Key Stage 3 Design and Technology V2.1
Details of the contents of each section are listed below.

• Considering people's needs and values
• Safety
• Moral Issues in design and technology
• Cultural issues in design and technology
• Quality in design and technology
• Quality: technical considerations
• Quality: aesthetic considerations
• Environmental considerations
• Recycling
• Sustainability
• Designing for disassembly
• Ergonomics and anthropometrics
• Principles of good design
• The design opportunity
• Design Brief
  • open brief
  • closed brief
• Specifications
  • design specification
  • product specification
• Hazy impressions of a design
• New designs: designing from natural form
• Using existing ideas
• Developing designs
  • design development animation
  • changing existing designs
• Evaluating
• Analysing
  • analysis
  • analysing a design brief
  • product analysis
• Communicating and modelling ideas:
  • modelling ideas
  • recording ideas
  • notes and sketches
  • isometric drawing
  • 1 point perspective drawing
  • 2 point perspective drawing
  • oblique drawing
  • orthographic projection
  • parts drawing

• Short exercises
• Focused practical tasks (FTPs)
• Design and make assignments (DMAs)
• Exercises in PDF format 
• Teacher's notes

• What is research
• Product analysis
• Value analysis
• Library search
• Internet search
• Experiments
• Observation
• Case study
• Interviews
• Survey
• Role play

• Quality in design and technology
• Inspection
• Quality control
• Quality Assurance
• Total Quality Management (TQM)
• Quality exercises

Technical Considerations

• Quality of timber and manufactured boards
• Quality of metals:
  • structure, shape, finish
• Quality of manufacturing, systems, products

Aesthetic Considerations

• Description of aesthetics.

• Making a list of tools, materials and activities
• Bubble chart
• Flow chart
• Gantt chart
• Parts drawing
• Product specification
• Cutting list
• Safety & risk assessment

• Market research
• Target group
• Identifying:
  • physical needs of target group
  • emotional needs of target group
  • intellectual needs of target group
  • sociological needs of target group
• Using the information in design proposals

• Workshop safety rules
• Safety in detail:
  • Designer's safety responsibility
  • Risk assessment
  • Safety rules and defined procedures
  • Hazard warnings and instructions
  • Safe materials
  • Safe storage of materials
  • Tool safety
  • Safety features on tools
  • Safe working practices
  • Safe working area
  • Product safety
• Risk assessment exercises

• Making metals/processing metal ores:
  • iron
  • basic oxygen steel making process
  • electric arc furnace
  • secondary steel making
  • formation of slabs, bloom and billets
  • hot rolling plate mills
  • hot rolling strip mills
  • hot rolling long products
  • cold rolling and drawing
  • coating
  • aluminium
  • aluminium alloys
  • copper
  • lead
  • zinc
  • tin
  • manganese
  • molybdenum
  • strontium
  • nickel
  • platinum
  • silver
  • cadmium
  • chromium
  • titanium
  • tungsten
  • vanadium

• Timber and manufactured boards (animation)
• Trees as a renewable resource
• Processing timber logs
• Timber conversion
• Manufactured boards

Plastics

• Plastic notes and animations
• Thermoplastics and thermsets
• Thermplastics:
  • thermoforming
  • line  bending (+ animation)
  • vacuum forming (+ animation)
  • plug and yoke (+ animation)
  • expanded polystyrene (+ animation)
  • structural foam
  • rotational moulding
  • injection moulding (+ animation)
  • gas assisted injection moulding (+ animation)
  • injection blow moulding (+ animation)
  • extrusion blow moulding (+ animation)
  • inserts in plastic moulding
  • blown film (+ animation)
• Thermosets
  • resins
  • hand lay-up of GRP (+ animation)
  • spraying resin and reinforcing material
  • resin transfer moulding (+ animation)
  • pultrusion process (+ animation)
  • injection moulding
  • compression moulding (DMC) (+ animation)
  • compression moulding (SMC) (+ animation)

• Marking out tools and processes (animation)
• Measuring tools and processes (animation)
• Measuring & marking out test (interactive)

• Temporary fixing methods
• Semi permanent fixing methods
• Permanent fixing methods
  • Silver soldering & brazing (+ animation)
  • cleaning after soldering
  • pickling (+ animation)
  • soft soldering
  • tinning the soldering iron
  • using a soldering iron
  • using a blow torch
  • tinning parts to be soldered
  • joining metals by forge welding
  • joining metals by gas welding
  • joining metals by electric arc welding
  • joining metals by riveting (+ animation)
  • pop riveting
  • joining wood: gluing wood to wood
  • wood joints (animation)
  • gluing laminates to sheet materials
  • joining wood using screws
  • joining materials using adhesives 

• introduction
• plastics
• metals
• painting steel
• lacquering metals
• galvanising and zinc plating 
• electroplating (+ animation)
• electroforming
• anodising
• patination
• bluing
• enamelling
• plastic coating
• etching (+animation)
• abrading, filing and grinding (+ animation)
• planishing
• knurling
• milling
• Wood finishing processes
  • abrading (+ animation)

