrical appliance casings, desk
surface hardness. lamps, used in resin form in the
manufacture of MDF.
Polyester Resin Similar to epoxy resin – Good heat resistance and The production of reinforced plastic
hard-wearing. composites.

Conclusion: Key Points: Key Words:

I have found that  thermosetting plastic are a • Thermosetting plastics are polymers • Tensile Strength – The ability of a
polymer that cannot be reheated and reshaped once that cannot be reshaped once set. material to resist stretching and
set. They are often quite strong and resistant to heat • It is difficult to recycle thermosetting pulling forces.
and chemicals. I don’t think thermosetting plastics will polymers. • Surface hardness – The ability of the
be suitable for this project. I will now look at material of a surface to resist
thermoplastics  scratches and other forces.
Thermoplastic​
Introduction: I will look at three thermoplastics and research their properties and applications.  
A thermoplastic is a polymer that can be reshaped when heated. Because of this it can be recycled.

Type​ Properties​ Applications​ Image

Acrylic​ Strong, stiff and scratches easily. Easy to fabricate, Car lights, baths, decorative items and shop
bonds well with adhesives and solvents, easy to signs.​
thermoform.​

Polypropylene​ Low density, lightweight and flexible, high impact Automotive applications, household goods,
resistance, heat resistant, chemically inert and containers, appliances, packaging.​
transparent.​

Hip Impact Polystyrene​ Easy to mould, light and strong, high impact Vacuum forming, appliance components,
strength, good machinability.​ toys, tv and audio-visual device parts,
cassettes, bike trailer, petrol tank, hot
and cold drinking cups.​

Conclusion: Key Points: Key Words:

I have found that  thermoplastics are a polymer that • Thermosetting plastics are polymers • Chemically Inert – A material that is
can be reheated and reshaped once set.  I don’t think that can be reshaped once set. very unreactive, as a result it will be
thermosetting plastics will be suitable for this project. • Thermoplastics can be recycled resistant to corrosion and other
I will now look at elastomers.  chemical reactions.
• Transparent – A material that allows
light to pass through, such as glass.
Elastomer​s
Introduction: On this page I will look at three elastomers and research their properties and applications.
An elastomer is a polymer with elastic properties, meaning it can stretch and bend without permanently deforming.

Type Properties Applications Image

Rubber Resistant to abrasion, tear resistant, high tensile Tyres and tubes, hoses, belts, matting,
strength, hard durable and flexible. flooring, medical gloves and adhesives.

Neoprene Abrasion resistant, tear resistant, resistant to aging Wetsuits, life jackets, knee and elbow pads,
from weather/sunlight, durable and flexible. laptop sleeves, iPod holders, hose car fan
belts and electrical insulation.

Silicone Flexible, thermal resistance, chemical resistance, Sealants, adhesives, lubricants, medicine,
electrical insulation. cooking utensils, thermal and electrical
insulation.

Conclusion: Key Points: Key Words:

I have found that elastomers are a polymer with • Elastomers are polymers with elastic • Elastic Properties – A material that
elastic properties. I don’t think elastomers will be properties can be bent and stretched without
suitable for this project. I will now look at Non-Ferrous • They are often resistant to abrasion. permanently deforming.
metals.  • Durability – The ability of a material
to resist normal wear and tear.
Non-Ferrous Metals​
Introduction:  I will research five non-ferrous and their properties and applications. I will use the textbooks to do this.
A non–ferrous metal is a metal or alloy that does not contain Fe. Due to the variety of non-ferrous metals they can have a variety of properties.
Type​ Description​ Properties​ Applications​ Image
Aluminium​ Used in its pure form and in a range of alloys.​ Soft, light, malleable and Aircraft and motor vehicle components,
corrosion resistant​ utensils, ladders and overhead electrical
cables.​

Copper​ Used in its pure form and in alloys.​ Very ductile and malleable, good thermal Electrical wires and cables, water pipes and
and electrical conductor, corrosion soldering iron bits.​
resistant.​

Lead​ Used in its pure form and in alloys.​ Very soft, heavy, malleable and corrosion Roofs, tank linings, alloyed with tin to make
​ resistant.​ soft solders.​

