Your journey to excellence inEngineering

Prefixes and powers of ten in calculations

Derived units used in mechanical and electrical engineering

Converting between units correctly

Standard form and engineering notation

Significant figures and rounding in engineering answers

Rearranging engineering formulae safely (with units)

Checking answers using dimensional consistency

Solving linear equations in engineering contexts

Solving simultaneous equations for unknowns

Solving quadratic equations in engineering problems

Proportion, ratios and scaling for designs

Using trigonometry to find missing sides and angles

Resolving forces into horizontal and vertical components

Sine rule and cosine rule in engineering triangles

Degrees and radians conversion

Arc length and sector area calculations

Using vectors and components in 2D problems

Understanding gradient as rate of change

Differentiating basic functions for engineering rates

Using differentiation to find turning points (optimisation)

Integrating basic functions to find totals/areas

Using integration with motion graphs (area under curve)

Density, mass and volume in mechanical contexts

Pressure and force relationships in engineering systems

Moments and equilibrium in static systems

Stress and strain: what they mean physically

Young’s modulus: interpreting and using the formula

Shear stress and shear strain in components

Modulus of rigidity and what it tells you

Factors of safety and allowable stress

Linear motion with uniform acceleration (SUVAT)

Newton’s laws in engineering motion problems

Momentum and impulse in collisions

Conservation of momentum in engineering scenarios

Angular velocity and angular acceleration

Centripetal acceleration and circular motion

Torque, rotational power and efficiency

Rotational kinetic energy and moment of inertia ideas

Density and buoyancy: upthrust calculations

Charge, current and time relationships

Coulomb’s law and electrostatic force

Electric field strength (two definitions) and use

Resistance vs resistivity (what’s different)

Temperature coefficient of resistance in practice

Series and parallel resistor networks

Ohm’s law and non-ohmic behaviour (recognising it)

Electrical power equations (P=VI, I²R, V²/R)

Electrical efficiency calculations

Kirchhoff’s laws for circuit analysis

Magnetism: fields and field lines

Magnetic flux and flux density (B)

Force on a current-carrying conductor (motor effect)

Electromagnets: factors affecting strength

Electromagnetic induction: what causes an emf

Lenz’s law and direction of induced effects

Alternating current waveforms and key features

Peak, period, frequency and angular frequency

RMS values and why they’re used

Impedance and phase (conceptually)

Capacitive and inductive reactance (what changes them)

AC power and power factor (what it means)

Resonance in RLC systems (what it looks like)

Transformers: stepping voltage up/down and efficiency

Aerospace engineering: typical work and outputs

Agricultural engineering: problems solved and systems used

Automotive engineering: lifecycle from design to maintenance

Biomedical engineering: devices, safety and compliance

Chemical engineering: plant, processes and products

Civil engineering: infrastructure design, build and maintenance

Energy generation engineering: solar, wind, hydro, gas, nuclear

Mechatronic engineering: sensors, systems and automation

Marine engineering: ships and offshore installations

Rail engineering: rolling stock and signalling systems

Functional areas in engineering organisations: overview

Research and development: turning needs into innovations

Sales and marketing: market research and product positioning

Design functions: briefs, drawings and documentation

Process monitoring and control: keeping systems stable

Manufacturing functions: converting materials to products

Maintenance: corrective vs preventative vs predictive

Quality management: standards, checks and trend analysis

Energy management: monitoring, control and sustainability

Health and safety management: risk assessment and reporting

Robotics in engineering: automation and hazardous environments

Cobots: designing safe human–robot collaboration

Drones: engineering uses and constraints

Virtual reality: collaboration and product visualisation

Augmented reality: overlays for guidance and information

Cloud computing: secure storage and scalable collaboration

Internet of Things: connected sensors for monitoring/control

Artificial intelligence: autonomy, data analysis and vision

3D printing: prototyping vs production and customisation

Digital twins: real-time monitoring and optimisation

Metals: crystals, grains and grain size effects

Alloys: how solid solutions change properties

Key pure metals used in engineering (Fe, Cu, Al, Zn, Sn, Ti…)

