Communication of design ideas: sketches, formal drawings, digital presentation

IGCSE Design & Technology (0475/0445) – Complete Syllabus Notes

1. Syllabus Overview

The Cambridge IGCSE Design & Technology syllabus is split into two compulsory components and a specialist option.

• Component 1 – Common Content (Product Design): required for all candidates.
• Component 2 – Project Preparation (Portfolio): practical project work that is examined through a portfolio.
• Specialist Option (choose ONE): Resistant Materials, Systems & Control, or Graphic Products.

2. Common Content – Product Design (Eight Design Stages)

The eight stages are given exactly as they appear in the syllabus. A brief “Syllabus wording” box follows each stage to remind you of the required terminology.

1. Observe need/requirement
   • Identify a problem or opportunity in a real‑world context.
   • Analyse users, market trends, legal or environmental constraints.
   Syllabus wording: “Observe a need/requirement and analyse the context.”
2. Design brief
   • State purpose, target users, constraints (size, cost, materials, sustainability) and success criteria.
   • Produce a clear, measurable specification table.
   Syllabus wording: “Design brief – purpose, users, constraints and success criteria.”
3. Research
   • Collect information on existing products, materials, processes, technologies and relevant standards.
   • Use catalogues, internet, interviews, site visits, and scientific data sheets.
   Syllabus wording: “Research – sources, analysis and relevance to the brief.”
4. Idea generation
   • Produce a wide range of concepts (thumbnail sketches, mind‑maps, mood boards).
   • Apply creativity techniques such as SCAMPER, morphological chart, random‑word, or TRIZ.
   Syllabus wording: “Idea generation – develop many concepts.”
5. Idea selection
   • Evaluate concepts against the brief using a decision matrix or weighted scoring.
   • Justify the chosen solution with a written rationale linked to success criteria.
   Syllabus wording: “Idea selection – evaluate and justify the final concept.”
6. Design development
   • Produce detailed, to‑scale drawings, CAD models, exploded views and prototypes.
   • Specify dimensions, tolerances, materials, processes, finishes and any required fasteners.
   Syllabus wording: “Design development – detailed drawings, specifications and prototypes.”
7. Implementation (realisation)
   • Manufacture the final product or a functional prototype.
   • Record each step, problems encountered, modifications made and safety precautions taken.
   Syllabus wording: “Implementation – manufacture and record the process.”
8. Testing & evaluation
   • Plan and carry out tests that directly address the original specification.
   • Analyse results, compare performance with success criteria, identify improvements and reflect on the whole design cycle.
   Syllabus wording: “Testing & evaluation – performance against the specification.”

3. Project Preparation – Portfolio Items & Marking Criteria

3.1 Required Portfolio Items (Component 2)

3.2 Project Assessment Criteria (Seven Marking Criteria)

4. Communication of Design Ideas

4.1 Why Communicate?

• Ensures the design intent is understood by clients, manufacturers, teammates and examiners.
• Reduces costly misunderstandings and helps meet brief constraints.
• Forms the visual backbone of the project folder and the final digital presentation.

4.2 Stages of Communication

1. Sketches – rapid visualisation of many ideas.
2. Formal drawings – precise, to‑scale representations for manufacture and assessment.
3. Digital presentation – polished, often CAD‑based, integrating drawings, tables and analysis.

4.3 Sketches

• Purpose: generate, explore and record ideas quickly.
• Characteristics: loose lines, multiple viewpoints, brief annotations, arrows and shading to suggest form.
• Tools: HB/HB‑2 pencils, coloured pencils, fine‑tip pens, markers, sketchbook, eraser.
• Practical tip: Produce 5–10 thumbnail sketches per concept; number each sketch and add a short note (e.g., “fold‑over lid”).

4.4 Formal Drawings (Technical Drawing)

• Scale: Choose a convenient scale (1:10, 1:20, 1:50) and indicate it on the title block.
• Standard Views: Front, side, top, and isometric (or exploded) views.
• Line Types (ISO 128)
  • Visible – thick continuous.
  • Hidden – thin dashed.
  • Centre – thin alternating long‑short dashes.
  • Cutting‑plane – thick dash‑dot.
• Dimensioning: Show all critical dimensions, tolerances and surface‑finish symbols (e.g., d = 45 ± 0.2 mm).
• Notation: Material call‑outs, thread specifications, fastener types, and any required symbols (e.g., welding symbols).
• Tools: Technical drawing set (ruler, T‑square, compasses, French curves), drafting paper, eraser, drafting triangle.
• Health & safety symbols (optional but useful): – include in the margin of the drawing where relevant.

4.5 Digital Presentation

• Software options
  • 2‑D/3‑D CAD: AutoCAD, Fusion 360, SolidWorks, Onshape.
  • Vector graphics: Illustrator, Inkscape (exploded views, diagrams).
  • 3‑D rendering: SketchUp, Blender, KeyShot (realistic images).
  • Document layout: PowerPoint, Google Slides, LaTeX (report formatting).
• Typical digital presentation structure
  1. Cover page – title, candidate name, centre, date.
  2. Design brief summary – problem statement and success criteria.
  3. Design rationale – why the final solution was chosen (linked to decision matrix).
  4. Annotated CAD images – orthogonal views, isometric, exploded view with call‑outs.
  5. Materials & processes table – material, grade, finish, manufacturing method, cost.
  6. Cost estimate – breakdown of material, labour, tool and overhead costs.
  7. Sustainability analysis – life‑cycle considerations, recyclability, carbon footprint.
  8. Testing & evaluation summary – key results, graphs, calculations (e.g., Stress = F/A).
  9. Conclusion & recommendations – future improvements, personal reflection.
• Presentation tips
  • Use a consistent colour palette and font (e.g., Arial 11 pt body, 14 pt headings).
  • High‑resolution images (≥300 dpi) for printed portfolios.
  • All dimension symbols must follow ISO standards.
  • Proofread for spelling, grammar and correct technical symbols.

