Evaluation
CCEA AS-Level Technology and Design 8900
Material Selection and Wood
Metals
Plastics
Composite and Emerging Materials
Processing Materials
Product Analysis and Design Communication
Design for Manufacture, Quality and Safety
Electronic Control SystemsOption A
Topic overviewControl systems, feedback and electronics safetyResistors, Ohm's law and power ratingsCapacitors and RC timingPotential dividers, sensors and comparatorsSwitches, pull-up and pull-down resistorsOutput devices and LEDsTransistors, Darlington pairs and thyristorsLogic gates, truth tables and flip-flops555 monostable and astable timers
Mechanical and Pneumatic ComponentsOption B
Topic overviewOpen and closed loop mechanical and pneumatic controlSafe working with compressed air and mechanismsLevers, linkages and momentsGear types and gear trainsPulleys, belts, chains and shaft fixingsCams, cranks and converting motionCompressed air supply and pneumatic valvesCylinders, shuttle valves, restrictors and reservoirsPneumatic circuits for logic, timing and speed control
Designing and Manufacturing ProductsOption C
Topic overviewResearch, questionnaires and specificationsIdea generation, critiques and computer simulationManufacturing planning and product evaluationCFRP, GRP, Kevlar and tungsten carbideSmart materials, nanotechnology and biophotovoltaicsIsometric, perspective and assembly drawingLaminating, steam bending, cutting and printing processesRisk assessment and product safety lawScales of production, JIT and cell productionQuality assurance, ISO 9001 and continuous improvementDesign influences and intellectual property rights
Product Development
Design for Manufacture, Quality and Safety
- 5 subtopics
- 15 things to know
- AS 1 Paper 1
What Design for Manufacture, Quality and Safety covers
Design for Manufacture, Quality and Safety is examined in Unit AS 1, Paper 1: Design and Materials, the compulsory core. It covers CAD modelling, virtual imaging and rapid prototyping, CAM and CIM, factor of safety and tolerances, testing and inspection of products and risks in workshop and manufacturing processes.
Where it is assessed
AS 1 Paper 1
Design and Materials, the compulsory core — a written examination.
Check the CCEA specification ↗The 5 subtopics
Each one has its own page. CCEA AS Technology and Design students sit this topic in the first year.
- CAD modelling, virtual imaging and rapid prototyping2D CAD, wire-frame and solid modelling, parametric modelling, virtual imaging and virtual reality, finite element analysis, and FDM, SLA and SLS rapid prototyping.Open →
- CAM and CIMCAM from CAD to finished part, toolpaths and G-code, simulation, a router batch calculation, the drawbacks of CAM, CIM stock and quality control, robots and a reorder calculation.Open →
- Factor of safety and tolerancesFactors of safety with worked failure loads and stress, why aircraft and lifts differ, limits and tolerances, clearance and interference fits, and tolerance stack-up.Open →
- Testing and inspection of productsInspection against testing, stages of inspection, destructive and non-destructive testing, go/no-go gauges and micrometers, sampling, proof load and fatigue tests, and camera inspection.Open →
- Risks in workshop and manufacturing processesHazard and risk, health and safety law in Northern Ireland, COSHH, the hierarchy of control and PPE, and the risks of lathes, drills, chisels, dust, laser cutting, casting, soldering and presses.Open →
What you need to know
Answer each one before you reveal it.
Your recallNot started
Evaluation
State three advantages of CAM over manual manufacture.
Key term
What is a proof load test?
Key term
What is a factor of safety?
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What is the difference between a hazard and a risk?
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What is 2D CAD drawing used for in manufacturing?
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What is computer-aided manufacture (CAM)?
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Explain why designers cannot simply design to the exact working load.
Key term
What is the purpose of testing and inspecting components and products?
Numbers
Which law places health and safety duties on employers and employees in Northern Ireland?
Key term
Which CAD drawing tools save time compared with drawing by hand?
Process
Describe the stages that take a design from CAD to a finished CAM part.
Key term
A bracket fails at a load of 3,000 N and carries a working load of 750 N. What is its factor of safety?
Key term
What is the difference between inspection and testing?
Key term
What do the COSHH regulations require of an employer?
Take Design for Manufacture, Quality and Safety further
The same content, four other ways.
Commonly confused
Pairs that lose marks when they are blurred together.
CAM vs CIM
CAM: using computers to control individual machines that make parts. CIM: linking design, stock, production, quality and assembly through one computer system.
Hazard vs Risk
Hazard: anything with the potential to cause harm. Risk: the likelihood of harm occurring combined with its severity.
Destructive testing vs Non-destructive testing
Destructive testing: loading a sample until it fails so that it cannot be used again. Non-destructive testing: checking a part for flaws without damaging it, such as by ultrasound.
Questions from this topic
Each one with the model answer underneath.
- 1
What is 2D CAD drawing used for in manufacturing?
Model answer
2D CAD produces accurate, dimensioned drawings such as orthographic views and cutting profiles. The drawings can be edited, stored and shared electronically.
- 2
Which CAD drawing tools save time compared with drawing by hand?
Model answer
Copy, mirror and array commands repeat features instantly, and layers separate different information. Libraries insert standard parts such as fixings without redrawing them.
- 3
What is solid modelling?
Model answer
Solid modelling builds a CAD model that has volume and mass, not just edges or surfaces. The model can be sectioned, weighed and checked for clashes with other parts.
- 4
Compare a wire-frame model with a solid model.
Model answer
A wire-frame model shows only the edges of an object, so it can look confusing and cannot be shaded. A solid model contains the full volume, so it can be rendered, sectioned and analysed.
- 5
Describe how a simple solid model is built from a 2D sketch.
Model answer
A 2D profile is sketched and fixed with dimensions and constraints. The profile is extruded or revolved into a solid, then features such as holes and fillets are added.
- 6
What is parametric modelling, and why is it useful?
Model answer
Parametric modelling links the features of a model to dimensions and rules. A change to one dimension updates the whole model and its drawings automatically.
What is inside Levo
Six ways to work the same material.
Design for Manufacture, Quality and Safety revision questions
- Is Design for Manufacture, Quality and Safety examined at AS in CCEA Technology and Design?
- Yes. It sits in AS 1 Paper 1, which you take in the first year, so it is on the AS paper as well as counting towards the full A level.
- What does Design for Manufacture, Quality and Safety cover in CCEA AS-Level Technology and Design?
- 5 subtopics: cad modelling, virtual imaging and rapid prototyping, cam and cim, factor of safety and tolerances, testing and inspection of products and risks in workshop and manufacturing processes. Each one has its own page with questions and model answers.
- How is Design for Manufacture, Quality and Safety organised?
- By the CCEA 8900 specification, subtopic by subtopic, so it matches the order you are taught it in.
Every question in Design for Manufacture, Quality and Safety, on a schedule.
Attempt a question from memory, write the correct version, then attempt it again. Levo records the jump between your first attempt and your last, and brings each question back on the day you are due to forget it.
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