AQA GCSE (9-1)

Design and
Technology

M J Ross
 Contents
Core technical principles
Section 1  New and emerging technologies 1
Chapter   1 Industry and enterprise 2
 2 Sustainability and the environment 7
 3 People, culture and society 13
 4 Production techniques and systems 21
 5 Informing design decisions 25

Section 2  Energy, materials, systems and devices 31

Chapter   6 Energy generation 32
 7 Energy storage 38
 8 Modern materials 43
 9 Smart materials 49
10 Composite materials and technical textiles 55
11 Systems approach to designing  60
12 Electronic systems processing 64
13 Mechanical devices 70

Section 3  Materials and their working properties 79

Chapter 14 Papers and boards 81
15 Natural and manufactured timbers 84
16 Metals and alloys 88
17 Polymers 91
18 Textiles 94

iv
Specialist technical principles
Section 4 Common specialist technical principles 101
Chapter 19 Forces and stresses on materials and objects 102
20 Improving functionality 105
21 Ecological and social footprint 111
22 The six Rs 119
23 Scales of production 124

Section 5A  Papers and boards 130

Chapter 24 Sources, origins and properties 130
25 Working with papers and boards 133
26 Commercial manufacturing, surface treatments and finishes 141

Section 5B  Timber based materials 147

Chapter 27 Sources, origins and properties 147
28 Working with timber based materials 151
29 Commercial manufacturing, surface treatments and finishes 159

Section 5C  Metal based materials 163

Chapter 30 Sources, origins and properties 163
31 Working with metal based materials and fixings 166
32 Commercial manufacturing, surface treatments and finishes 176

Section 5D  Polymers 180

Chapter 33 Sources, origins and properties 180
34 Working with polymer based materials and fixings 185
35 Commercial manufacturing and quality control 194

Section 5E  Textile based materials 199

Chapter 36 Sources, origins and properties 199
37 Working with textile based materials and fixings 204
38 Commercial manufacturing, surface treatments and finishes 211

Section 5F  Electronic systems 216

Chapter 39 Selection of materials and components 216
40 Working with electronic components 220
41 Commercial manufacturing and quality control 228

v
 Designing and making principles
Section 6  Designing principles 237
Chapter 42 Investigation, primary and secondary data 238
43 The work of others 245
44 Design strategies 254
45 Communication of design ideas and prototype development 259

Section 7  Making principles 269

Chapter 46 Selection of materials and components 270
47 Tolerances and allowances 273
48 Material management and marking out 276
49 Specialist tools, equipment, techniques and processes 281
50 Surface treatments and finishes 284

Index290

vi
Section 1
New and emerging technologies

In this section:
Chapter 1 Industry and enterprise 2 1
Chapter 2 Sustainability and the environment 7
Chapter 3 People, culture and society 13
Chapter 4 Production techniques and systems  21
Chapter 5 Informing design decisions 25

Section 1 New and emerging technologies 1

 SECTION 2 ENERGY, MATERIALS, SYSTEMS AND DEVICES Power generation is more efficient during periods of heavy rainfall. At other times, water is
pumped back up to the top of the reservoir when the demand for electricity is low. The flow of
water through the turbine is easily controlled, making it simple to alter the power being produced
depending on the demand at different times of the day.
Transformer

Reservoir Dam

Sluice
gate

Outflow

Turbine and generator

What might be the impact on the natural environment and wildlife of constructing
Q7 a dam at the end of a valley and flooding the valley to create a reservoir for a
hydroelectric power station?

Q8 List as many positive factors for hydroelectric power as you can.

Biofuel
2 The production of biofuel is becoming a viable way of producing energy for our transportation
and heating needs. Oil- and starch-producing crops are grown, harvested and refined into a
number of products, including biodiesel. The process is commonly known as biomass energy
production. The term biomass can include other solid biofuels such as wood chips and farm waste.

Food
Sun products
energy

Crop
refining

Renewable
resource Biodiesel
(as well as production
used cooking oil)
Renewable
fuel

CO2
Glycerine
Existing
products
technology

In 2016, only about 3% of fuel for the UK’s transportation system came from biodiesel,
according to the Department of Transport. A growing number of companies and private users
are recycling spent cooking oil, (a waste product from the catering industry) and converting it
into biodiesel by refining it independently.

36 Section 2 Energy, materials, systems and devices

Shape memory alloy

CHAPTER 9 SMART MATERIALS

Most materials have some form of memory, meaning that they will try to resist deformation or
spring back to their original shape. Shape memory alloys (SMA) take this a step further; they
can remember a preset shape and return to it despite being dramatically reshaped. The stimulus
for returning to the preset shape is heat or electricity.

High outflow temperature moves Low outflow temperature moves

SMA valve to reduce hot water input SMA valve to increase hot water input

Hot water Cold water Hot water Cold water

inlet inlet inlet inlet

Nitinol, an alloy of nickel and titanium, is the most commonly used SMA. To program its shape
memory, the nitinol must be held in the desired position and heated to around 540°C, then
allowed to cool. It can then be deformed to a different shape. When it is heated to around 70°C,
it will spring back to its programmed shape. This can also be achieved by passing an electric
current through it. It can be re-programmed by reheating it to 540°C.

