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Design, Technology and Engineering

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Resources provided for hard material technologies covering Engineering, Resistant Materials and Product Design. Designed by a former blacksmith with 8 years teaching experience and 6 years examination and moderation experience!

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Resources provided for hard material technologies covering Engineering, Resistant Materials and Product Design. Designed by a former blacksmith with 8 years teaching experience and 6 years examination and moderation experience!
 BTEC Engineered World Exam Unit 1 - Engineering materials revision mind map
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BTEC Engineered World Exam Unit 1 - Engineering materials revision mind map

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This is a step by step guide to enable your students to create a mind-map that recaps the following materials; Titanium Tungsten Duralumin Optical Fibres Modern Metallic Foams Carbon Fibre GRP Kevlar Tungsten Carbide There are two pathways (hard for merit/dist students and easy for L1/pass students) or you could just print my version and add it to a revision pack. I might include timers when mine undertake the task to prevent procrastination. Could be used for a different subject applying the same principles.
BTEC 2016 KS5 Engineering Unit 3 Design and Manufacture Learning Aim A work booklet B
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BTEC 2016 KS5 Engineering Unit 3 Design and Manufacture Learning Aim A work booklet B

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This 66 page booklet (pdf) follows on from part A and covers the rest of the learning aim A syllabus including material properties, power transmission, and manufacturing processes. There are lots of pages that repeat in format so that students can draw, research and learn about; Sand, die and investment casting. Machining including turning, milling and drilling. Injection, extrusion, blow and rotational moulding. Slip, tape and press forming ceramics. Press forming, stamping, drop forging metals and backward/forward impact extrusion. 3D printing. Compression moulding (metals and thermosets). Laying up. Soldering, brazing. MIG, TIG, Oxy welding. This is a “build your own” textbook, its just activities. My students complete notes in lesson time and then type them up in study periods… Some haven’t started yet but they’ll have too soon. I’m hoping they will re-visit their notes are part of the controlled assessment “research”. I’ve also started to get them to complete the research tasks before lessons so that they have examples of products before we go through the processes. This booklet is to help me as much as them because I would hate to forget to include teaching a process to find the design brief included something I hadn’t covered with them! I’m going to look into the other learning aims this term… Hopefully! Sorry it’s a pdf but I’ve paid for license for the images in some of the activities!
BTEC Level 2 Engineering - Unit 1: The Engineered World - Manufacturing processes.
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BTEC Level 2 Engineering - Unit 1: The Engineered World - Manufacturing processes.

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This is a team work based game that introduces students to the following topics: Surface mount technology CNC machinery Pick and place robotics Drop forging Shearing Teams of four/five are assigned roles (I've assigned teams of 4 because I have classes of 20+) but you could do teams of three by merging the writer/explainer role. Five paragraphs (1 about each process) are put out on different tables and students have to work as a team to produce a quick poster of each process using words and pictures. I'm going to give the team with the best 5 posters a prize at the end. Students are each given specific tasks and their are rules to keep them in check. A five minute timer and two minute timer are in the powerpoint to help you move them on and keep the pressure/pace of the competition going. They could even vote for the winning team at the end or you could get the teams to swap posters and add in anything they think was missing.
BTEC Engineering Level 2 - Unit 1 Exam - Smart Materials Lesson
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BTEC Engineering Level 2 - Unit 1 Exam - Smart Materials Lesson

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Slide 1: Bell - Highlight the five most important words from each smart materials definition. Slide 2: Review the words for piezoelectricity with the group. Slide 3 & 4: Two youtube clips - one explaining cigarette lighters (because they are universally liked by all teenagers) and one that covers ultrasound. Slide 5: Slide that covers benefits and limitations (Your high ability can copy these out while the rest answer the key question at the top of the page. ) Slide 6: Review of the 5 words for electrochromic glass with the group. Slide 7: Grand designs electrochromic glass clip. Slide 8: Same as 5. Slide 9-15: Same structure repeated for SMAs and SMPs covering a range of applications. Slide 16: A wordle with the key terms from the lesson to enable your students to write their own definition of a smart material. Worksheet with some key questions for everyone to be completed during powerpoint and to avoid them getting that glazed look and break up the note taking/clip watching. This can also be used as evidence to later mark (and then remark in order to close the loop just in case ofsted rock up.) Save yourself a day's worth of hunting for appropriate videos and download this fully editable resource. Happy Sunday.
BTEC Engineering Level 2 - Unit 1: The Engineered World - Surface nanotechnology (automotive)
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BTEC Engineering Level 2 - Unit 1: The Engineered World - Surface nanotechnology (automotive)