Brass​ Alloy of Copper and Zinc.​ Very ductile with high copper Tubes, pressings, forgings, a range of
content, strong, touch and good molten castings.​
fluidity with high zinc content.​

Solder​ Alloy of Lead and Tin Malleable, corrosion resistant, very soft, Electronics, plumbing, jewellery making and
LMP and good molten fluidity.​ repair. Soldering is used where welding isn’t
safe or effective.​

Conclusion: Key Points: Key Words:

I have found out that non-ferrous metals are metals that
don't contain iron. I think some non-ferrous metals, such as
Aluminum,  could be suitable for this project. I will now
research ferrous metals.
• Non-Ferrous metals are an alloy or
pure metal that doesn't contain
iron.
• Alloy – A metal that combines two or
more elements. This is normally none so that the
material has better properties, such as strength
or conductivity
• Ductility – The ability of a material to be
stretched without losing strength or breaking.
Ferrous Metals
Introduction: I will look at four different kinds of ferrous metals and research their properties and applications. I will use the textbooks to do this.
A ferrous metal is pure or an alloy containing  iron. Because of this most ferrous metals rust easily and are magnetic.

Type Description Properties Applications Image

Iron  Pure Fe Ductile, malleable, magnetic. Used in steel alloys, construction, machines and the automotive industry
The only pure ferrous metal,

Mild Steel An alloy of Fe and C Strong fairly malleable and Wires , rivets , nuts and bolts, pressings, girders, general work material.
0.1% - 0.3% C ductile.

Cast Iron An alloy of C and Fe Weak in tension, strong and Machine beds, brake drums, engine cylinder heads, valve bodies, manhole covers.
3.2% - 3.55 C tough in tension, very fluid
when molten. Some carbon is
present as graphite – self
lubricating

Stainless Steel An alloy of C, Cr Mn and Fe Corrosion resistant, strong Food processing and kitchen equipment, surgical and medical instruments, cutlery
1% C, 27% Cr, 0.8% Mn and tough and decorative items.

Conclusion: Key Points: Key Words:

I have found out that ferrous metals are
metals containing iron. I think some ferrous metals could be
suitable for this project .
• Ferrous metals contain or are pure
iron.
• Most ferrous metals can rust and
are magnetic.
• Malleable – The material can be
bent or pressed into shape without
cracking or breaking.
• Corrosion Resistance – The ability of
a material to resist to oxidisation.
Material Testing
Introduction: I will test the properties of 6 materials to determine if they could be used for this project. 
Test Description

Toughness Toughness is the ability of a material to withstand sudden shocks or impacts. To test a materials toughness, I will clamp the
material in a vice, protruding from the vice by a set amount. I will then swing a hammer from a set angles (30°, 60°,90°) so that
it hits the material. The toughness can be determined by how much the material bends, and if it is permanently damaged or
deformed.

Hardness The hardness is the ability of a material to resist scratching, wear and tear and impacts. The material will be placed underneath
a hammer that is dropped from 30°, 60 °and 90°. The hardness can be determined by the dent / marks on the surface of the
material.

Bending A material that bends can change shape when a force is applied without cracking or breaking. The material is placed above a
gap with the ends supported. 550g of weights are added to the middle of the material and the deflection is measured. The
weight is then removed, and the material can then bend back towards its original position.

Elasticity Test Elasticity is the ability of material to bend and stretch without permanently deforming. The end of the material is placed in a
slot. Weights are then hung on the end of the material, and the bend of the material is measured in mm. An elastic material
will be end to bend without permanently deforming.