2
SMA used as a self-expanding surgical stent

Nitinol can also be used as muscle wire. The wire is first stretched and then, when an electrical
current is passed through it, it will contract approximately 5% of its length. This is used in dental
braces.

Name and Appearance Image Characteristics Uses

stimuli
Shape memory Mid-grey metal A shape can be Frames for
alloy (Nitinol) wire of varying programmed glasses, dental
thickness. when heated to braces, self-
540°C; it can be expanding stents
Heat or electricity Also available in
sheets deformed and used in surgical
will return to the procedures to
memory shape open capillaries,
when reheated to fire sprinklers
70°C

Explain how a piece of shape memory alloy could be used in a fire detector
Q5 controlling a sprinkler system.

Chapter 9 Smart materials 51

 SECTION 2 ENERGY, MATERIALS, SYSTEMS AND DEVICES 9. Explain one reason why Kevlar is an appropriate choice of material for the firefighter
protective gloves shown below.  [2]

10. Give two applications for microencapsulated fabrics.  [2]

11. (a) Draw the correct circuit symbol for a PTM and a PTB switch.  [2]

(b) Describe one operational difference between a PTM and a PTB switch.  [2]

12. Use notes and sketches to show the difference between an analogue and digital
electrical signal.  [4]

13. (a) Name the type of motion shown below:  [1]

2 (b) Give one application or machine which exhibits the type of motion you have
named in your answer to (a).  [1]

14. Identify the class of lever shown below for the car foot pump.  [1]

15. (a) Describe the action a follower goes through when following a snail shaped cam. [2]

(b) Name two types of cam follower.  [2]

16. Explain one reason why an idler gear is used in a gear train.  [2]

78 Section 2 Energy, materials, systems and devices

Non-woven textiles

CHAPTER 18 TEXTILES
Non-woven fabrics are made directly from fibres without being spun into yarns. The most
commonly available non-woven fabrics are bonded fabrics made from a web of fibres held
together with heat or adhesive. Common uses of non-woven fabrics include disposable products
such as garments worn by surgeons and crime scene investigators, dishcloths and interfacings.
Non-woven fabrics can be given special treatments such as flame resistance to make head rest
covers on trains and aircraft.

Felting is a mechanical process which has traditionally been done by hand, but is now mainly
machine produced. It involves matting together wool or synthetic fibres using a combination of
heat, pressure, moisture and movement to mesh the fibres together in a random way. Felt can be
formed into shapes when wet (see drape formed hats in Chapter 37), but it does not have any
elasticity and will not drape well when dry. It is not strong and can pull apart under tension, but
unlike woven fabric, will not fray when cut.
3

Name Appearance Image Characteristics Example uses

Bonded Random laid fibres Fabrics lack Disposable
fabric are visible in the strength, they have products such as
fabric, it can have no grain so can be protective clothing
small holes or a cut in any direction worn for hygiene
textured surface and do not fray purposes, tea
bags, dish cloths
and dusters
Felted Matted fibres Can be formed Hats, handicraft,
fabric randomly with moisture and pads under
interspersed, wide heat; once dry it furniture to prevent
range of colours has no elasticity scratching,
and thicknesses or drape, and can soundproofing and
pull apart easily. insulation
Woollen varieties
can be expensive

Q5 What might happen to woollen felted products if they are washed in hot water?

Chapter 18 Textiles 97
Chapter 38 – C
 ommercial manufacturing,

CHAPTER 38 COMMERCIAL MANUFACTURING

surface treatments and finishes
Objectives
• Know and understand how textile based materials are selected and processed for
commercial products
• Understand why aids are used to judge quality and accuracy before and during processing
• Understand how surface treatments and finishes affect the functional and aesthetic properties
of textile products

Textiles for commercial products

Commercial textile production has developed significantly over the last 50 years owing to new
materials being invented as well as new industrial manufacturing methods and higher levels of
computer driven automation. Both ‘technology push’, in the form of new materials and ‘market pull’
with demand for greater performance of fabrics, have contributed to a huge and expanding industry.
The introduction of stretch fabrics has transformed aerodynamics, especially seen in cycling and
swimming, enabling items of clothing to fit tightly thus reducing drag yet allowing for freedom
of movement by the wearer. Wicking fabrics have also been of huge benefit to athletes and
outdoor adventurers by allowing perspiration to evaporate quickly, keeping the wearer dry.
Sportswear and outdoor apparel have gone through more changes than many other areas of
textiles over the last few decades owing to constant developments in new technologies, giving a
greater range of physical and working properties to use. These fabrics can also take advantage
of microencapsulation. (See Chapter 10 for more detail.) 5E

How have developments in commercial textiles helped to improve comfort and safety
Q1 in motorsport apparel?