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A presentation that covers the basics of nano technology. Slide 1-4 - A maths task helping your high achievers transfer their knowledge of SI to engineering and to help your less able to understand the nano means very small. Also a reading task with a few nano sized facts to consolidate. Slides 5 - The slow mo guys (two young geeks on you tube) explain the principles of hydrophobic materials with some amazing slow motion videos that usually grab the attention of the students. (As a teaser you can promise to show other slow motion video at the end of the lesson but be careful which ones you choose some covering explosions contain inappropriate language and in others the geeks undertake seriously dangerous/reckless activities.) Whereas others have a much more scientific focus. Slide 7-9 - The applications covered in brief (tyres, clearcoat and petrol/oil). Slide 10 - The disadvantages. The first worksheet asks students to write the definition of nanotechnology and then explain three areas where they might be used in the automotive sector. The second worksheet is a series of pictures which students can cut and classify into two or more groups of their choice (alone, as a group or with a neighbour.) They then need to annotate on the meaning of each picture. The powerpoint takes about 10-15 minutes, the students can spend most of the lesson completing the main sorting and annotating task and the answers can be discussed with each table as you wander around the room telling them to stay on task and stop drawing on the tables..... Every resource is in powerpoint and fully editable. Enjoy.
A-level Product Design - Build your own textbook - Manufacturing processes.
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A-level Product Design - Build your own textbook - Manufacturing processes.

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This booklet allows students to gather information on manufacturing processes including alloying, moulding, printing, machining to name a few. This pack should upload into google drive or classroom with little formatting (or as an editable pdf.) I plan to use this so that I can monitor my students progress, how easy it is for us to assume they have made their own notes... And even more frustrating that deep down we know they don't. There a 28 pages in total including the relevant section of the specification. I plan to create a booklet for each section! Thanks for looking.
A-level Product Design - Build your own textbook. Woods/metals/plastics.
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A-level Product Design - Build your own textbook. Woods/metals/plastics.

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This booklet allows students to gather information on woods, metals, polymers using material properties. This pack should upload into google drive or classroom with little formatting (or as an editable pdf.) I plan to use this so that I can monitor my students progress, how easy it is for us to assume they have made their own notes... And even more frustrating that deep down we know they don't. There a 9 pages in total including the relevant section of the specification. I plan to create a booklet for each section! Thanks for looking.
BTEC Engineering - Unit 7 Machining
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BTEC Engineering - Unit 7 Machining

5 Resources
A selection of resources that can be used to deliver Unit 7: Machining including teaching materials, worksheets and booklets that can be used alongside the online assignment briefs. Some editable some pdf. I have working drawings for the six making projects are students undertake, if you are interested please get in touch as they are 2D design tools files so can't be uploaded. Most of this bundle is focused on drilling and turning because we have limited lathe access for our students.
Engineering BTEC Level 2 - Unit 1: The Engineered World - Bionics
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Engineering BTEC Level 2 - Unit 1: The Engineered World - Bionics

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A lesson all about the applications, advantages, and disadvantages of Bionic eyes Prosthetic Limbs Mechanical Hearts/pacemakers Breast Implants Cochlear Implants The first pages are to encourage debate and to classify the pictures and also helps the teacher to gauge the level of prior knowledge in the room (lots of the information will overlap with you top set Science students, if you have any.) The presentation is designed to raise some important issues about disability and health in relation to the applications of bionics. (Might be worth preparing the LADS for a serious discussion, especially when it comes to breast augmentation and cancer.... You could always create new slides on artificial windpipes instead but I fancied a challenging debate and not a lesson where issues such as disability, cancer, deaf/blindness and injury caused through war etc. became topics of banter.) There is then a group task, each group gets a fact sheet about one of the five suggested bionic applications and another sheet with questions that they need to answer and present to the rest of the group. I'm going to give my A2 sugar paper, marker pens and 20 minutes. There's no plenary, I think it'll be a push to get through all five presentations in one lesson. I might use the following lessons to produce a "How much can you remember?" Mindmap. Will being delivering this lesson soon so will be able to give better time/activity guidance. No worksheets, just an editable powerpoint.
KS3 Minilight Project
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KS3 Minilight Project

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Teacher powerpoint slides, individual activities and exemplars for a 14 hour project for KS3 year 7 or year 8. This project is skills based. Students will need a USB cable (which can be recycled from a keyboard or device) and a LED card (can be purchased in bulk on AliExpress.) The plywood base uses 18mm and 3mm ply, however the base can be made from a solid piece of timber with a slot rebated on a table router. This pack contains. 1 - Choosing a design brief and writing a specification. 2 - Drawing design ideas in isometric, 2D and using tinkerCAD, including a PDF of exemplars. 3 - Storyboard planning task, including images and machine infographics. 4 - Pillar drill matching and writing activity (in class, cover or homework). 5 - Soldering reading/word frame activity (in class, cover or homework.) 6 - Evaluation This activity can be extended with the use of multiple layers and embellishment on the base. For ITTs it can be simplified using Vinyl Cut stickers on backboards that are precut, this saves time and file conversion. YouTube CAD tutorials available.
A-level Product Design - Build your own textbook - Paper/boards/textiles/smart materials.
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A-level Product Design - Build your own textbook - Paper/boards/textiles/smart materials.

