explore form, function and surface using models, samples, material exploration and technical notes

Three‑Dimensional Design – Cambridge IGCSE 0400

Learning Outcomes

By the end of this unit students will be able to:

• Record visual research and develop a clear design brief (AO1).
• Analyse form, function and surface and translate ideas into accurate two‑point or three‑point perspective drawings, orthographic sketches and scale models (AO2).
• Choose, test and justify appropriate materials, processes and finishes, including specialist techniques such as CAD, laser‑cutting and kiln firing (AO3).
• Produce a well‑structured technical notebook that documents the design process, material trials and construction steps (AO4).
• Evaluate the final object against the brief, considering ergonomics, sustainability and cultural context (AO5).

Key Concepts

Concept	Definition	Design Influence
Form	Shape, structure and spatial relationships of an object in three dimensions.	Determines visual impact, stability and how the object occupies space.
Function	Intended use, ergonomic requirements and performance criteria.	Guides dimensions, material strength and user interaction.
Surface	Texture, finish, colour and any treatment applied to the exterior.	Influences tactile experience, visual perception and durability.

Intention – Research – Realisation – Reflection (IRRR)

This four‑stage framework mirrors the syllabus wording and helps learners organise their work.

1. Intention – Define the design problem, target audience and sustainability goals.
2. Research – Investigate historical/contemporary designers, cultural & social contexts, material properties and existing products.
3. Realisation – Develop form, test function, apply surface treatments and document every step.
4. Reflection – Critically evaluate the outcome against the brief, AOs and environmental impact.

Research & Inspiration

Before any modelling, complete the following research tasks and record them in the technical notebook.

• Study at least two designers (e.g., Isamu Noguchi, Zaha Hadid, Naoto Fukasawa) and note how they balance form, function and surface.
• Identify a design movement (Bauhaus, Minimalism, Sustainable Design) and summarise its core principles.
• Cultural & Social Context – Investigate local craft traditions, user‑community practices or accessibility standards that may affect the design.
• Collect two visual sources (photos, sketches, screenshots) and write a 50‑word annotation for each.

Design Brief Checklist

All projects must start with a written brief that covers the points below. Use the table as a template in your notebook.

Item	Details to Include
Target audience	Age, abilities, cultural background, specific needs.
Purpose & functional requirements	Primary function, secondary uses, ergonomic considerations.
Constraints	Budget, material availability, size limits, safety regulations.
Sustainability goals	Use of recycled/up‑cycled materials, waste minimisation, life‑cycle impact.
Timeline & deliverables	Milestones for research, modelling, surface treatment and final presentation.

Materials, Techniques & Safety

Experiment with at least three media, mixing hand‑craft with digital fabrication. Record observations in a “Material Trials” table.

Material / Technique	Key Properties	Typical Uses & Example Projects
Clay (earthenware, stoneware, polymer)	Plastic when wet; hardens on firing; can be glazed or painted.	Ceramic vessel, sculptural maquette, prototype component.
Wood (hardwood, softwood, reclaimed timber)	Strong, carveable, joinable, can be stained or varnished.	Furniture, desk organizer, sustainable product case.
Metal (wire, sheet, cast, CNC‑cut)	Durable, weldable, bendable, polishable or patinated.	Armature, jewellery piece, industrial‑style prototype.
Plastics (acrylic, PET, PLA, polymer clay)	Lightweight, mouldable, heat‑shapable, printable.	Transparent components, 3‑D printed prototype, mass‑production model.
Found & recycled objects (cardboard, fabric, up‑cycled plastic, reclaimed metal)	Varied textures, often lightweight, environmentally friendly.	Assemblage, surface studies, experimental structures.
Digital fabrication (CAD, 3‑D printing, laser cutting, CNC milling)	Precision, repeatability, ability to create complex geometries.	Technical components, intricate patterns, rapid prototyping.
Finishing equipment (kiln, spray booth, polishing wheel, heat gun)	Controls temperature, gloss level, texture.	Glazing ceramics, applying matte/metallic finishes, surface smoothing.