Commercial developments in the area of home and business furnishings have led to a greater
range of choice through colours, styles and levels of quality. Furnishings cover a multitude of
interior, and increasingly, exterior quality textiles, including carpets, rugs, upholstery fabrics,
curtains, cushions and many more. These products all form part of our living and working spaces
and are chosen for many different reasons. Aesthetics are very important to most people, but the
physical and working properties may well be of equal or greater concern to a customer.

Chapter 38 Commercial manufacturing, surface treatments and finishes 211

 SECTION 5 SPECIALIST TECHNICAL PRINCIPLES
Section 5 Exercises
Exercises in this section are generic so that answers may be given in context that apply appropriate
techniques, knowledge and understanding from any of the material areas.

1. Choose one of the materials in the table below.

Materials
Solid white Low carbon
Ash Acrylic Cotton
board steel

Name one surface finish or treatment that can be applied to the material to enhance the
functional or mechanical properties.

Use notes and/or sketches to explain how the surface finish or treatment can be changed
to improve or enhance its properties. [5]

Name of material: _________________________________________________________

Surface finish or treatment: _________________________________________________________

2. Describe two ways that materials can be shaped or formed.

Give examples in your answers. [4]

3. Five materials are listed in the table below. Choose one material:
5
x Materials
Corrugated Low carbon Polyvinyl
Plywood Wool yarn
card steel chloride (PVC)

(a) State one raw primary source material of your chosen material. [1]

(b) Give one stock form in which the material is likely to be available. [1]

(c) Describe the manufacturing process(es) used to turn the raw primary source material
into a stock form. You may include sketches in your answer. [3]

(d) Describe two ways that one of the materials can be modified. [4]

4. Choose one product or component from the table below and describe two features that
make it suitable for mass production. [4]

Aluminium PET water

Foil lined board Cotton skirt Pine roof truss
drink can bottle

234 Section 5 Specialist technical principles

 CHAPTER 43 THE WORK OF OTHERS
Designer investigation:
Philippe Starck 1949–present
The truly multi-faceted French designer, Phillippe Starck was born in Paris where his design studio
is based to this day. His father was an aeronautical engineer and it is said that young Starck had
a passion for design from an early age, hence attending Ecole Nissim de Camondo, a school of
product design and interior architecture in Paris. He started by designing inflatable furniture and,
although not a great success, it gathered much needed attention.

Starck was offered a job as an artistic director with Pierre Cardin which was a good stepping
stone but he preferred much simpler designs than the flamboyance of Cardin. Having successfully
created interior designs for Parisian nightclubs he launched Starck Products in 1979. His big break
came in 1982 after being selected to work on the private residence of the then French President.
Since then he has worked on numerous projects from simple mass produced items for brands
such as Alessi and Microsoft to furniture, electrical goods and a number of top end hotels. He is
involved in all aspects of design and has even produced motorbikes, electric vehicles and yachts. 6
Starck is a prolific and innovative designer who has produced many iconic products; some that
have already become modern classics such as the ‘Juicy Salif’ lemon squeezer. He is considered
by some to put form ahead of function, making some of his products beautiful but impractical
to use. He often utilises organic forms which are sleek, simplistic and streamlined. Much of his
work can be quirky and humorous; he readily confesses that he likes to inject mystery, magic
and quirkiness into his designs. Starck likes to work at reducing the amount of materials used in
manufacture and packaging, selecting energy efficient and sustainable options where possible.

The Juicy Salif lemon squeezer, by Phillipe Starck

Chapter 43 The work of others 253

 Drawing techniques

CHAPTER 45 COMMUNICATION OF DESIGN IDEAS

There are three main types of 3D drawing styles that you are likely to use within your portfolio.
These vary in their level of complexity to produce and have different advantages
and disadvantages.
Oblique projection uses a 45-degree angle
to draw lines that represent the depth of the
side (end) and the top (plan) of the drawing.
The front of the drawing is face on to the
viewer which actually creates a visual lie. It
is impossible to see the front of a cuboid
straight on and also see the side and the top.
Oblique projection is a technique that can 45° Ø53
get an idea across quickly and simply. It
can be very useful in the early stages of
developing ideas.
Isometric projection uses a 30-degree
angle and is much more realistic. For a basic 32
15
5
cuboid, all of the height, width and depth
lines follow the 30-degree isometric grid
lines. Dimensioning can be done accurately
and, by using simple techniques, complex
shapes can be constructed or carved out of
the main cuboid.
Isometric projection is very good for
45° Ø53
6

62
design ideas that have a geometric shape.
With some practice, it is also good to 32

convey ideas quickly and to show where

components and parts fit in relation 30° 30°
32 to others. R12
15
5
Two-point perspective uses two
vanishing points that are set to the outer
edges of the page. The main construction
lines that create the width and depth are all
projected back to the two
vanishing points.
Two-point perspective gives the most
62

realistic view as it emulates the way the

32
viewer’s eye sees perspective, meaning that
things get smaller the further away they are.
30° 30°
It is great technique to give a realistic view
R12
of what a product or prototype might look
like. It is not so easy to add dimensions, in
comparison to isometric projection.