• recycling symbols

• Moral issues:
  • the design opportunity
  • the design specification
  • the design
  • choice of manufacturing material
  • recycling materials
  • use of energy
  • the manufacturing process
  • quality
  • health and safety
  • transporting the product
  • sales
  • after sales
• Cultural issues:
  • culture
  • cultural evidence
  • cultural diversity
  • cultural change
  • cultural identity
  • cultural tourism
  • souvenirs
• Environmental issues:
  • designed environments
  • transport
  • industry

• Mechanisms animations

(Contents detailed below)

• packaging
• resistant materials packages
• important features of a product package

• Rivet types
• Riveting with countersunk head rivets
• Riveting with snap head rivets
• Pop rivets

• Introduction: what is a structure? 
• Frame structures
• Shell structures
• Combination of frame and shell structures
• Stone structures
• Brick and block structures
• Concrete structures
• Composites
• Loads
• Forces:
  • compression
  • tension
  • torsion
  • shear
• Structural sections
• Joints in wooden structures
• Knock-down fittings
• Joints in metal structures
  • welding
  • soldering and brazing
  • riveting
  • nuts, bolts, screws
• Joints in plastic structures
• Physical and chemical properties, and characteristics of materials used in structures
• Support and reinforcement of structures
• Equilibrium
• Centre of gravity
• Moments
• Force diagrams
  • parallelogram of forces
  • triangle of forces
• Testing structures
• Interactive Exercises: exploring the qualities of structures / calculations / interpreting numeric information
• Bridges (details opposite)

Bridges Animation

• beam bridges
• continuous span bridge
• simple span bridge
• cantilever span bridge
• cantilever with suspended span bridge
• Warren deck truss bridge
• Warren (through) Truss
• Pratt Truss (through truss)
• Howe Truss (through truss)
• Lattice Truss (through truss)
• Plate girder bridge 
• Deck beam bridge
• Orthotropic beam bridge
• Rigid frame (inclined legs)
• Rigid Frame (with V- legs)
• Stone arch bridge
• Open spandrel deck arch bridge
• Spandrel braced arch bridge
• Cantilever through truss bridge
• Trussed deck arch bridge
• Trussed through arch bridge
• Ribbed arch bridge
• Suspension bridge
• Cable stayed bridge

• Recording ideas and designs using notes and sketches (animation)

• Design development animation

• Isometric drawing animation and exercises

• Oblique drawing animation

• 1 point perspective drawing animation and exercises

• 2 point perspective drawing animation and exercises

• Parts drawing and cutting list animation

• Orthographic projection

• The reason that wood joints are used

• Butt joint

• Lapped joint

• Tongue and grooved joint

• Finger joint / comb joint

• Dovetail joint

• Lapped dovetail joint

• Housing joint

• Corner bridle joint

• Through mortice and tenon joint

• Stopped mortice and tenon joint

• "T" halving joint

• Bare faced tenon joint

• Dowelled joint

• Cross halving joint

• "T" bridle joint

Measuring Tools Animations

• steel rule
• micrometer
• digital micrometer
• vernier caliper
• height gauge
• depth gauge
• micrometer depth gauge
• internal caliper
• external caliper
• combination set
• dial gauge 
• screw pitch gauge
• feeler gauge
• limit plug gauges (GO / NOGO gauges)
• limit ring gauge
• snap gauge
• drill gauge
• radius gauge
• protractor
• spirit level
• electronic devices 

• pens and pencils
• scriber
• marking knife
• engineer's square
• woodworker's try square
• dividers trammel
• odd leg calipers
• marking gauge 
• cutting gauge
• mortice gauge
• centre punch
• dot punch
• mitre square
• centre square
• sliding bevel
• bradawl
• surface gauge
• straight edge
• vee block
• angle plate
• templates
• surface plate

The hand tools animation consists of:

• planes:

  • jointer plane

  • jack plane

  • smoothing plane

  • bench plane sizes

  • plane parts

  • sharpening angles for plane cutting irons

  • grinding and honing

  • frog angles

  • rebate plane

    • marking out a rebate

    • planing a rebate

  • shoulder plane

  • bull nose plane

• spokeshaves

• wood chisels:

  • firmer chisel 

  • bevel edged chisel

  • mortice chisel

    • using a mortice chisel

  • gouge

• cold chisel

• tinsnips and shears

  • using tinsnips

• saws for wood:

  • tenon saw

  • dovetail saw

  • cross cut saw

  • rip saw

  • coping saw

• hacksaw

• junior hacksaw

• abra file

• hammers and mallets:

  • engineer's ball pein hammer

  • sledge hammer

  • rubber mallet

  • plastic faced hammers

  • soft faced hammers

  • rawhide mallet

  • bossing mallet

  • raising hammer

  • planishing hammer

  • doming hammer

  • cross pein hammer

  • claw hammer

  • woodworker's mallet

• files:

  • description

  • roughness of cut

  • hand file

  • flat file

  • half round file

  • round file

  • square file

  • three square file

  • knife file

  • needle files

  • Swiss wax files

• drills:

  • brace and bit

  • how to use a brace and bit

  • twist drills

  • countersink

    • riveting with countersunk head rivets

  • hand drill / wheel brace

• Taps and dies:

  • taps and tap wrench

  • tapping a thread

  • die and diestock

  • cutting an external thread

  • drunken threads.