Ferrous alloys: carbon steel types and typical uses

Stainless steel (austenitic): why it behaves differently

Non-ferrous alloys: Al alloys, Ti alloys, brass, bronze

Polymers: amorphous structures and what that implies

Thermoplastics vs thermosets vs elastomers (properties and uses)

Common thermoplastics by abbreviation (PC, PS, ABS, PET, PLA, PA66)

Common thermosets and typical applications

Elastomers: thermoset vs thermoplastic elastomers

Composites: matrix and reinforcement roles

Fibre composites: GFRP vs CFRP and why they differ

Particle composites: cemented carbide and what it’s for

Composite structure choices (fibre alignment, matrix/reinforcement ratio)

Physical properties: density, melting point, conductivity, resistivity

Chemical/functional properties: corrosion resistance, ferromagnetism, light transmission

Mechanical properties: hardness, toughness, modulus, strengths, ductility

Strength-to-weight ratio and design decisions

Heat treatment: what it changes inside steel

Quench hardening: purpose and outcomes

Tempering: reducing brittleness after hardening

Annealing: softening and improving workability

Normalising: refining grain structure and properties

Case hardening: tough surface, ductile core

Manufacturing process choice: accuracy, finish, cost and waste

Forming: press work (piercing/blanking) in sheet metal

Forming: closed die drop forging (steel forgings)

Casting: sand casting (cast iron components)

Casting: hot chamber die casting (zinc alloys)

Casting: investment casting (titanium components)

Moulding: thermoplastic injection moulding (complex mouldings)

Moulding: thermoset compression moulding (complex mouldings)

Moulding: wet lay-up for GFRP

Moulding: resin transfer moulding (RTM) for CFRP

Machining: drilling setup for hole size and hardness

Machining: manual vertical milling (faces, edges, slots)

Machining: CNC vertical milling and its advantages

Machining: manual turning (parallel turning, facing, parting)

Machining: CNC turning and its advantages

Machining: surface grinding for hardened steel finishing

Cutting: band sawing for metals

Cutting: abrasive slitting discs (grinding as cutting)

Cutting: shearing/guillotining sheet metal

Cutting: CO₂ laser cutting for thermoplastic sheet

Writing user requirements that are testable

Defining product functions clearly

Aesthetics and finish: specifying what “good” looks like

Dimensions and tolerances (at concept stage)

Weight restrictions and why they matter

Ergonomics and anthropometrics in design requirements

Choosing candidate manufacturing methods for the PDS

Choosing candidate materials for the PDS

Cost breakdowns: materials, components, labour, equipment

Quantity and batch size implications

Designing for safety (hazards and controls)

Designing for maintenance and serviceability

Interfaces and interactions between components

Reliability requirements and how to express them

Legal requirements: intellectual property basics for designers

Legal requirements: health and safety duties in design

Legal requirements: environmental legislation impacts

Sustainability in the PDS: refuse, reduce, reuse, repurpose, recycle

Selecting materials using properties from Unit 2

Matching materials to function, environment and sustainability

Selecting manufacturing processes using Unit 2 knowledge

Researching existing products to inform design ideas

Using catalogues and databases to select bought-out components

Sketching in good proportion (quick, clear communication)

Isometric sketching for 3D communication

Oblique drawing for quick 3D representation

Orthographic sketching (single and linked views)

Detail sketches with notes and technical language

Generating multiple initial concepts (not just one)

Constraints and trade-offs in early-stage ideas

Considering mechanical principles in concept sketches

Assembly arrangements and how parts will fit together

Estimating costs during concept generation

Sustainability across the product life cycle

Physical modelling: choosing modelling sheet materials

Physical modelling: casting and moulding modelling materials

Modelling systems (e.g., modular kits) for mechanisms

Safe and effective use of hand tools for modelling

Using 3D printing, laser cutting and CNC for prototypes

Spreadsheet cost modelling: material choice changes cost

Spreadsheet cost modelling: labour (skilled vs unskilled)