Which 3D drawing technique would you choose if you were intending to make an
Q4 accurate prototype of a product?

Chapter 45 Communication of design ideas and prototype development 261

 SECTION 7 MAKING PRINCIPLES
Chapter 48 – M
 aterial management and
marking out
Objectives
• Understand how effective design planning can minimise waste
• Be aware of how design adaptations and use of tessellation can save time and materials
• Understand how to calculate the surface area and quantity of required materials
• Understand the value of using measurement and marking out to create an accurate and
quality prototype
• Understand the use of datum points and coordinates
• Be able to recognise and characterise the appropriate tools and methods to mark out a range
of materials to create prototypes

Planning
The key to material management is to plan ahead. Working out the best way to fit the required
parts of a product onto the material efficiently is not as straightforward as one might imagine.
Material tends to come in specific sizes, depending on the type of material. Papers and boards
come in ‘A series’ sizes, for example A4 sheets are 210mm x 297mm. These A series sizes
are all rectangular, so if you wanted to cut a square shaped section from the sheet you would
automatically have waste. However, if you wanted a number of identical squares you could get a
much larger sheet and divide it up, producing less waste than using a number of smaller sheets.

7 Q1
Using the standard A series paper sizes (covered in Chapter 25) answer the
following questions.
(a)  Calculate the waste if you cut a 210mm square from a sheet of A4 paper.
(b) Calculate the waste if you cut a 195mm square from a sheet of A4 paper.
(c) Which larger size of A series paper would be the most economical to use if you
wanted to produce 66 squares at 195mm x 195mm?

As the majority of materials come in rectangular or other specific shapes and sizes there are
a few basic rules to follow in order to use materials efficiently. For example, starting from the
most effective edge or corner of a sheet and not somewhere in the middle, means that the
material remaining is as large as possible and is in its most useable form. If cutting discs from a
rectangular sheet consider the following options:

Waste Waste
piece A piece B

Waste A and B
in one piece

Extra circles cut from otherwise wasted material

276 Section 7 Making principles

 AQA GCSE (9-1) DESIGN AND TECHNOLOGY INDEX
Index
0–9 belt 76 card based food packaging 142
2D sketching 259 bending 104, 108 carding 201
3D printing 192 wood 157 carton board 132, 142
3D sketching 259 bespoke 124, 207 cartridge paper 81
bias 201, 207 casing 224
billet 172 casting 173
A binding 140 metal 177
ABS 184 biofuel 36, 116 polymer resin 193
absorbency 80 biomass 36 cast iron 88
acrylic 92, 203 Biopol 43 cedar 86
additives bio-polymers 180, 183 cellulose fibres 130
paper and board 145 bitumen 180 Chanel, Coco 246
plastic 181 blackening 179 charts 241
textiles 199 blanking 175 children's wooden toys 159
Adidas 244 blast furnace 163 chipboard 87
aesthetics 266 blasting 179 circuit boards 216
air-drying 147 bleed proof paper 81 circular cam 74
Alessi 248, 249, 253 blended fibres 96 climate change 118
alkaline cells 41 block and tackle 76 closed loop 60
Allen key 152 blockboard 149 CMOS 220
allowances 275 blow moulding 196 CMYK 143
alloy 45, 88, 90, 164 boards 81, 149 CNC 22, 216
aluminium 48, 90, 164, 217 fibreboard 82 coated metals 179, 217
ore 88 manufactured 87, 148 coal 33
analogue 64 bolts 168 cog 38, 76
analysis of data 241 bonded fabric 97 collaboration 254
anatomy 240 borehole 116 colour bars 145

I animal skins 199

annealing 175
bowing 147
brass 90
colour printing 143
combing 201
communication 259
annotation 262 Braun 250
anodising 179, 217 brazing 174 components 220
anthropometrics 239, 240 breadboard 265 composite materials 55, 106
Apple 250 Breuer, Marcel 247 compression 39, 103
appliances 228 broadband 45 manufactured board 148
aramids 57, 200 buildings 4 conductive fabrics 57
architecture 247 bulk buying 223 coniferous 84
architrave 152 button 205 continuous improvement 11
Art Deco 248 buzzer 63 continuous production 126
Art Nouveau 248 conversion 147
ash 85 cooking utensils 176
astable 65 C Coolmorph 48, 184
CAD 3, 21, 22, 192, 212, 265 cooperative 6
automation 2, 3, 21
calendering 131, 215 copper 90
robotics 3
calico 96 clad circuit board 216
cam 74 corn starch 43
B eccentric 74 corrosion 285
Bakelite 93 heart shaped 74 corrugated card 82
balsa 85 pear 74 cotton 94, 200
batch production 125 snail 74 cotton paper 81
batik 206 CAM 21, 23, 213 counters 67
batteries camshaft 74 countersink 152
alkaline 41 canting 206 cracking 181
disposal 42 capacitor 222 crank 74
rechargeable 41 carbon 88, 111 crank and slider 73
Bauxite 88, 164 dioxide 111 creasing 136
Beck, Harry 245 footprint 111, 120 crop marks 145
beech 85 offsetting 12 crowdfunding 5
beliefs 17 carbon-fibre reinforced plastic (CRP) crude oil 180
bell crank 73 56 cupping 147

