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| Subject | Teacher | Unit | Duration | out of |
| Week | Details & links | Assessed work / further work | |
| ALMOST everything you need to
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| Unit 2: Knowledge and Understanding of
Product Design |
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| 2.1 Materials and components Sources, classification, formation and structure of materials and components Paper, card and boards • Sources, classification and structure of paper, card and boards — copier paper — card — corrugated board — common carton boards. |
P17 — 18, 66 — 68 | ||
| Woods • Sources, classification and structure of woods — softwoods — hardwoods. • Cellular structure, fibres and grain direction. |
P19 — 20, 68 — 72 | ||
| Polymers • Sources, classification, structure and manufacture of thermoplastics — acrylic — PET — HDPE — PVC — LDPE — PP — PS — thermosetting plastics — polyester resins. • Monomers, polymerisation and cross-linking. |
P18 — 19, 72 — 74 | ||
| Metals and alloys • Sources, classification, structure and production of ferrous metals — steel •Sources, classification, structure and production of non-ferrous metals — copper — aluminium — zinc — tin — brass • Specialist alloys for specific tasks — steel — aluminium alloys. |
P20 — 21, 74 — 76 | ||
| Composites
and laminates • Manufacture of composite materials — carbon fibre — glass reinforced plastics (GRP) — medium density fibreboard (MDF) — laminates — plywood. |
P76 — 78 |
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| Components • Pencils — graphite — coloured. • Pens and marker pens — water — spirit based. |
P78 — 79 | ||
| 2.2 Working properties of materials Working properties of materials and components, relating to the composition and structure of materials • Aesthetic properties, for example colour, style, texture. • Functional properties, for example strength, durability, flammability. • Mechanical properties, for example plasticity, ductility, hardness and malleability. |
P80 — 81 | ||
| 2.3 Hand and commercial processes Hand and commercial methods of preparing, processing, manipulating and combining materials and components to enhance their properties including associated tools, machinery and equipment including CAD/CAM in relation to: • drawing — pictorial, information and accurate working drawings |
P81 — 83 | ||
| • computer graphics — desktop publishing (DTP) — 2-dimensional design to create and modify designs and layouts — 3-dimensional modelling for creating photo realistic images and ‘virtual’ products |
P84 — 85 | ||
| • typography — theory and practice including typeface design and application |
P85 — 87 | ||
| • 2D/3D modelling and prototyping — rapid prototyping using CAD/CAM — block modelling |
P87 — 88 | ||
| • CNC machining — milling machine — lathe |
P163 — 166 | ||
| • production of nets — constructing nets — structural packaging design — commercial production of packaging nets — cutting, wasting, abrading, shaping, bending, casting, moulding |
P30, 89 — 92 | ||
| • thermoforming — blow moulding — injection moulding — vacuum forming |
P28 — 30, 92 — 93 |
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| •joining, preparation for finishing. | P31, 93 — 95 | ||
| Finishing
processes Applied finishes to improve quality and provide enhanced aesthetic or functional properties: • surface coating — anodising — painting — varnishing • self-finishing — plastics • surface decoration — CNC engraving — vinyl cutting. |
P95 — 97 | ||
| Printing
processes Understanding how one-off/batch/high-volume (mass) product manufacture is achieved using printing processes: • computer printers — ink jet — laser • black and white printing and full colour printing • computers in pre-press and quality control • offset lithography, screen-printing, letterpress • finishing and binding ready for distribution. |
P97 — 102 | ||
| 2.4 Product manufacture Scale of production How and why products are manufactured using: • one-off production • batch production, including short-term print runs • high volume (mass) production • continuous production. |
P23 — 24 | ||
| Systems
and control • Computer integrated manufacture (CIM) — information handling — stock control and just in time(JIT) — planning — quick response manufacturing — CAD/CAM. |
P24 | ||
| Quality
control in production • Using quality assurance (QA), quality control (QC) and total quality management (TQM) systems. • Quality control during final print run — colour density on colour bars — registration marks — crop marks — greyscale. • Meeting specifications and tolerances. |
P32 — 34, 104 | ||
| Quality
standards • Meeting aesthetic, performance and price requirements. • Testing against external quality standards such as British, European and international standards. • Standard performance tests — tensile strength — hardness — toughness and ductility workshop tests. |
P14 — 15, 34, 102 — 103, 105 | ||
| Health
and safety procedures in production • Principles of health and safety legislation — The Health and Safety at Work Act (1974). • Principles of health and safety at work — Health and Safety Executive (HSE) risk assessments. |
P15, 35 — 36 | ||
| 2.5
Design in practice The effects of design and technological changes on society • Mass production and the consumer society. • The ‘new’ industrial age of high-technology production. • The global market place. • Issues related to local/global production. |
P108 — 112 | ||
| Influences
on the development of products • Aesthetics, balance, colour, decoration, design, form, function, line, scale, shape, styling, surface pattern, texture. • Design and culture, for example Arts and Crafts, Art Nouveau, Art Deco, Bauhaus, Memphis and modern design movements. • New materials, processes and technology — computers and design — eco-design — environmentally-friendly processes — miniaturisation — modern production techniques — ‘smart’ materials. |
P112 — 120 | ||
| The basic principles and application of
anthropometrics and ergonomics • Interacting with products, users, equipment and environments. • Applying anthropometric data. • Ergonomic considerations for designs and models — standard sizes and dimensions. |
P130 — 132 |
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