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This booklet allows students to gather information on papers, boards, textiles and smart materials using material properties. This pack should upload into google drive or classroom with little formatting (or as an editable pdf.) I plan to use this so that I can monitor my students progress, how easy it is for us to assume they have made their own notes... And even more frustrating that deep down we know they don't. There a 7 pages in total including the relevant section of the specification. I plan to create a booklet for each section! Thanks for looking.
A-level Product Design - Build your own textbook - Temporary and permanent joining methods.
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A-level Product Design - Build your own textbook - Temporary and permanent joining methods.

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This booklet allows students to gather information on methods used to join different types of materials. This pack should upload into google drive or classroom with little formatting (or as an editable pdf.) I plan to use this so that I can monitor my students progress, how easy it is for us to assume they have made their own notes... And even more frustrating that deep down we know they don't. There a 14 pages in total including the relevant section of the specification. I plan to create a booklet for each section! Thanks for looking.
BTEC Engineering Component 1 bundle
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BTEC Engineering Component 1 bundle

3 Resources
Manufacturing processes independent study booklet and pro-formas for Learning Aim A & B with all stages of assignment clearly labeled. Student led booklets that can be used in powerpoint or uploaded and converted to google slides with ease. (Can also be printed or turned into a pdf if you choose.) Happy engineering!
Level 2 BTEC Engineering - Unit 1: The Engineered World  -Modern materials in engineering.
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Level 2 BTEC Engineering - Unit 1: The Engineered World -Modern materials in engineering.

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This resources is an adaptable lesson PowerPoint including worksheets covering the advantages and disadvantages of Titanium, Tungsten, Superalloys, Modern high performance ceramics, Kevlar and Optical Fibres. In the bell task students can annotate the first slide in pairs or teams to establish prior knowledge. The main task is a series of six fact slides, one for each material. I print and place these on the tables and then students can move around the room to each table copying down the facts. However, you could a copy of each material slide to a table and use KAGAN strategies (5 minutes - 10 minutes per slide to copy each and swap) if they are a lively bunch or you want them to remain seated. Discussions for a plenary or save for your next starter. If you are unsure there are some free Unit 1 resources for other topics available so that you see my resources in more detail before committing to buy! Free for NQT's, just get in touch.
AQA Product Design - Metals Theory Booklet
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AQA Product Design - Metals Theory Booklet

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This is a 58 page booklet that students can use to record their understand of the metals exam theory, including all processes. There are spaces for diagrams, some reading activities and “information cards”. One the front page there are references to each page in the AQA Design and Technology: Product Design Textbook by Hodder Education. This is a build your own textbook and is provided as a powerpoint, but could be used as a google slides document or printed and hand written.
Level 2 BTEC Engineering - Unit 1: The Engineered World - Blended Wing Bodies.
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Level 2 BTEC Engineering - Unit 1: The Engineered World - Blended Wing Bodies.

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A set of resources including four worksheets and a presentation that aims teach students about blended wing bodies used in the aerospace engineering sector. The bell work is a spot the difference task that aims to encourage students to compare and contrast traditional aircraft with aircraft that have blended wing bodies. This moves into a discussion about their advantages and disadvantages. From this point students should be able to answer all of the questions in the worksheets. Types of questions include multiple choice questions, learning of key terms, and given statements where students have to justify the answers. The final task is a long answer question, ideal as an extension for more able students, or a homework for all. Please look at my other free resources if you are curious about my teaching style and want to see what's on offer before you commit to buy! Free for NQT's, just get in touch.
Level 2 BTEC Engineering - Unit 1: The Engineered World - Investment Casting
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Level 2 BTEC Engineering - Unit 1: The Engineered World - Investment Casting

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Three pdf worksheets aimed at teaching students the stages of investment casting. The first resource asks students to watch a ten minute youtube clip and then write the stages of investment casting onto the worksheet. There are times given (in minutes and seconds) where the teacher can pause the video and students are given keywords to allow them to learn the correct terminology. This could also be given as a homework. The second task is to revise the process by cutting and sticking the icons into the correct order. Any questions just ask! *Colours correted, some of the pictures were wax coloured, not aluminium coloured