290 AQA GCSE (9-1) Design and Technology Index

current rating 220 E client 238

AQA GCSE (9-1) DESIGN AND TECHNOLOGY INDEX

cutlines 110 E12 resistor series 222 loop 61
cutting eccentric cam 74 responding to 267
efficiently 276 economic challenge 244 felling 84
fabric 206 efficient working 11 felt 207
papers and boards 135 elastane 95, 203 felting 97
PCBs 225 elasticity 80 ferrous 88
wood 155 elderly 18 fibre optics 45
electrical conductivity 80 fibres
electrical fittings 181, 194 filament 200
D electroless plating 198 staple 200
data electrolysis 88, 164 finite resources 7, 113
primary 238 electroplating 179, 198 fire resistant 58
secondary 239 embossing first angle projection 263
sheet 283 metal sheet 175 first order lever 72
datum 278 paper 146 flame
debossing 146 ply form 133 retardants 58, 202
deciduous 84 emerging technologies 2 hardening 233
decisions 68 emissions 117 resistant 58
deforestation 85, 114, 150 encapsulation 138, 146
flat follower 75
density 80 end of life disposal 28
flat pack furniture 159
depth stop 178 energy
desertification 115, 150 flax 200, 203
compressed 38
design fleece 200
electrical 32
brief 242, 265 flexibility 107
generation 32
fixation 256 flocking 198
hydroelectric 35
for maintenance 27 flow soldering 230
kinetic 40
specification 242 mechanical 38 flyer 141
De Stijl 248 nuclear 34, 37 flywheel 40
destructive testing 258 potential 38, 40 FMS 23
developing times renewable 32, 34 foam core board 83
PCB manufacture 232
die cutting 137, 142
solar 35
storage 38
focus group 239
foil lined board 82
folding 108
I
digital 64 tidal 35
DIL 220 environment 9 paper 136
Digital Light Processing 192 environmental challenge 244 follower 74
dimensional accuracy epoxy resin 93 footprint
depth stop 178 equilibrium 71 carbon 111, 120
go/no go fixture 161 ergonomics 240 ecological 112
laser settings 197 etching 198 social 112
repeating print 214 circuit board 216 forces 102
DIP 220 PCB manufacture 232 bending 104
dip coating 179 times 232 compression 103
disabled 18 e-textiles 57 shear 104
domestic appliances 228 euroslot 142 tension 102
dowel 152 evaluation 258, 267 torsion 103
drag 173 evergreen 84 former 157, 207
drape forming 207 exploded drawing 262 fossil fuels 33
drawing 259 extraction 163 Foster, Norman 247
drilling extrusion 196 fracking 33
for oil 116 fractional distillation 180
metal 170 F freehand sketching 257, 259
PCBs 224 fabric interfacing 108 frequency 67
plastics 187 Fairtrade 6, 113 frosting 198
wood 154 faiths 17 FSC 150
dual in-line package 220 farming 116 fulcrum 71
ductility 80 fashion 15, 26 functionality 266
duplex board 82 fasteners fur 200
duralumin 164 paper and board 139 furnace 88, 163
dyeing fabric 213 textiles 106, 205 furnishings 211
dynamic load 102 Favrile glasswork 249 Fused Deposition Modelling 192
Dyson 229, 250 feedback fusibility 80

AQA GCSE (9-1) Design and Technology Index 291

 AQA GCSE (9-1) DESIGN AND TECHNOLOGY INDEX G innovation 266 lever 71
galvanizing 179 input components 62 classes 72
Gap 251 integrated circuit 64, 220 Life Cycle Assessment 8, 11, 27,
gas 33 interfacing 97, 107 117, 183
gathering 209 fusible 108 line bending 190
gauge 167, 185 sew-in 108 linen 203
gears 38 interlocking 98 linkage 72
driven 76 interviews 239, 254 bell crank 73
idler 76 intuitive design 256 crank and slider 73
train 75 investigation 238, 252 parallel motion 73
generator 32, 37, 40 iron ore 163 push/pull 73
glass reinforced plastic (GRP) 55 ISO 134 reverse motion 73
global warming 11, 150 isometric projection 261 treadle 74
go/no go 161 Issigonis, Alec 249 lithography 144
Gore-Tex 56 iterative design 238, 255, 256 litmus paper 54
granules London Underground 245
polymer 186 low carbon steel 89
graphene 14, 46 J Low density Polyethylene 92
graphic design 245 jig 125, 279 lubrication 233
graphite 46 job roles 15 LunaTik 5
graphs 241 joint 158 LYCRA 95
greenhouse 111 joint overlap 275
green timber 147 Juicy Salif 253
grid paper 82 Just In Time 11, 24 M
gsm 134 machine screws 168, 186
Mackintosh, Charles Rennie 248
K magnitude 71
H Kaizen 11 mahogany 85
hand tools 176 Kamikatsu 123 malleability 80
hank 204 kerf 155 manufactured board 149, 160
hardboard 149 laser cutting 197 manufactured timber 84

