By Revision Genie
Design and Materials
Unit 1
Factors in Material Selection
Physical Properties of Materials
Mechanical Properties of Materials
Hardwoods vs Softwoods
Properties of Pine
Properties of Ash
Properties of Beech
Properties of Oak
Properties of Mahogany
Manufactured Boards Overview
Uses of Plywood
Uses of MDF
Finishes for Wood
Ferrous vs Non-Ferrous Metals
Properties of Aluminium
Properties of Copper
Properties of Brass
Properties of Mild Steel
Properties of Stainless Steel
Metal Finishing Techniques
Thermoplastics vs Thermosetting Plastics
Properties of HDPE
Properties of ABS
Properties of Epoxy Resins
Modern Composite Materials
Applications of Graphene
Thermochromic and Photochromic Materials
Processing: Wasting Techniques
Processing: Forming Techniques
Processing: Moulding Techniques
Processing: Extrusion
Product Analysis Criteria
Evaluating Product Form and Function
Ergonomics and Anthropometrics in Design
Environmental Issues in Product Design
The Design Process Steps
Sustainability in Design
2D Communication Methods
3D Modelling Techniques
Computer-Aided Design (CAD)
Computer-Aided Manufacture (CAM)
Computer-Integrated Manufacture (CIM)
Factor of Safety in Design
Tolerances in Manufacturing
Testing and Inspection Methods
Minimising Manufacturing Risks
Unit 2
Electronic and Microelectronic Control Systems
Electronic Control Systems Overview
Input, Control, and Output Concepts
On/Off Continuous Control Systems
Open and Closed Loop Systems
Feedback in Control Systems
Circuit Symbols and Diagrams
Safety in Electronic Systems
Resistors: Properties and Ratings
Capacitors: Types and Applications
Diodes for Circuit Protection
Ohm's Law Calculations (V = I × R)
Power Calculation (W = V × I)
Series Resistor Calculations
Parallel Resistor Calculations
Voltage Divider Formula Applications
Time Constant in RC Circuits
LED Maximum Current and Resistance
Monostable Circuit Time Period Formula
Astable Circuit Frequency Formula
Transistor Base Resistor Calculations
Resistors in Series and Parallel
Voltage Divider with LDRs and Thermistors
RC Circuits: Charging and Discharging
Switch Types and Applications
Pull-Up and Pull-Down Resistors
Lamps and Relays as Output Devices
Motors and Solenoids in Circuits
Buzzers and LEDs as Outputs
AND Gate Function and Truth Tables
OR Gate Function and Truth Tables
Exclusive OR Gate Logic
NOT Gate Logic and Applications
NAND Gate Logic and Truth Tables
NOR Gate Logic and Truth Tables
ENOR Gate Logic and Applications
Comparator Circuits
Set–Reset Flip-Flop Using NAND Gates
Transistor Switching Circuits
Darlington Pair Configuration
Thyristor Properties and Uses
Monostable Circuits with 555 Timer
Astable Circuits with 555 Timer
Programmable Systems Overview
Advantages of Peripheral Interface Controllers (PICs)
Comparing Hardwired and Programmable Systems
Unit 3
Mechanical and Pneumatic Control Systems
Introduction to Mechanical Control Systems
Introduction to Pneumatic Control Systems
Inputs in Mechanical Systems
Inputs in Pneumatic Systems
Control in Mechanical Systems
Control in Pneumatic Systems
Outputs in Mechanical Systems
Outputs in Pneumatic Systems
Continuous and On/Off Control
Mechanical Advantage Calculation
Velocity Ratio Calculation
Efficiency Calculation
Moments Calculation
Transmission Speeds for Gears
Transmission Speeds for Pulleys
Transmission Speeds for Chains and Sprockets
Force, Pressure, and Area in Cylinders
Operation of Compressor Installations
Filter, Regulator, and Lubricator Units
Three-Port Valves and Actuators
Five-Port Valves and Actuators
Single and Double Acting Cylinders
Shuttle Valves in Pneumatic Systems
Flow Restrictors and Reservoirs
Piping and T Connections
Time Delay Pneumatic Circuits
Logic Circuits in Pneumatic Systems
Speed Control of Cylinders
Automatic Reciprocation Circuits
Spur Gears Operation
Bevel Gears Operation
Worm Gears Operation
Rack and Pinion Gears Operation
Pulleys and Belts Types
Jockey Wheels in Pulley Systems
Crank and Slider Mechanisms
Types of Motion in Mechanical Systems
First, Second, and Third Class Levers
Bell Crank and Parallel Linkages
Cam Profiles and Followers
Fixings to Shafts