Scratch Test Emery cloth is moved across the material 1 time with a set amount of pressure. This will scratch the material. I will then look at
the material to determine how much it scratches.
Material Testing
Introduction: I will test the properties of 6 materials to determine if they could be used for this project. 
Toughness Test Scratch Test Elasticity Test
Aluminum 25mm bend
90° 60° 30° Aluminum Very Scratched
Mild Steel 1 mm bend
Aluminum 5° 4° 3° Mild Steel Mildly Scratched
MDF 20mm bend
Mild Steel 0° 0° 0° MDF Fine Scratches Plywood 12mm bend
Plywood A few scratches – only Acrylic 15mm bend
MDF 2° 3° 3° visible in certain HIPS 550g – Above scale
lighting 50g – Above Scale
Plywood 0° 0° 0° (> 50mm)
Acrylic 0° 0° 0° Acrylic Slight Scratches

HIPS Slight Scratches Conclusion:

HIPS Above Scale Above Scale 25° Aluminium: Aluminium is a relatively flexible material, as it bent
quite a lot on the bending, toughness and elasticity tests. It also
Hardness Test Bending Test scratches easily and is not a very hard material.
Mild Steel: Mild steel is a very tough and hard material. It only 
90° 60° 30° bent a little in the elasticity and bending test, meaning that is rigid
Aluminum 4° bend
Aluminum Medium dent Small dent Tiny dent and sturdy. It is more resistant to scratches than aluminium, but
still scratches quite easily.
Mild Steel No bend MDF: MDF is quite flexible but not to the same amount as
Mild Steel Very small No dent Very faint
dent mark aluminium. The material is also quite hard and resistant to
MDF 3° bend scratches.
MDF Very Small Little dent Tiny mark
Mark Plywood: Plywood is a very tough material, and is somewhat
Plywood No bend resistant to bending, as seen in the bending and elasticity tests.
Plywood Large Dent Little Dent Faint Dent The material isn't very hard but is resistant to scratching.
Acrylic 2 Bounces Small Scuff Tiny scuff Acrylic 2° bend Acrylic: Acrylic is a quite tough and hard material but is does bend
Scratch a decent amount in the bending and elasticity tests. It is quite
HIPS Collapsed with 550 g. resistant to scratches.
HIPS Large Dent Small Dent Small Dent 450g was a 25° bend. HIPS: Hips is an extremely flexible material, as seen in the bending,
toughness and elasticity tests, where they had to be adjusted to
properly test the material. The material is relatively hard and
resistant to scratches.
Production Plan for the Tool Box Page 1
Task Tools Needed Material Needed Time Needed Health and Safety
1 Paint the metal for the end pieces with • Paint brush • Mild Steel 5 Minutes Be careful not to get the engineer's blue
engineer's blue. • Engineer's blue on your skin or clothes
2 Mark out the dimension of the end • Scribe • Mild Steel 20 Minutes Be careful around any sharp points on
pieces and the areas that need to be • Steel Rule the materials and tools.
drilled on the Mild Steel • Engineers Square Make sure your fingers are clear of the
• Centre Punch top of the centre punch when using the
• Hammer hammer.
3 Cut the end plates. • Guillotine – Allows for precise and quick • Mild Steel 30 Minutes Be careful when using the
cutting. saw/guillotine, don't put hands near the
• Tin snips sharp points of the tools.
• A hacksaw could also be used, but this would
be slower and less precise
4 File the end plates to the correct size. • File • Mild Steel 20 Minutes
Check that the material has been cut to
the right size, if not continue to file.
5 Drill the end plates using a pilar drill or • Pilar Drill • Mild Steel 15 Minutes Wear goggles
hand drill. • Hand Drill Ensure that the guard is closed
• Hand Vice Secure the work in a hand vice,
to minimize the chance of the
material becoming loose.
6 Bend the parts of the end plate that • Box pan and Press • Mild Steel 15 Minutes Ensure there is nothing near to the
need bent. moving parts of the machine
7 Repeat steps 1 – 6 for the main body of As Above
the box. The holes that will rivet the
end plates to this piece should not be
drilled until later.
8 Clamp the body piece to one of the end • Mole grips • Mild Steel 5 Minutes Make sure your fingers don’t become
pieces with mole grips, clamps or • Clamps trapped between the clamps / metal
masking tape. • Masking Tape pieces.
Production Plan for the Tool Box Page 2
Task Tools Needed Material Needed Time Needed Health and Safety
9 Drill through a rivet hole on the end • Hand Drill • Mild Steel 2 Minutes Wear goggles
piece. • Power Drill Ensure that the guard is closed
Secure the work in a hand
vice, to minimize the chance of
the material becoming loose.
1 Rivet through this hole to secure the • Rivet Gun • Mild Steel 2 Minutes Be careful when using the rivet gun, so
0 two pieces together • Rivets that you are not injured
1 Repeat steps 9 and 10 until all of the • As Above
1 holes have been riveted. Then repeat
steps 9 – 11 until the other end piece is
secured.
1 Mark where to drill and bend the • Scribe • Mild Steel 5 Minutes Be careful around any sharp points
2 material for the shelf pieces. • Steel Rule on the materials and tools.
• Engineers Square Make sure your fingers are clear of
• Centre Punch the top of the centre punch when using
• Hammer the hammer.
1 Drill the holes on the shelf pieces. • Pilar Drill • Mild Steel 10 Minutes Wear goggles
3 • Hand Drill Ensure that the guard is closed
• Hand Vice Secure the work in a hand
vice, to minimize the chance of
the material becoming loose.
1 Fold the shelf pieces using the box pan • Box pan and Press • Mild Steel 15 Minutes Ensure there is nothing near to the
4 and press. moving parts of the machine