I
hardening 177 Kevlar 57, 58, 200 manufacturing specification 242
hardness 80 kiln-drying 147 market
hardwood 84 kinetic energy 40 pull 14
Harry Thaler 109 Kinetic Energy Recovery System 40 research 25, 239
harvesting 114 Kirigami 137 share 26
headstock 172 knife edged follower 75 testing 258
health and safety 282 marketability 267
knitted yarns 98
Health and Safety at Work Act 113 marking out 135, 277, 278
knock-down fittings 153
Health and Safety Executive 113 mass production 126
heart shaped cam 74 material
hertz 67 L costing 264
hides 199 lacquer 179 management 276
hierarchy of sustainability 119 laminating 107, 138 properties 80
high density polyethylene 92 paper 146 protection 284
High Impact Polystyrene 92 plastics 190 requirements 277
high speed steel 90 textiles 205 mathematical modelling 264
hinges wood 148, 157 McQueen, Alexander 246
plastic 187 lamp 63 MDF 87, 148
wood 154 landfill 123 flexible 44
Honda ASIMO 255 larch 86 measurements
housing 224 Laser cutter 197 human 240
hydraulics 39 laser sintering 192 measuring 277
hydrocarbons 181 lathe 157 mechanical advantage 71
hydroelectric 35 CNC 160, 177 mechanical devices 70
hydrographic printing 198 metals 172 melamine formaldehyde 93
layout paper 82 metal foam 48
I LCD 46 metals 88
inclusive design 18 LDR 62, 69 ferrous 88
industrial design 249 lead time 125 non-ferrous 89
industrial revolution 2 leaflet 141 microcontroller 64, 68, 223
injection moulding 195 lean manufacturing 11, 24 microencapsulation 59
ink jet card 83 LED 63, 68 microfibres 59

292 AQA GCSE (9-1) Design and Technology Index

microns 134 orthographic projection 263 planned obsolescence 25, 122

AQA GCSE (9-1) DESIGN AND TECHNOLOGY INDEX

MIG 174 oscillating plastics
mild steel 88 motion 70 thermoforming 92
milling 173 output 66 thermosetting 93
CNC 177 output 63 pleating 209
metals 177 output components 63 ply
Mini 249 outsourcing 283 fabric 205
miniaturisation 120, 228 oxidisation 89, 285 paper 133
minimum wage 113 plywood 87
mining 115, 163 pneumatics 39
model construction 265 P POÄNG chair 107
modelling 257, 264 painting 162, 286 polarity 61
breadboard 265 plastic 198 pole 61
CAD 265 Pantone 144 polishing
card 265 paper 81 metals 179
toile 265 paper sizes 134 polymers 189
modifications 267 parallel motion 73 pollution 11, 34
monomers 180 Paris agreement 118 atmospheric 118
monostable 65 parison 196 oceanic 118
Morris, William 246 Parley 244 polyamide 95, 200
motor vehicles 229 patent 5 poly-cotton 96
mouldings 152 patina 89 polyester 95
mountboard 132 pattern 125, 279 polyester resin 93
movement 70 fabric alignment 214 polyethylene terephthalate 92
linear 70 metal casting 173 polyhydroxy-butyrate 43
oscillating 70 repeat 279 polylactic acid 43, 184
reciprocating 70 PCB 216 polymerisation 180
rotary 70 PCB lacquering 233 polymers
muscle wire 51 PCL 184 thermoforming 91
muslin 96 pear cam 74 thermosetting 91
PEFC 150 polymer seating 194
N
nails 153
people 13
percentiles 241
perforate 135
Polymorph 48, 184
polypropylene 92
polyvinyl chloride 92
I
nanomaterials 47 peripheral interface controller 65, 223 poplin 96
nanotechnology 47 perspective 261 portfolio 259
natural fibres 94 PH 54 potential energy 40
natural resources 7 PHB 43, 184 powder coating 179
nesting 277 phenol formaldehyde 93 power generation 32
net 110, 137 photochromic Pozidriv 152
newsprint 132 particles 50 PPE 282, 287
nimby 34 pigments 50 presentation of data 241
Nitinol 51 photoresist PCB 217, 231 Pressed chair 109
Nomex 58, 200 PIC 65, 223 pressing 175
non-destructive testing 257 pick and place assembly 230 press stud 205
non-ferrous 88, 89 piezoelectric 53 pressure switch 62
non-finite resources 7 pig iron 164 Primark 251
non-woven textiles 97
pigments primary data 238
nuclear 34, 37
photochromic 50 printing 145
nuts 168
thermochromic 49 3D 192
nylon 95, 200
pine 86 discharge 214
polyamide 184
pins 153, 280 fabric 213
pipeline 116 heat transfer 198, 215
O piping 210 hydrographic 198
oak 85 fabric trim 210 mordant 214
oblique projection 261 metal tube 166 resist 214
offset lithography 144 polymer tube 185 processing yarn 200
oil 33 pitch 167 product analysis 239
one-off production 124 pivot 71 production
open loop 60 PLA 43, 184 batch 125
ore 88, 163 place of work 4 continuous 126
oriented strand board 149 planed all round 147, 151 mass 126
origami 137 planks 147 one-off 124