The machine tool animations illustrate: 

• CNC:

  • description of computer numerical control

  • links between CAD, CAM and computer control

  • main difference between manual and CNC machines

  • 5 axis CNC miller

  • CNC lathe

• buffer:

  • using a buffer

  • pickling

  • etching

• sanding machines

  • disc sander

  • orbital sander

  • belt sander

  • reciprocating sander

  • spindle sander

    • abrasive papers and cloths

    • abrading

    • emery cloth

• grinding machines:

  • bench grinder

  • surface grinder

  • angle grinder

• drilling machines:

  • pillar drill

  • chuck key safety

  • portable power drill

  • twist drill bit

  • SDS drill bit

  • taper shank drill bit

  • grinding angles for drill bits

  • reamers

  • centre drill

  • countersinks

  • masonry drill bit

  • brad point drill bit

  • auger bits

  • flat bit

  • Forstner bit

  • counterbore and plug ctter

  • hole saw

• vertical milling machine

• router (power router):

  • router cutters

  • router collet

  • setting the depth of cut

  • using a power router

  • routing jig

  • router safety

• horizontal milling machine

• centre lathe:

  • lathe parts

  • holding work in a three jaw chuck

  • holding work in a four jaw chuck

  • turning between centres

  • facing off

  • parallel turning

  • taper turning

  • cutting tools

    • cutting tool grinding angles

• power hacksaw

• planer / thicknesser:

  • planing a face

  • planing an edge

  • thicknessing

• wood saws:

  • bandsaw

    • using a bandsaw

  • circular saw

  • circular saw power tool

  • jig saw

  • fret saw:

    • parallel arm mechanism

    • parallel link arm mechanism 

    • C-arm mechanism

• morticer:

  • using a morticer

• wood lathe:

  • belt and pulley arrangement

  • turning between centres

  • turning on a face plate

  • scraping action

  • cutting action

  • chisels, scrapers and gouges

• Shears:

  • bench shears

  • pneumatic guillotine

  • press tool.

Casting pewter, soldering and brazing, electric arc welding, beaten metalwork: making a copper dish

• Hardwoods and softwoods
• Timber conversion
• Timber defects
  • Cup shake
  • Heart shake
  • Star shake
  • Splits and shakes
  • Fungal attack
  • Woodworm (beetle attack)
  • Twisting, checks, bowing, resin sacks
  • Seasoning
  • Cutting veneer
  • plywood
  • blockboard
  • faced chipboard
  • Medium density fibreboard (MDF)
  • Solid timber boards
  • Advantages/disadvantages of timber and manufactured boards

• types of motion

• levers: Class 1, Class 2, Class 3, bell crank lever

• linkages

• pulleys and belts:

  • used to transmit motion and torque 

  • change speed of rotation

  • stepped cone pulleys

  • pulley belts used to transport products

  • pulley belts used as bandsaws

  • pulleys used for lifting and hauling

• chain and sprocket drive

• chain parts

• Gears:

  • spur gears

  • gear train

  • bevel gears

  • worm gear

  • rack and pinion

• cams, rotary and linear, cam followers

• ratchet and pawl

• crank mechanisms

• crank and slider

• application of screw mechanisms:

  • for clamping

  • to control movement

  • for lifting

• ball screws

• couplings

  • flanged

  • split

  • flexible

  • universal joint

• friction used to oppose motion:

  • brakes

  • clamps

  • grips / knurling

• reducing friction by the use of lubricants and bearings

• lubrication

• bearings:

  • bush

  • ball bearing

  • roller bearing

• mechanisms used on a bicycle.

• description of "plastic"

• the main ingredients of most plastics

• thermoplastics

• thermosets

• thermoforming:

  • line bending

  • vacuum forming

    • commonly used materials

  • plug & yoke

• expanded polystyrene (EPS)

• structural foam

  • commonly used materials

• rotational moulding

  • commonly used materials

• injection moulding

  • commonly used materials

• gas assisted injection moulding

• injection blow moulding

• extrusion blow moulding

  • commonly used materials

• inserts in plastic mouldings

• blown film

• thermosets

• resins

• hand lay-up of glass reinforced plastic (GRP)

• sprayed polyester resin and reinforcing material

• resin transfer moulding

• pultrusion process

• injection moulding

• compression moulding:

  • dough moulding compound (DMC)

  • sheet moulding compound (SMC)

• commonly used abbreviations of the names of polymers.

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