Spreadsheet cost modelling: equipment (general vs specialist)

Running a design review meeting (presenting ideas clearly)

Giving and receiving peer feedback professionally

Selecting a preferred concept using comparison to the PDS

Setting up a parametric CAD model (units, planes, files)

CAD sketch commands: line, arc, circles, fillets, dimensions

CAD view controls: pan, zoom, orbit

CAD editing tools: trim, rotate, extend and refine

Creating 3D forms: extrude and revolve

Modifying 3D models: holes, chamfers, move face

Boolean operations: add, subtract, intersect

Using constraints to assemble parts in CAD

CAD analysis tools: mass and stress (what they’re for)

Building components from sketches (2D → 3D workflows)

Adding features: threads, countersinks, counterbores, fillets

Sketching on 3D faces to add detail

Iterating the CAD model to better meet the brief

Cost consequences of materials: volume, density and mass

Building assemblies: degrees of freedom (translation/rotation)

Assembly constraints: mate, angle, insert and tangent

Modifying parts due to assembly constraints (design-for-assembly)

Generating 2D drawings from 3D models

Drawing standards: working to BS 8888 (or equivalent)

Setting up 2D CAD: templates, limits, scale and title blocks

Using layers effectively (create, lock, freeze, visibility)

Line types, hatching and conventions in drawings

Using coordinate methods (absolute, relative, polar)

Modify commands in 2D CAD (mirror, array, copy, fillet)

Dimension styles and editing dimensions correctly

Producing component drawings with orthogonal views

Using sectional views to show internal detail

Producing assembly drawings and general arrangements

Creating parts lists / bills of materials (BOM)

Building a presentation pack from design documentation

Choosing media: graphical vs written vs verbal communication

Tone, language and handling questions in presentations

Responding constructively to feedback and updating designs

Reviewing where requirements were achieved in the process

Identifying stages that could be improved next time

Reflective practice using the ERA cycle

Reflective practice using Driscoll’s model

SWOT/SOAR self-review and action planning

Clarifying a problem: what needs fixing and why

Researching a project theme using credible sources

Defining constraints: time, cost, scope, ethics, legality, sustainability

Generating ideas with creativity tools (mind maps, reverse thinking, etc.)

Using Six Thinking Hats to broaden solution thinking

Writing an initial specification for alternative solutions

Using sketches, diagrams and storyboards to explain ideas

Outlining processes: tools, assemblies and high-level flowcharts

Rough costings and budgets using a spreadsheet

Initial technical estimates (mass, volume, materials, performance)

Feasibility criteria: size/complexity and achievable benefit

Feasibility criteria: time, budget and expertise required

Feasibility criteria: risks, unknowns and unproven tech

Feasibility criteria: sustainability and environmental impact

Feasibility criteria: legal constraints (e.g., H&S legislation)

Selecting a solution using objective testing

Comparing solutions with cost–benefit thinking

Using graphs/tables to compare solutions (bar charts, histograms, etc.)

Process capability and fitness-for-purpose comparisons

Resource planning: people, equipment, info and support

Time planning with a Gantt chart

Critical path analysis to set priorities

Building contingency into project plans

Monitoring progress with milestones and regular reviews

Keeping a logbook: problems, solutions, iterations and decisions

Teacher monitoring and peer review checkpoints

Risk vs issue: what each means in a project

Scoring severity, probability and impact

Calculating “severity” from probability × impact

Mitigation strategies: prevent, reduce, accept, transfer

Managing risks and issues throughout delivery

Writing a technical specification for the chosen solution

Interfaces: physical, software, human and electrical/electronic

Standards, tolerances, security and operating conditions

Reliability, maintenance and performance requirements

Design tools: drawings, CAD, diagrams and documentation

Simulation models (circuits, pneumatics/hydraulics, software models)

Physical modelling and rapid prototyping choices

Process/program design (flow charts, operation sheets)

Design references: formulae, tables, pseudocode, ergonomic records

Safety regulations relevant to the chosen specialist area

Sustainability and cost/demand considerations in design