AQA GCSE (9-1) Design and Technology Index 293

 AQA GCSE (9-1) DESIGN AND TECHNOLOGY INDEX product miles 117 resources silk 95
properties finite 7, 33 sinkholes 115
physical 80 natural 9 SI units 277
working 80 non-finite 7 six Rs 119
prototype 4, 124, 192, 212, 265, rethink 120 sizing 130, 145
267 reusable 28 sketching 257
provenance 150 reuse 121 slag 163
pulley 76 reverse motion 73 slash and burn 114
block and tackle 76 RGB 143 slivers 201
pulp 130 Rietveld, Gerrit 248 smart materials 49
Puma 20 rip-stop 96 snail cam 74
punching 175 risk assessment 283 social
push/pull 73 rivet 106, 168 challenge 244
push to break 62 robotics 3, 23 footprint 112
push to make 62 roll media 5, 6
PVC fabric 205 paper 133 society 18
roller follower 75 softwood 84, 86, 150
rollers 131 solar 35
Q Rossi, Aldo 248 soldering 225, 226
quality control rot 123, 285 solid white board 83
electronics 231 rotary systems 74 solvent cement 193
metals 178 rotational moulding 195 Sottsass, Ettore 248
papers and boards 144 rough sawn 147, 151 sources
plastics 197 routing 160 metals 163
textiles 214 rubberising 198 papers and boards 130
wood 161 rust 179, 285 polymers 180
Quant, Mary 246
textiles 199
Quantum Tunnelling Composite 52
timber 147
quartz 53 S
speaker 63
quenching 177 safe working conditions 113
specification 242
questionnaires 239, 254 sanding
spinning 200

I
quilting 210 metals 171
sportswear 211
QWERTY 240 plastics 189
spot varnishing 146
wood 156
spruce 86
sawing
R metals 171 stabilisers 182
radioactive 34, 37 plastics 188 stainless steel 90
rag paper 81 wood 155 stain protection 215
recordings 264 scales of production 124 standard mouldings 152
recover 123 schematics 262 staple fibres 200
recycle 28, 111, 122 score 110, 135 Starck, Philippe 245, 253
recycling screen printing 213 static load 102
batteries 219 screws 186 steam 32, 157
metals 165 machine 168 steel 88, 164, 176
paper 131 wood 152 stereolithography 192
PCBs 219 seals 140 stiffening 107
plastics 183 seam allowance 275 stiffness 104
primary 121 seasoning 147 stitching 208
secondary 121 secondary data 239 stock forms
tertiary 122 second order lever 72 metals 166
timber 87 sectional view 263 papers and boards 133
reduce 120 selection of materials 270 plastics 185
redundancy 223 self-healing polymers 52 textiles 204
reel 204 selvedge 96 timber 151
refining 164, 180 sensor 61 strength 80
refuse 119 sewing 208 stress 102, 240
registration marks 144 shale gas 33 stripboard 216
reinforcing 105 shape memory alloy 51 strut 103
religious groups 20 shear force 104 studding 166
renewable energy 34 shears 206 subsystems 60
repair 121 sheet subtasks 60
research 252 metal 167 surface
resin 193 paper 133 mining 115
resistors 221 plastic 182, 185 mount technology 230

294 AQA GCSE (9-1) Design and Technology Index

surface (cont.) tidal energy 35 V

AQA GCSE (9-1) DESIGN AND TECHNOLOGY INDEX

preparation 286 tie 103 vacuum forming 191
treatments 284 Tiffany, Louis Comfort 249 vanishing point 261
sustainability 7 TIG 174 varnish 162
metals 165 timber Velcro 205
papers and boards 131 conversion 147 veneer 87, 148
plastics 182 manufactured 84 verdigris 89
textiles 202 natural 84 vinyl decals 198
timber 150 timer virtual
switches 62 marketing 6
555 65
synthetic fibres 95 retail 6
tin 90
systems 60 voltage 220
tissue paper 132
approach 255
titanium 44, 48
closed loop 60
diagram 60, 262
tjanting 206 W
toggle switch 62 warp 96, 98, 201
open loop 60
toile 265 Wassily Chair 247
tolerance waste
T component 222 disposal 9
tailstock 172 material 161 nuclear 34
tallow 17 tools reduction 11
tanalising 161 marking and cutting out 279 wasting
tanning 199 specialist 281 metals 171
technical textiles 56 tool steel 89 plastics 189
technology wood 156
tooth pitch 155
emerging 2 wave soldering 231
torsion 103
technology push 13, 26 wax batik 206
Torx 152
tempering 177 weave
toughness 80
template 125, 279 plain 96, 201
tracing paper 82
Templier, Raymond 248 twill 201
tension 102 trademark 5 weaving
transportation 117