Safety & Tool‑Handling (required for AO3)

• Kiln – Wear heat‑resistant gloves, use a kiln‑safety checklist, ensure proper ventilation.
• Laser cutter / CNC mill – Wear safety glasses, never leave the machine unattended, follow material‑specific fire‑risk guidelines.
• Power tools (drills, saws) – Secure workpiece, keep hands clear of moving parts, use ear protection.
• General workshop – Keep the area tidy, store chemicals (paints, solvents) in labelled containers, know emergency shut‑off procedures.

Form Development

When shaping the object, consider the following systematic steps.

• Geometric basis – Identify underlying primitive shapes (cube, cylinder, sphere, organic curve).
• Scale & proportion – Relate dimensions to the human body or intended environment; use a 1:1 or 1:4 scale as appropriate.
• Perspective drawing – Produce two‑point (for most objects) or three‑point (for dramatic angles) drawings. Include a scale bar, horizon line, vanishing points and labelled dimensions.
• Structural analysis – Sketch load‑bearing lines, calculate minimum wall thickness, perform simple weight tests on prototypes.
• Construction method – Decide between additive (building up, modelling clay, 3‑D printing) or subtractive (carving, CNC milling) processes.

Function Considerations

Expand the functional‑requirement table to cover a broader range of design drivers.

Functional Requirement	Design Implication
Ergonomic grip	Rounded edges, appropriate diameter, non‑slip surface (rubberised coating or textured finish).
Load‑bearing	Reinforced joints, thicker walls, high‑strength material (metal, hardwood).
Portability	Lightweight material, modular or collapsible construction, integrated handles.
Environmental resistance	Water‑proof finishes, UV‑stable pigments, corrosion‑resistant metals, sealed joints.
Durability / wear resistance	Hard‑wear surfaces, protective coatings, rounded corners to reduce chipping.
Modularity & expandability	Standardised connection points, interchangeable components, easy assembly/disassembly.
User interaction (moving parts)	Clearances for hinges, low‑friction bearings, tactile feedback mechanisms.

Surface Exploration

Surface choices affect visual perception, tactile experience and functional performance. Use the terminology below when describing finishes.

Property	Definition	Typical Effect
Gloss	Degree of specular reflection; measured from matte (0) to high gloss (100).	High gloss → sleek, modern; matte → understated, non‑reflective.
Texture frequency	Size and repetition of surface irregularities (fine, medium, coarse).	Fine → subtle tactile cue; coarse → strong visual impact.
Porosity	Ability of a surface to absorb liquids or gases.	High porosity → suitable for glazing; low porosity → easier to seal.
Reflectivity	Amount of light reflected; influences perceived depth.	Metallic finishes create depth; matte finishes flatten.

Choose at least two techniques for each project (examples below):

• Stamping, carving or laser‑etched patterns.
• Washes, glazes, enamels, or acrylic paints.
• Polishing to high sheen, sanding to matte, or applying a clear coat.
• Adding decorative layers – metal leaf, fabric appliqué, resin inlays.

Technical Documentation & Reflection

A systematic notebook demonstrates process control and critical thinking. Use the headings below for every project.

1. Brief & Design Intent – Include the Design Brief Checklist.
2. Research & Inspiration – Annotated bibliography, image bank, thumbnail sketches, cultural context notes.
3. Material Trials – Table of experiments (material, tool, observation, finish quality, safety notes).
4. Form Development – Perspective drawings, orthographic sketches, scale models, structural analysis.
5. Construction Log – Step‑by‑step measurements, tools used, problems & solutions, safety checks.
6. Surface Treatment Log – Materials, application method, drying/firing times, visual outcome, gloss measurement.
7. Evaluation & Reflection – Complete the template below.

