Embedded Files
hl WEEK
hl WEEK
Lesson 1: Structural systems (design and test a bridge) document
Lesson 2: Electronic systems (fly swatter teardown and analysis) document
Lesson 3: Mechanical systems (assemble mechanical movements and calculate gear ratio etc) document
Lesson 4: Product Analysis (assemble and disassemble): IKEA LÄTT Chair + Modular Kibu Wired Headphones document.
Finite Element Analysis Lesson
Finite Element Analysis Lesson
This can be spready over 1-3 lessons. My students enjoyed the experiments
1 lesson - Students follow the Youtube Tutorial and follow the process on their bracket. Download similar bracket as per the YT video.
2-3 lessons - 3D print a range of brackets (download brackets 3MF files, Autodesk Fusion File).
3D print files with different infill % (optional e.g. 20% & 50%). Students calculate infill % by comparing slicing software and weighing scale
Students drill a pilot hole and screw bracket onto a sheet of ply/MDF
Students apply weights (1kg at a time) until bracket fails
Students records data and results on worksheet
Safety: Risk Assessment, googles
Materials/Equipment: 3D printer, plywood/MDF, drill bit (3mm), CAD software
Extension: Students design a bracket that would be better than examples
Curriculum Links: A2.2.5, B2.2.4 & B3.2.2
3D printed brackets with different infill percentages
Students calculate infill percentage by weighing bracket and comparing it to slicing software
Students carry out experiements (destructive testing) until brackets fail/break
Students run simulations and compare results whilst testing
Product Teardown
Product Teardown
Students create a short Insta Reel/TikTok
Component Analysis (A3.3 – Mechanical Systems): The video breaks down internal elements like heating coils, springs, lever mechanisms, and switches - perfect for identifying types of motion and conversion mechanisms.
Materials & Processes (B3.2 – Structural Systems): Viewers can observe material choices (metal chassis, plastics, insulating coatings), joinery, and assembly methods - ideal for discussions on manufacturing and design for durability.
Functionality & Evaluation (B3.3 – Mechanical Application): As each component is demonstrated, it becomes clear how each serves a specific function (e.g., coil heating toasting, deflection spring for bread pop-up).
Production Insight (A4.1 – Manufacturing Techniques, HL): Students can reflect on design for manufacture - how part tolerances, modular assembly, and process selection impact product reliability and cost.
Sustainable Product Design
Sustainable Product Design
Covers key principles of sustainable product design, life-cycle thinking, and material choices that support C3.2 (Life-cycle Analysis) and C4.1 (Evaluating Sustainability & Impact).
Product Evolution Challenge: Bicycle
Product Evolution Challenge: Bicycle
Highlights evolution of structural systems, materials (wood to metal to composites), and design aesthetics.
Useful for discussing A3.2 (Structural Systems) and B3.2 (Material/Process Selection) as you analyze historical advancements.
Sparks discussion on functionality, usability, and future improvements.
Product Evolution Challenge: Telephone
Product Evolution Challenge: Telephone
Clearly demonstrates design transformation - materials, miniaturization, user interaction.
Connects to C3.2 (Life-cycle & Sustainability) by reflecting on obsolescence and technological ethics.
teardown / reverse engineering challenge
teardown / reverse engineering challenge
Disassembly: Clearly shows step-by-step taking apart of a common electric sharpener, perfect for observing construction techniques and joinery.
Component Analysis: Highlights key parts (motor, gears, housing, shavings container) - ideal for discussion on materials, mechanisms, and manufacturing processes (A3.3 / B3.2).
Design Evaluation: Lets students identify potential issues (e.g., jamming, ease of cleaning) to inspire focused redesign efforts (accessibility, sustainability etc.).
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