Combining Gears and Pulleys
Combining Chains and Sprockets
Mechanical and Pneumatic Integration
Designing Industrial Pneumatic Systems
Designing Industrial Mechanical Systems
Integration with Electrical Control Systems
Safety in Mechanical Systems
Safety in Pneumatic Systems
Unit 4
Product Design
Understanding the Design Process
Research Methods in Product Design
Primary and Secondary Sources
Questionnaires and Surveys in Design
Specifications in Product Design
Design, Engineering, and Manufacturing Specs
Idea Generation Techniques
SCAMPER Method for Design
Attribute Analysis in Design
Lateral Thinking for Innovation
Using Design Critiques Effectively
Refining Design Ideas
2D and 3D Computer Simulations
Work Orders and Schedules in Design
Flow Process Charts for Planning
Gantt Charts in Product Planning
Critical Path Analysis in Design
Selecting Manufacturing Processes
Formative and Summative Evaluation Techniques
Evaluating Strengths and Weaknesses of Designs
Fitness for Purpose in Product Design
Testing and Reviewing Products
Compliant and Composite Materials
Applications of Carbon Fibre Reinforced Plastic
Glass Reinforced Plastic Properties
Kevlar Characteristics and Uses
Applications of Tungsten Carbide
Nanotechnology in Product Design
Biophotovoltaics and Emerging Technologies
Smart Materials in Design
Shape Memory Alloys in Products
Piezoelectric Materials in Design
Light-Emitting Polymers for Innovation
2D Communication Methods in Design
3D Communication Methods in Design
Freehand Sketching Techniques
Orthographic Projection Basics
Isometric Projection Techniques
Creating Perspective Drawings
Assembly and Exploded Drawings
Rapid Prototyping in Design
Processing Materials: Laminating
Steam Bending Techniques
Die Cutting in Manufacturing
Water Jet Cutting Applications
Laser Cutting Processes
CNC Router, Milling, and Lathe Use
3D Printing in Product Design
Dye Sublimation Techniques
Safety Requirements in Product Design
Five-Stage Risk Assessment
Health and Safety at Work Act
Control of Substances Hazardous to Health
Employee and Consumer Safety Standards
Trades Description Act Overview
British Standards in Design
Scales of Manufacturing Production
Continuous Production Systems
Mass Production Techniques
Batch Production Processes
One-Off Production Characteristics
Cell Production in Manufacturing
Flexible Manufacturing Systems (FMS)
Just-In-Time (JIT) Manufacturing
Quick Response Manufacturing (QRM)
Kanban and Concurrent Engineering
Quality Assurance Systems in Design
ISO 9001 Standards Overview
Statistical Testing Methods in QA
Right-First-Time Principles
Continuous Improvement in Manufacturing
Fashion and Miniaturisation in Design
Cultural and Social Influences on Design
Scientific Advances in Product Design
Intellectual Property Rights Overview
Design Rights in Product Design
Registered Design Protection
Understanding Patents
Trademarks in Product Design
Copyright and Design Protection
Unit 5
Product Development Coursework
Choosing a Product for Redesign
Analyzing Similar Products
Evaluating Product Function and Purpose
Assessing Materials and Production Methods
Fitness for Purpose Evaluation
Ergonomic and Aesthetic Analysis
Sustainability Considerations in Design
Referencing Source Materials Effectively
Writing a Design Specification
Generating Innovative Design Modifications
Sketching Annotated Design Ideas
Evaluating Redesign Viability
Planning the Making Process
Creating Development Sequence Drawings
Producing Final Working Drawings
Material Selection for Prototypes
Using Making Skills and Techniques
Recording Design Changes During Making
Testing the Prototype Against Criteria
Evaluating the Prototype Objectively
Proposing Further Development Ideas
Presenting Information on A3 Sheets
Creating an Electronic Portfolio
Communicating Ideas with Mixed Media
Understanding the Non-Linear Design Process
Incorporating Creativity in Product Development
Balancing Practical and Aesthetic Features
Exploring Industrial Production Techniques
Considering Target Audience Needs
Addressing Environmental Impact in Design
Unit 6
Systems and Control Advanced Study
Introduction to Advanced Control Systems