1 Attach the shelves to the box using • Rivet Gun • Mild Steel 2 Minutes Be careful when using the rivet gun, so
5 rivets • Rivets that you are not injured

1 Mark out the pieces for the lids. • Scribe • Mild Steel 5 Minutes Be careful around any sharp points
6 • Steel Rule on the materials and tools.
• Engineers Square Make sure your fingers are clear of
• Centre Punch the top of the centre punch when using
• Hammer the hammer.
Production Plan for the Tool Box Page 3
Task Tools Needed Material Needed Time Needed Health and Safety
1 The holes for the handles will be cut • Pilar Drill • Mild Steel 10 Minutes Wear goggles
7 out by  chain drilling. Drill holes 5 mm • Hand Drill Ensure that the guard is closed
from the edge of the handle, every 5 • Hand Vice Secure the work in a hand
mm vice, to minimize the chance of
the material becoming loose.
1 Use a coping saw to finish cutting out • Coping Saw • Mild Steel 40 Minutes Be careful when using
8 the handles. the saw/guillotine, don't put hands near
the sharp points of the tools.

1 File the handles to the correct size • File • Mild Steel 60 Minutes Be careful around the handles, as the
9 area around the parts that have been
drilled are sharp.

2 Cut the piano hinges to the correct • Hacksaw • Piano Hinges 10 Minutes Be careful when
0 length using the saw/guillotine, don't put
hands near the sharp points of the
tools.
2 Mark the areas on the toolbox that • Scribe • Mild Steel 5 Minutes Be careful around any sharp
1 need to be drilled for the hinges • Steel Rule points on the materials and tools.
• Engineers Square Make sure your fingers are clear
• Centre Punch of the top of the centre punch when
• Hammer using the hammer.
2 Drill through the marked points using a • Pilar Drill • Mild Steel 10 Minutes Wear goggles
2 pilar or hand drill • Hand Drill Ensure that the guard is closed
• Hand Vice Secure the work in a
hand vice, to minimize the chance
of the material becoming loose.
2 Attach the hinges to the box using • Rivet Gun • Mild Steel 10 minutes Be careful when using the rivet gun,
3 rivets. • Piano Hinges so that you are not injured
• Rivets
2 Repeat steps 21-23 on the lid • Same as above
4
Flowchart of the Toolbox Production Plan.
Production Plan for the Tray Page 1
Task Tools Needed Material Needed Time Needed Health and Safety
1 Paint the metal for the tray with • Paint brush • Mild Steel 5 Minutes Be careful not to get the engineer's blue
engineer's blue. • Engineer's blue on your skin or clothes
2 Mark out the dimension of the tray and • Scribe • Mild Steel 20 Minutes Be careful around any sharp points on
the areas that need to be drilled on the • Steel Rule the materials and tools.
Mild Steel • Engineers Square Make sure your fingers are clear of the
• Centre Punch top of the centre punch when using the
• Hammer hammer.
3 Cut the tray piece. • Guillotine – Allows for precise and quick cutting. • Mild Steel 30 Minutes Be careful when using the saw/guillotine,
• Tin snips don't put hands near the sharp points of
• A hacksaw could also be used, but this would be the tools.
slower and less precise
4 File the tray piece to the correct size. • File • Mild Steel 20 Minutes
Check that the material has been cut to
the right size, if not continue to file.
5 Drill the tray piece using a pilar drill or • Pilar Drill • Mild Steel 15 Minutes Wear goggles
hand drill. • Hand Drill Ensure that the guard is closed
• Hand Vice Secure the work in a hand vice,
to minimize the chance of the