Reflection Template (AO5)

Prompt	Response
What worked well?
What did not work as expected?
How did the surface finish affect the perception of form?
Did the final object meet the functional brief? Why or why not?
How could the design be improved for the next iteration?
What sustainability considerations were addressed? Include a brief life‑cycle analysis.
Link to Assessment Objectives (AO1‑AO5)	✓ AO1 – research recorded ✓ AO2 – drawings accurate ✓ AO3 – material justification ✓ AO4 – notebook complete ✓ AO5 – critical evaluation

Cross‑Curriculum Links

• Graphic Communication – Produce orthographic drawings, exploded diagrams and digital renderings.
• Textiles – Explore fabric‑based surface treatments or integrate woven components.
• Science & Technology – Apply basic principles of load‑bearing, material strength and heat treatment.
• Geography / Environmental Studies – Assess environmental impact of material choices and propose greener alternatives.

Sample Activities (Diverse 3‑D Areas)

1. Functional Desk Organizer (Product Design)

1. Research three existing organizers (commercial, DIY, cultural). Record form, function and surface notes.
2. Complete the Design Brief Checklist (target: university students; budget: £15; sustainability: reclaimed wood).
3. Develop three thumbnail sketches with dimensions, material and surface ideas.
4. Select two materials (e.g., reclaimed hardwood and laser‑cut acrylic).
5. Build a 1:4 scale model; document measurements, tools, challenges.
6. Apply two finishes (natural oil stain, matte acrylic paint); record drying times and visual impact.
7. Complete the technical notebook and Reflection Template.
8. Present the model, exploded view diagram and selected notebook pages, explaining the interaction of form, function and surface.

2. Small Ceramic Vessel (Craft & Material Study)

1. Investigate traditional pottery from a chosen culture; note surface decoration techniques.
2. Brief: functional drinking vessel for a specific cultural ceremony; sustainable goal – use locally sourced clay.
3. Model: hand‑built coil or slab construction; test wall thickness for strength.
4. Surface: apply a slip‑carved pattern and a low‑gloss glaze.
5. Document firing schedule, safety precautions, and final evaluation.

3. Jewellery Piece – Metal & Resin Inlay (Fine‑Scale Design)

1. Research a contemporary jewellery designer who combines metal with resin.
2. Brief: pendant for a teenage market; budget £10; emphasis on tactile surface.
3. Materials: 1 mm copper sheet, resin, polymer clay for inlay.
4. Techniques: laser‑cut metal pattern, resin casting, polishing.
5. Safety: wear gloves and eye protection when handling resin and laser cutter.
6. Record each step in the notebook and evaluate ergonomics, visual appeal and sustainability (use of up‑cycled copper).

Assessment Criteria (Full Rubric)

Criterion (AO)	What Examiners Look For
Understanding of Form (AO2)	Clear development of three‑dimensional shape, accurate perspective, appropriate scale, and structural integrity.
Functionality (AO2)	Design fulfills the stated purpose safely and ergonomically; functional requirements are justified.
Surface Treatment (AO3)	Thoughtful choice of texture, gloss and colour that enhances visual appeal and functional performance; safe use of specialist processes.
Technical Documentation (AO4)	Comprehensive, well‑organised notebook showing research, material trials, construction steps and reflective evaluation.
Creativity & Originality (AO5)	Innovative approach to solving design problems, evidence of personal style and risk‑taking.
Sustainability & Material Awareness (AO3‑AO5)	Consideration of environmental impact, use of recycled/up‑cycled materials, and justification of material choices through a brief life‑cycle analysis.

Glossary (Key Terms)

• Maquette – A small‑scale model used to explore form.
• Load‑bearing – Ability of a component to support weight or force.
• Porosity – Measure of how much liquid a material can absorb.
• Ergonomics – Design principle that adapts a product to human use.
• Exploded view – Diagram showing components separated to illustrate construction.
• Life‑cycle analysis – Assessment of environmental impact from raw material extraction to disposal.
• Up‑cycled – Material that has been transformed into a product of higher value.