Design and Technology – Resistant Materials

The best way to predict the future is to design it” — Buckminster Fuller

At Thomas Mills High School and Sixth Form in year 7 and 8 pupils complete a rotation of subject areas including Resistant Materials, Food and Nutrition, Computing and Information Technology, each rotation lasts 8 to 9 weeks.

In Resistant materials we focus in introducing the following concepts of design and technology:

  1. Creative Problem Solving — Pupils learn how to come up with ideas and design solutions to real-world problems, thinking about what people need and want.
  2. Practical Skills — They get hands-on experience using tools and machines (like saws, drills, and even laser cutters or 3D printers) to build their designs.
  3. Understanding Materials — They explore the properties of different types of wood and other materials—learning which are best for different jobs and why.
  4. Thinking About the Bigger Picture — Pupils consider how their designs affect the environment, society, and people’s lives. They learn to make responsible and sustainable choices.
  5. Using Technology — They use computer-aided design (CAD) software to bring their ideas to life digitally before making them physically.
  6. Evaluating and Improving — They test their ideas, get feedback, and learn how to improve their designs—just like real designers and engineers do.

Key Stage 3

 

 
 

 

In Year 7 our focus the introduction of designing and making skills through the design and manufacture of a wooden puzzle and a metal key fob. Pupils will also start to develop their sketching skills with different 3D drawing styles.

8 week rotation

Practical work
Wooden puzzle
Metal key fob

Sketching
One Point Perspective and Isometric drawing

Knowledge:

Pupils will be introduced to a variety of tools and machines through two design and make projects. They will use wood and metal to experience working with different material types. They will learn how to mark out, cut, file and sand and join materials together.

Pupils will learn about health and safety in the workshop.

We will introduce sketching skills including one point perspective and Isometric drawing.

Skills:

Manufacturing – Pupils will learn the following skills:

Marking out using steel rule

Cutting out using coping saw, scroll saw, junior hacksaw and tin snips

Sanding/filing using cork block and glasspaper, files and disc sander

Joining materials using wood glue

Staining timber using wood dye

Sketching – Pupils will begin developing their 3D sketching skills with different styles including one point perspective and isometric.

Evaluating – Pupils will evaluate their making by looking at what went well and what could be improved in the future.

Useful Links

One point perspective

BBC Bitesize – Timbers
https://www.bbc.co.uk/bitesize/guides/zjgyb82/revision/3

Assessments:

There are three assessments over the 8 week rotation, the first is the design booklet that pupils complete over the 8 weeks and includes homework and examples of sketching and their evaluation. The second assessment come from the puzzle and key fob that they make. The third assessment is an end of unit test that recalls their knowledge from the resistant materials rotation.

Assessment 1:  Booklet – Pupils will complete sections of the booklet each week.
Assessment 2:  Practical work – Pupils will be assessed on the puzzle and key fob they have manufactured.
Assessment 3:  End of unit test – Recall of knowledge assessment

 

 
 

 

In Year 8 our focus the development of designing and making skills through the design and manufacture of a wooden storage box. They will personalise their box with a pewter handle and Jesomite top. Pupils will also develop their sketching skills with different 3D drawing styles.

8 week rotation

Practical work
Wooden storage box

Sketching
Two Point Perspective and Isometric drawing

Knowledge:

Pupils will create a pine storage box, they will learn how to use different materials such as Pewter and Jesmonite. We will focus on creating a quality finish and how to sand timber properly. Pupils will learn about casting metals as we create the pewter handle for the storage box. Pupils will develop the sketching skills they learnt in Year 7 with more advanced isometric sketching and the introduction of 2 point perspective.

Skills:

Manufacturing – Pupils will apply the following skills:

Marking out using steel rule and try square

Cutting out using tenon saw.

Sanding/filing using a disc sander, cork block, glasspaper and files

Joining materials using wood glue, dowels and nuts and bolts

Composite materials – Jemonite design for the top of the box.

Sketching – Pupils will develop their isometric sketching skills and will be introduced to 2 point perspective.

Evaluating – Pupils will evaluate their making by looking at what went well and what could be improved in the future.