material becoming loose.
6 Bend the parts of the tray piece that • Box pan and Press • Mild Steel 15 Minutes Ensure there is nothing near to the
need bent. moving parts of the machine
7 Clamp the folded tabs to one of the • Mole grips • Mild Steel 5 Minutes Make sure your fingers don’t become
sides of the tray with mole grips, • Clamps trapped between the clamps / metal
clamps or masking tape. • Masking Tape pieces.
8 Drill 2 rivet holes through the side • Hand Drill • Mild Steel 2 Minutes Wear goggles
• Pilar Drill Ensure that the guard is closed
Secure the work in a hand
vice, to minimize the chance of
the material becoming loose.
9 Rivet through these holes to secure the • Rivet Gun • Mild Steel 2 Minutes Be careful when using the rivet gun, so
two pieces together • Rivets that you are not injured
Production Plan for the Tray Page 2
Task Tools Needed Material Needed Time Needed Health and Safety
1 Repeat steps 7 – 9 until all of the tabs As above
0 are riveted
1 Cut the aluminum for the handle to the • Steel rule • Aluminum 5 Minutes Be careful when using the saw, don't put
1 correct length • Scribe hands near the sharp points of the tools.
• Engineer's square
• Hacksaw
1 Mark out the point where the • Steel rule • Aluminum 5 Minutes Be careful around any sharp points
2 Aluminum needs to be bent, and where • Scribe on the materials and tools.
the holes should be drilled • Engineer's square Make sure your fingers are clear of
• Centre Punch the top of the centre punch when using
• Hammer the hammer.
1 Drill the holes in the aluminum • Pilar Drill • Aluminum 5 Minutes Wear goggles
3 • Hand Drill Ensure that the guard is closed
Secure the work in a hand
vice, to minimize the chance of
the material becoming loose.
1 Bend the aluminum • Box pan and Press • Mild Steel 15 Minutes Ensure there is nothing near to the
4 moving parts of the machine
1 Attach the handle to the tray using • Rivet Gun • Mild Steel 2 Minutes Be careful when using the rivet gun, so
5 rivets. • Rivets that you are not injured
Flowchart of the Tray Production Plan.
Hand Tools
Introduction: On this page I will describe all of the hand tools that I used in this project.
Name Image Description Health and Safety
Engineer's Blue and Engineers blue is painted onto a piece of metal so that it can more easily be marked. It is applied using a Wear and apron and goggles, as this can cause
paint brush paintbrush. irritation and permanently stains.

Scribe A scribe is used to mark lines on a piece of metal. It should be held like a pen or pencil, and dragged along The scribe has a sharp point, so be careful when
the material, normally using a steel rule or engineers square to ensure a straight line. using and carrying the tool 
A steel rule is used to measure distances and to produce a straight line. The tool should be placed on the
Steel Rule
material and lined up with the area that needs to be measured or marked.
An engineer's square is used to mark a 90° angle from a specific point. The tool should be placed flat against
Engineer's square
the material ,with the corner at the point where the line needs to begin.
This tool is used to create a small dent at a specific point. This point is used as a reference when drilling, and The Centre punch has a sharp point, so be careful
Centre punch it also stops the drill from slipping. It is used by placing the tip at the point where the dent needs to be, then
hitting the head once with a hammer. when using and carrying the tool 