I
Tesla 229 commercial 212
tessellation 277 treadle linkage 74 webbing 107
testing 257 trends 15, 26 WEEE 123, 219
Tetra Pak 142 TTL 220 weft 96, 98, 201
textile design 246 turbines 32, 37 welding
textiles 94 turning 172 metals 174
animal-based natural fibres 95 metals 177 plastics 193
animal sources 199 wood 157, 160 Westwood, Vivienne 247
chemical sources 200 twill weave 201 wind 34
felt 97 twisting 147, 201 wooden toys 159
mixed fibres 96 two-point perspective 261 wood joints 158
plant-based natural fibres 94 wood pulp 81
raw materials 199 woodscrews 152
synthetic fibres 95
U wool 95
vegetable sources 200 Under Armour 251 working conditions 113
woven 96 underground mining 115 working drawing 263
thermal conductivity 80 upcycle 121
thermistor 62 updates 26
upgrades 26 Y
thermochromic pigments 49
urea formaldehyde 93, 194 yarn 200, 201, 204
thermoforming plastics 91, 181
thermosetting plastics 91, 181 user-centred design 254
third angle projection 263 UV degradation 285 Z
third order lever 72 UV exposure Zara 251
thread 167 PCB manufacture 232 zinc 90
throw 61 UV varnishing 146 zip 205

AQA GCSE (9-1) Design and Technology Index 295

AQA GCSE 8552 (9-1) Specification map

3.1 Core technical principles

Unit 5D
Unit 5C
Unit 5A

Unit 5B

Unit 5E

Unit 5F
Unit 4

Unit 6
Unit 2

Unit 3

Unit 7
Unit 1
New and emerging technologies
3.1.1 New and emerging technologies 
Energy, materials, systems and devices
3.1.2 Energy storage and generation 
3.1.3 Developments in new materials 
3.1.4 Systems approach to designing 
3.1.5 Mechanical devices 
Materials and their working properties 
3.1.6 Materials and their working properties 

3.2 Specialist technical principles

Unit 5D
Unit 5C
Unit 5A

Unit 5B

Unit 5E

Unit 5F
Unit 4

Unit 6
Unit 2

Unit 3

Unit 7
Unit 1

Common specialist technical principles

3.2.2 Forces and stresses 

3.2.3 Ecological and social footprint 
3.2.7 Scales of production 
Specialist material areas
3.2.1 Selection of materials or components Materials covered in Units 5A-F

3.2.4 Sources and origins  

Papers and boards
 
Timber based materials
3.2.5 Using and working with materials  
Metal based materials
3.2.6 Stock forms, types and sizes  
Polymers
 
Textile based materials
3.2.8 Specialist techniques and processes
 
Electronic and
3.2.9 Surface treatments and finishes mechanical systems

The content in each section of the textbook covers the same specification points as the corresponding downloadable
teaching unit, e.g. Section 1 complements Unit 1.
 3.3 Designing and making principles

Unit 5D
Unit 5C
Unit 5A

Unit 5B

Unit 5E

Unit 5F
Unit 4

Unit 6
Unit 2

Unit 3

Unit 7
Unit 1
Designing principles
3.3.1 Investigation, primary and secondary data 
3.3.2 Environmental, social and economic challenge 
3.3.3 The work of others 
3.3.4 Design strategies 
3.3.5 Communication of design ideas 
3.3.6 Prototype development 
Making principles
3.3.7 Selection of materials and components 
3.3.8 Tolerances 
3.3.9 Material management 
3.3.10 Specialist tools and equipment 
3.3.11 Specialist techniques and processes 
AQA GCSE (9-1)
Design and
Technology
This book provides detailed About the author Cover picture:
and concise coverage of all the Mike Ross has 16 years’ ‘Stony Sunrise’
topics covered in the new AQA experience teaching Design Paper and acrylic on masonite,
8552 Design and Technology and Technology in secondary 90x45x3cm © Amy Genser 2015
(9-1) specification, written schools in the state and private www.nummer40.com
and presented in a way that is sectors. He has been Head
accessible to teenagers and of Technology for 13 years
easy to teach from. It can be and has taught and overseen
used both as a course text and all Design and Technology
as a revision guide for students disciplines at GCSE as well as A
nearing the end of their course. level Product Design for both
Resistant Materials and Graphics
It is divided into 12 sections specialisms. He has also taught This book has been
covering every element of Electronics at GCSE and A approved by AQA.
the specification. Sections level. He has a BEd degree
5A to 5F of the textbook in Secondary Design and
cover each of the specialist Technology Teaching.
technical areas. These sections
would complement practical
classroom experience.
Each chapter contains
relevant questions and exercises
from past papers, which can be
set as homework. Answers to all
these are available to teachers
only, in a Teachers Supplement
which can be ordered from
our website
www.pgonline.co.uk

ISBN: 978-1-910523-10-0