Useful Links

Two point perspective

Jesmonite

BBC Bitesize – Timbers
https://www.bbc.co.uk/bitesize/guides/zjgyb82/revision/3

Assessments:

There are three assessments over the 8 week rotation, the first is the design booklet that pupils complete over the 8 weeks and includes homework and examples of sketching and their evaluation. The second assessment come from the pine storage box that they make. The third assessment is an end of unit test that recalls their knowledge from the resistant materials rotation.

Assessment 1:  Booklet – Pupils will complete sections of the booklet each week.
Assessment 2:  Practical work – Pupils will be assessed on the pine storage box they have manufactured.
Assessment 3:  End of unit test – Recall of knowledge assessment

The course is assessed as 50% written exam paper (1hr 45mins) where pupils are tested on their knowledge of materials, design, and making. The other 50% comprises of their Project which is a design and make task based on a real challenge set by the exam board.

Our aim for Y9 is to build on the practical work skills that have been introduced from KS3 Resistant Materials, this will be achieved through mini projects throughout the year. The mini projects also focus developing pupils sketching (2D and 3D), modelling and evaluating skills. We also teach the ‘Timbers’ specialism area of the course so that pupils understand the materials they will be using and use this knowledge in their design work.

Term 1

Design and make
Tote Box Project

Theory
Unit 7 — Timbers

Knowledge:

During Year 9 we focus on the ‘Timbers’ specialism part of the specification as this will allow pupils to understand the key materials they will be using.

We start by building on KS3 knowledge and developing learning about natural and manufactured timbers including hardwoods and softwoods. We also study the ecological and social impact of the timber trade and how we can make it sustainable.

Students will develop their designing skills both on paper with different presentation skills and on computers using 3D CAD packages.

We will practice and develop their manufacturing skills with exploring different jointing methods and then students will design and make a wooden tote box. Once manufactured and tested students will develop their evaluation skills.

Skills:

During this term pupils will start to develop the following skills:

Working with materials – understanding the working properties and limitations of different materials

Joining materials – to be able to create a range of basic wood joints – dowelled butt joint, lap joint and finger joint.

Sketching – To be able to sketch in isometric and two-point perspective

CAD – To start to develop CAD skills and be able to use Sketchup for Web to be able to draw a modern style house.

Evaluate – To be able to reflect on your tote box design and draw out the positive points and be able to suggest some improvements.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

2 point perspective

Sketchup for web
https://www.sketchup.com/en/products/sketchup-for-web?srsltid=AfmBOopbNhEARPmhm9vhTuepI-wMG1QTqJZ0G4uhPYbSYtIR4VwFbYLw

How to evaluate
https://technologystudent.com/despro_flsh/evalprod1.html#google_vignette

Assessments:

There are four core assessments this term. One is an online ‘Timbers’ specialism assessed through the Seneca learning platform. The second is the research, design and development and evaluation of their tote box, this will be a mixture of hand sketches and computer-based work. The third assessment is of the practical task, a pine tote box. The final assessment is an end of term written assessment covering the learning of the term.

Autumn 1:  Project paperwork – Tote box project research, design, development and evaluation
Autumn 2:  Practical work – Pine tote box
Autumn 3:  3D CAD – Modern house design using SketchUp for Web
Autumn 4:  Written assessment – end of term test – timbers pt 1

 


 

Term 2

Design and make
LED Lamp project

Theory
Unit 1 — Metals and Electronics
Unit 7 — Timbers

Knowledge:

Durning this term we focus on a mini project based around the design and manufacture of an LED Lamp. Pupils will focus on creating ideas, design development and modelling of design ideas in card before manufacture in sheet aluminium. They will also learn how to solder and create a simple lighting circuit. We will continue with some of the specialist timbers knowledge but also focus on the metals and electronics areas from the core knowledge. Pupils will also research and present work on the past and present designers and companies we are required to study.

Skills:

This term focusing on the following skills:

Working with materials – understanding the working properties of metals and electronics, pupils will be able to shape aluminium and be able to solder simple circuits on a PCB.

Sketching – To be able to sketch freehand in isometric and add shading/rendering to design ideas, to be able to produce a working drawing of their design with dimensions.

Research – To be able to find and present relevant information on past and present designers and companies.