Electronic vs Mechanical Control Systems
Input, Control, and Output in Systems
Open and Closed Loop Systems with Feedback
Safety in Advanced Control Systems
Advanced Circuit Symbols and Diagrams
Advanced Resistor Types and Ratings
Capacitors: Electrolytic and Non-Polarised
Voltage Divider Circuits in Depth
Time Constant Calculations
555 Timer: Monostable Circuits
555 Timer: Astable Circuits
Transistor Calculations and Applications
Light Dependent Resistors (LDR) in Systems
Thermistors and Their Applications
Variable Resistors in Advanced Circuits
Lamps and Relays in Output Systems
Motors and Solenoids in Control Systems
Buzzers and Sound Output Devices
Logic Gates: AND, OR, NOT Functions
Truth Tables with Three Variables
Set-Reset Flip-Flops Using NAND Gates
Darlington Pair Configurations
Thyristors in Control Systems
Programmable Systems: Advantages and Disadvantages
Peripheral Interface Controllers (PICs)
Mechanical Advantage and Velocity Ratio
Efficiency in Mechanical Systems
Moments and Torque Calculations
Transmission Speeds for Gears and Pulleys
Pneumatic Components: Valves and Cylinders
Designing Sequential Pneumatic Circuits
Gears: Spur, Bevel, Worm, and Rack
Pulleys and Belts: Types and Applications
Cams and Followers: Profiles and Terminology
Linkages: Bell Crank and Parallel
Bearings and Lubrication in Mechanical Systems
Combining Pneumatic and Mechanical Components
Integrated Applications of Control Systems
Unit 7
Advanced Product Design
Understanding Environmental Impact in Design
Climate Change and Product Design
Reducing Environmental Impact by Design
The 6Rs in Product Design
Environmental Audits and Life Cycle Assessment
Sustainable Material Selection
Biodegradable and Photodegradable Plastics
Innovation for Sustainable Product Design
Product Life Cycle Stages
Life Cycles for Fad, Fashion, and Basic Products
Reasons for Product Redesign
Advances in CAD and CAM Systems
Quick Response Manufacturing Techniques
Flexible Manufacturing Systems in Design
Market Research in Product Design
Understanding Market Pull and Technology Push
Radical vs Incremental Product Innovations
Market Strategies in Product Design
Exploring the Four Ps: Product
Exploring the Four Ps: Price
Exploring the Four Ps: Place
Exploring the Four Ps: Promotion
ICT in Marketing Strategies
Quality Control Processes in Design
Quality Assurance Systems in Manufacturing
Designing for Maintenance and Repair
Inclusive Design Principles
Designing for Scale Production
Minimizing Environmental Impact in Manufacturing
Reducing Packaging Waste in Product Design
Effective Communication of Design Ideas
Rendering Techniques for Design Communication
Impact of Dyson on Product Design
Impact of Bayliss on Product Design
Memphis Design Movement Influence
Apple's Influence on Product Design
Ethical and Social Factors in Product Design
Economic Considerations in Product Design
Environmental Factors in Product Design
Unit 8
Product–System Design and Manufacture Coursework
Identifying the Problem or Need
Formulating a Design Brief
Identifying Potential Clients or End Users
Analyzing Existing Solutions
Research Techniques for Problem Analysis
Formulating a Detailed Design Specification
Referencing Source Materials in Research
Generating Initial Design Ideas
Evaluating Design Proposals Against Criteria
Selecting a Concept for Development
Numerical Analysis in Concept Development
Documenting Design Decisions During Development
Justifying Design Decisions
Integrating User and Environmental Considerations
Ergonomic and Aesthetic Development
Producing Working Drawings for Manufacture
Creating a Product Prototype
Incorporating Technological Systems in Prototypes
Demonstrating Making Skills and Processes
Recording Changes During Prototype Creation
Evaluating the Final Product Outcome
Testing the Product Prototype
Drawing Conclusions from Product Testing
Proposing Further Development Based on Testing
Using Energy Sources in Product Design
Incorporating Control Systems (Input, Process, Output)
Integrating Advanced Product Design Features
Presenting Portfolio Evidence Effectively
Using ICT for Portfolio Presentation