The tool is heavy and can cause injury if it hits a

This tool is used to create a strong and precise force to an area. It is used to hit the head of the centre punch.
Hammer You should hold the handle, then move the tool down so that the head connects with the area. finger or your hand, so always keep your hands away
from the area being hit.
When closing the tin snips the sharp points are
Tin Snips Tin snips are used to create a cut through thin metal. They are held and operated like scissors. closed with a  lot of force, so keep your hands away
from the closing area.
Files are used to remove a layer of material from a piece. This material is removed through abrasion. The tool
The tool can cause cuts and scratches if dragged
File is held with one hand on the handle, and the other on the other end of the tool. It is then moved back and across skin, so always be careful not to move your
forth across the material. The tool comes in different strengths so that different amounts of material can be hands across the tool
removed
This tool is used to attach two pieces of sheet metal together, and access is only needed to one size. The rivet
Rivet gun should be placed in the tool and lined up with the pre-drilled hole. The tool is the squeezed a few times until
the rivet is permanently secured.
This is a thin saw that can cut curved lines. The blade is placed above the area that needs to be cut and The blade is sharp and can heat up when cutting, so
Coping Saw moved back and forth like a normal saw. never touch the blade.

The blade is sharp and can heat up when cutting, so

Hacksaw A hacksaw is a saw that is made to cut larger, straight lines. It is operated in the same way as another saw.
never touch the blade.
Power Tools
Introduction: On this page I will describe all of the power tools that I used in this project.
Name Image Description Health and Safety
Guillotine  This tool is similar to tin snips, but can create straighter, longer and more accurate cuts. The tool The blade can be very sharp, so make sure
is lined up under the blade, then pulled down to cut the material. The material may then need to your hands are never below it when cutting.
be moved along if the cut is longer than the blade.
Pilar drill This tool can create a level and precise hole. The material should be placed underneath the drill, Wear goggles and an apron, as small pieces
with the point that needs drilled directly under the drill bit. The tool should then be turned on may be flung out of the tool. Also ensure the
and lowered until the drilling is finished. guard is down and that the material is tightly
secured. Never put your hand below the tool
when drilling
Hand Drill This tool is used to drill holes. You should hold the handle and line the drill bit up with the point Wear goggles and an apron, as small pieces
being drilled. You then squeeze the trigger and push down until the hole has been fully drilled. may be flung out of the tool.  Never put your
hand below the tool when drilling

Box Pan and Press This tool can create bend thin pieces of metal and other materials, up to 90°. The material Be careful not to get your hands trapped, as
should be placed on the tool with the line being bent on the bending part. It should then be there are many moving parts that could cause
securely clamped down. The bending lever should then be lifted until the desired angle is met. injury.
Risk Assessment
Introduction: On this page I will think about the dangers involved in the production of the toolbox.

Tools Hazards Level of Risk How to prevent injury

Pillar Drill • Getting your hand injured by the drill bit.
• Material being ejected and flying out of the machine.
• The piece becoming loose and spinning about.
• Being burnt
Moderate • Use a tightly secured hand vice or other clamp so that your hand is never below the drill bit.
This will also prevent the material becoming loose.
• Always ensure that the guard is down when using the machine. This will minimise the risk of
material being ejected towards the user. You should also wear goggles and an apron to
reduce the risk of injury of a piece of material does hit you.
• Because of friction the material and drill bit can heat up during drilling. To avoid being burnt
you shouldn't touch the material or drill bit immediately after drilling. Instead allow it to
cool.

Hand Tools • Getting cut by any sharp points.
• Getting any metal filings in your eyes.
Minimal • To prevent being cut you should always be cautious when carrying and using any tools. You
should also avoid touching any sharp points on tools like a saw of scribe.
• When filing or cutting small metal filings will be produced. Because of this you should not
touch your face to avoid getting these filings in your eyes.
• You should also always wear an apron.

Power Tools • Getting your hand injured by the drill bit.
• Material being ejected and flying out of the tool.
• The piece becoming loose and spinning about.
• Being burnt
Moderate • While drilling, make sure your hands and fingers are not below the drill/drill bit, as it can
cut or injure you.
• The drill bit spins rapidly during drilling and can heat up because of friction. You should
never touch the drill bit during/shortly after drilling to prevent being injured.
• Metal filings can be ejected while drilling. Because of this you should wear goggles and an
apron to minimise the risk of being injured.
• To prevent the material form spinning the material should be tightly secured using mole
grips or a hand vice before drilling. If the material does begin to spin you should
immediately stop drilling.