Evaluate – To be able to reflect on your LED lamp design and draw out the positive points and be able to suggest some improvements.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

Technology student Metals and electronics
https://technologystudent.com/designpro/metals1.htm
https://technologystudent.com/pcb/solder1.htm

Assessments:

There are four core assessments this term. One is an online core knowledge metals and electronics assessed through the Seneca learning platform. The second is the design ideas and development of their LED Lamp (paperwork). The third assessment is of the practical task, LED Lamp (practical work). The final assessment is a research task on the work of past and present designers and companies.

Spring 1: Seneca Knowledge assessment – Metals and Electronics
Spring 2: Design portfolio – Design and development of LED lamp
Spring 3: Practical work – Manufacture of LED lamp
Spring 4: Research presentation – The work of past and present designers and companies

 


 

Term 3

Design and make
Footstall project

Theory
Unit 7 — Timbers

Knowledge:

This term we complete the theory on “timbers” focusing on the following topics:

Forces and stresses

Stock forms

Scales of production

Tools and processes

Surface treatments and finishes

Pupils will produce their most demanding product to date, a pine footstall using mortise and tenon joints. We will also continue to develop both sketching and CAD presentation skills.

Skills:

Manufacture – Pupils will be able to use mortise machine, bobbin sander and biscuit cutter.

Final finish – Pupils will apply knowledge of sanding and sealing timber to product a high-quality lasting finish to their footstool.

Working drawings – Pupils will use working drawings with dimensions to mark out and produce their footstall.

Sketching presentation – Pupils will be able to render designs to represent different material types in both CAD and on paper.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

BBC Bitesize Edexcel – timbers
https://www.bbc.co.uk/bitesize/guides/zhyny4j/revision/1

Technology Student
https://www.technologystudent.com/

Assessments:

There are four core assessments this term. One is a formal assessment of the theory covered this year and will uses exam style questions.  The second assessment will be on the design pages of the footstool. The third assessment is the marking of the practical work for the footstool. The fourth assessment will be via Seneca and will focus on the ‘Timbers’ knowledge.

Summer 1: Y9 Assessment – Formal assessment on theory and skills covered this year
Summer 2: Sketching and drawing – Rendered 3D designs of footstool
Summer 3: Practical work – Manufacture of footstool
Summer 4: Online Timbers knowledge assessment – Seneca test on timbers.

Key Stage 4

 

 
 

 

The course is assessed as 50% written exam paper (1hr 45mins) where pupils are tested on their knowledge of materials, design, and making. The other 50% comprises of their Project which is a design and make task based on a real challenge set by the exam board.

Our aim for Y10 is to build further on the practical work skills that we have been developing in Year 9 Resistant Materials, this will be achieved through mini projects throughout the year. The mini projects also focus getting the pupils ready for their NEA coursework. We also teach the core theory of the course. In the June of Y10 the exam board release the themes for the pupils NEA coursework which we start straight away, this is worth 50% of their final grade and will be completed before easter of Year 11.

Term 1

Design and make
Mobile phone holder

Theory
Unit 1 – Core

Knowledge:

The first term of Year 10 shifts the theory focus from the ‘timbers’ specialism we were studying in Year 9 to the “core” content we will cover the following topics:

New and Emerging technologies

Energy generation and storage

Modern and smart materials, composite materials and technical textiles

Mechanical devices

We will also further develop design presentation skills through a mini project where we research and develop a solution for a mobile phone holder. This project helps to develop skills that will be used in the NEA coursework later in the year.

Skills:

During this term pupils will refine the following skills:

Working with materials – understanding the working properties and limitations of different materials

Sketching – To be able to present design ideas to a high standard

CAD – To refine CAD skills and be able to use Sketchup for Web to create dimensionally accurate designs

Manufacture – To be able to produce a high quality product that uses the skills learnt from Year 9. The phone holder should be dimensionally accuracy and have a finish that will protect and enhance the aesthetic appearance of the product.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

Sketchup for web
https://www.sketchup.com/en/products/sketchup-for-web?srsltid=AfmBOopbNhEARPmhm9vhTuepI-wMG1QTqJZ0G4uhPYbSYtIR4VwFbYLw

BBC Bitesize – Edexcel core
https://www.bbc.co.uk/bitesize/examspecs/zb6h92p

Assessments:

There are four core assessments this term. One is an online core theory assessed through the Seneca learning platform. The second is the research, design and development and evaluation of their mobile phone holder, this will be a mixture of hand sketches and computer-based work. The third assessment is of the practical task, mobile phone holder. The final assessment this term will be a formal test paper using past paper questions.

Autumn 1:  Online assessment using Seneca – Core knowledge
Autumn 2:  NEA project work – Research and design paperwork for the mobile phone holder project
Autumn 3:  Practical work – Mobile phone holder
Autumn 4:  Written assessment – Y10 Autumn assessment (exam style questions)

 


 

Term 2

Design and make
Candle holder

Theory
Unit 1 – Core

Knowledge:

Durning this term we complete the last mini project before the final NEA coursework starts. We will be refining the research and development stages of the design process.

The “core” theory continues this term focusing on the following sections:

Papers and Boards

Polymers

Textiles

Contexts that inform design decisions

Environmental, social and economic challenges

We will also further develop our understanding of materials and processes through the manufacture of a candle holder.

Skills:

This term focusing on the following skills:

Research – be able perform research and present findings in the form of product analysis and inspiration boards.

Modelling – To be able to produce card models to develop a final design.

Drawing– To be able to present accurate working drawings with dimensions.

Manufacture – To be able to shape and join metals to create a candle holder.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

BBC Bitesize – Edexcel core
https://www.bbc.co.uk/bitesize/examspecs/zb6h92p

Assessments:

There are four core assessments this term. One is an online core knowledge assessed through the Seneca learning platform. The second is the design ideas and development of the candle holder (paperwork). The third assessment is of the practical task, Candle holder (practical work). The final assessment is the Year 10 spring assessment.

Spring 1:  Seneca Knowledge assessment – Core knowledge tests
Spring 2:  Design portfolio – Design and development of Candle holder using card models
Spring 3:  Practical work – Manufacture of Candle holder
Spring 4:  Trial exam – Spring assessment using past paper questions

 


 

Term 3

Design and make
Start of NEA coursework section 1.1

Theory
Unit 1- core

Knowledge:

This term we start the NEA coursework. The design themes are released on the 1st June. We also conclude the “core” theory focusing on the following topics

Design strategies

Developing and communicating design ideas.

Pupils will complete the following parts of their coursework

Investigation into NEA contexts

Choose context and link a client to it.

Product analysis

Mood board

Research into materials and tools available

Skills:

Investigate – Pupils will investigate the design themes and choose one for their project, they will present their investigations in their design portfolio.

Research – Pupils will research existing products that are related to their problem and carry out a product analysis

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

BBC Bitesize – Edexcel core
https://www.bbc.co.uk/bitesize/examspecs/zb6h92p

BBC Bitesize – NEA help
https://www.bbc.co.uk/bitesize/guides/zmshsrd/revision/1

NEA help guide on Teams in the files section.

Assessments:

There are four core assessments this term. One is an online core knowledge assessed through the Seneca learning platform. The second is a trial exam with past paper questions. The other two assessments are first couple of sections of the NEA coursework; this takes the form of a computer-based portfolio.

Summer 1: Online core assessment using Seneca
Summer 2: Trial Exam on all theory content
Summer 3: NEA coursework section 1.1 Investigation of design contexts
Summer 4: NEA coursework section 1.1 Research in existing products, tools and materials available

 

 
 

 

The course is assessed as 50% written exam paper (1hr 45mins) where pupils are tested on their knowledge of materials, design, and making. The other 50% comprises of their Project which is a design and make task based on a real challenge set by the exam board.

In Year 11 our focus is on the completion of the NEA coursework which is worth 50% of the final grade, this is made up of a design portfolio and the manufacture of a product. We also look at exam techniques and practice questions as well as revision for the final exam.

Term 1

NEA coursework
Section 1.1
Section 1.2
Section 2.1
Section 2.2
Section 2.3
Section 2.5

Theory
Unit 7 – Timbers revision

Knowledge:

The first term of Year 11 shifts the theory focus to the NEA coursework. We finish off the investigation and research of section 1.1 and then create a design specification and brief. Section 2 of the NEA is the creation of a range of possible design solutions that get narrowed down and developed to a final product.

We will also revise the ‘timbers’ theory work that was studied in Year 9.

Skills:

This term involves the application of the following skills:

Research/Investigating – Pupils will investigate potential solutions for their chosen design context

Presentation – Pupils will present their investigations in section 1.1 of their design portfolio.

Sketching/CAD – Pupils will present a range of solutions for their chosen context using a combination of hand sketching and CAD work.

Modelling – Pupils will use a variety of materials to model part or all of the final product to help aid the development of the design.

Reviewing/evaluating – Research and design ideas will be reviewed/evaluated as the project progresses taking into account the views of the end user/client.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

BBC Bitesize – Edexcel timbers
https://www.bbc.co.uk/bitesize/guides/zhyny4j/revision/1

BBC Bitesize – NEA help
https://www.bbc.co.uk/bitesize/guides/zmshsrd/revision/1
https://www.bbc.co.uk/bitesize/guides/zvkck2p/revision/1

NEA help guide on Teams in the files section.

Assessments:

There are four core assessments this term. One is an online timber specialism assessed through the Seneca learning platform. The second is the first section of the NEA coursework. The third assessment is a trial exam paper using past exam questions. The final assessment this term will be the second section of the NEA coursework.

Autumn 1:  Online assessment using Seneca – Timbers knowledge
Autumn 2:  NEA project work – Section 1.1 and 1.2 – Investigation, specification and design brief
Autumn 3:  Trail exam paper – Exam board past paper
Autumn 4:  NEA project work – Section 2 – initial design ideas developed to final design

 


 

Term 2

NEA coursework
Section 3.1
Section 3.2
Section 4.1

Theory
Unit 1 – Core revision

Knowledge:

Durning this term we complete the NEA coursework the focus moves from investigating and designing to manufacture and testing. All the skills the students have learnt over the course are put to the test with the manufacture of their product. Once built, the product will be tested and an evaluation formed that considers the views of the user group/client.

We continue to prepare for the final exam with revising the core section of the theory that was covered in Year 10.

Skills:

This term involves the application of the following skills:

Manufacture – To be able to produce a prototype solution to the chosen context. Pupils will use the skills they have learnt in the workshop over the course to produce a high-quality solution to their design problem.

Test – Pupils will test their product against their design specification to ascertain its success.

Evaluate – Pupils will form an evaluation of the success of their product considering the views of the user group/client and the environmental impact their design has by completing a life cycle analysis.

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

BBC Bitesize – Edexcel core
https://www.bbc.co.uk/bitesize/examspecs/zb6h92p

BBC Bitesize – NEA help
https://www.bbc.co.uk/bitesize/guides/z47w7p3/revision/1
https://www.bbc.co.uk/bitesize/guides/zjhxh39/revision/1

NEA help guide on Teams in the files section.

Assessments:

There are four core assessments this term. One is an online core knowledge assessed through the Seneca learning platform. The second is section 3 of the NEA coursework the manufacture of the final product. The third assessment is a trial exam paper (past paper). The final assessment is section 4 of the NEA coursework which is the evaluation of the project.

Spring 1:  Seneca Knowledge assessment – Core knowledge tests
Spring 2:  NEA project work – Section 3.1 and 3.2 – Manufacture and Quality and accuracy
Spring 3:  Trial Exam – Past paper
Spring 4:  NEA project work – Section 4.1 Testing and evaluation

 


 

Term 3

Theory
Unit 1 — Core
Unit 7 — Timbers

Knowledge:

This term will only include a few weeks teaching as pupils will be starting their GCSE exams. The primary focus for the lessons will be revision and exam technique.

Skills:

Revision– Pupils will be employing various different revision techniques to help prepare for their final exam.

Exam technique– Pupils will understand how to answer different styles of questions in the final exam paper

Useful Links

Exam board and course information
https://qualifications.pearson.com/en/qualifications/edexcel-gcses/design-and-technology-9-1-from-2017.html

Seneca
https://senecalearning.com/en-GB/

BBC Bitesize – Edexcel core
https://www.bbc.co.uk/bitesize/examspecs/zb6h92p

BBC Bitesize – Edexcel timbers
https://www.bbc.co.uk/bitesize/guides/zhyny4j/revision/1

Focus Revision materials, link on TEAMS

Assessments:

In class assessments, online tests and revision will be carried out before the pupils sit their GCSE exam.

Are you interested in:

Designing and making practical products, working with wood, metal and plastics, or developing creative and technical problem-solving skills?

Leading to a career in:

Engineering, product design, architecture, carpentry, manufacturing, construction, or industrial design.

Head of Department:

Mr S Sparkes