4.6 Comparison of Communication Methods

5. Specialist Options – Detailed Overview

5.1 Resistant Materials

• Key Topics
  • Properties of metals (ferrous & non‑ferrous), polymers (thermoplastics & thermosets), woods, composites.
  • Specific material list (as per syllabus):
    • Thermoplastics: LDPE, HDPE, PET, PVC, PMMA, PS, PP, ABS.
    • Thermosets: polyester resin, melamine‑formaldehyde (MF), urea‑formaldehyde (UF).
    • Metals: mild steel, stainless steel, aluminium, brass, copper, titanium.
    • Woods: hardwoods (oak, beech), softwoods (pine, spruce), engineered wood (MDF, plywood).
    • Composites: fibre‑reinforced plastics (glass fibre, carbon fibre), sandwich panels.
    • Smart/modern materials: shape‑memory alloys, thermochromic polymers, piezoelectric ceramics.
  • Joining methods – mechanical (screws, bolts, rivets), welding (MIG, TIG, spot), adhesives, soldering, polymer bonding.
  • Heat‑treatment, surface‑finishing (painting, anodising, powder coating, polishing).
  • Manufacturing processes – casting, forging, extrusion, injection moulding, CNC milling, laser cutting.
• Typical Project Examples
  • Metal toolbox with hinged lid and internal compartments.
  • Wooden ergonomic chair with laminated back‑rest.
  • Polymer kitchen gadget (e.g., multi‑function slicer) using ABS.
  • Composite drone frame incorporating carbon‑fibre sheets.
• Suggested Practical Activities
  • Cutting, drilling, filing, and shaping metal and wood.
  • Soldering copper wires, brazing steel joints.
  • Injection moulding a small plastic part.
  • CNC milling a 3‑D prototype.
  • Surface‑treatment tests – hardness, corrosion resistance, paint adhesion.

5.2 Systems & Control

• Key Topics
  • Electrical circuits – series, parallel, mixed, protective devices (fuses, circuit breakers).
  • Sensors – temperature, proximity, light, force, ultrasonic.
  • Actuators – DC/stepper motors, solenoids, pneumatic cylinders.
  • Micro‑controllers & programmable logic – Arduino, Raspberry Pi, PLC basics.
  • Control concepts – open‑loop vs. closed‑loop, feedback, PID control.
  • Diagramming – circuit schematics (ISO 7010 symbols), ladder diagrams, block diagrams.
  • Programming – flowcharts, pseudocode, basic C/C++ for Arduino.
  • Testing equipment – multimeter, oscilloscope, data‑logging software.
• Typical Project Examples
  • Automated door latch with infrared sensor and solenoid.
  • Temperature‑controlled fan using a thermistor and PWM motor control.
  • Simple robotic arm with stepper motors and limit switches.
  • Smart lighting system with ambient light sensor and Arduino.
• Suggested Practical Activities
  • Bread‑board prototyping of a basic circuit.
  • Programming an Arduino to read a sensor and drive an actuator.
  • Creating a ladder diagram for a simple PLC‑controlled motor.
  • Using a multimeter to verify voltage, resistance and continuity.
  • Documenting safety considerations for electrical work (e.g., isolation, earthing).

5.3 Graphic Products

• Key Topics
  • Printing processes – screen‑printing, offset, digital, flexography.
  • Typography – classification of typefaces, hierarchy, legibility.
  • Colour theory – colour models (RGB, CMYK), colour harmony, contrast.
  • Layout & composition – grid systems, balance, alignment, white space.
  • Digital illustration – vector vs. raster, software tools (Illustrator, Photoshop, Inkscape, GIMP).
  • Packaging design – structural design, dielines, material selection, branding.
  • Brand identity – logo development, visual language, style guides.
• Typical Project Examples
  • Brand identity package – logo, business card, letterhead.
  • Promotional poster for a school event.
  • Eco‑friendly packaging for a consumer product (e.g., biodegradable box).
  • Series of screen‑printed tote bags.
• Suggested Practical Activities
  • Creating a vector logo and exporting it in various formats.
  • Designing a dieline in Illustrator and producing a physical mock‑up.
  • Screen‑printing a simple graphic onto fabric.
  • Producing a multi‑page brochure using layout software.

6. Health & Safety (Common Content)

• Risk Assessment – complete before any practical activity; identify hazards, evaluate risk, implement control measures, review regularly.
• Personal Protective Equipment (PPE) – safety glasses, hearing protection, gloves, aprons, steel‑toe boots where required.
• Safety symbols (ISO 7010) – include in drawings and work‑area signage:
  • General danger –
  • Eye protection –
  • Electrical hazard –
• Safe operating procedures – correct blade guards on saws, proper grounding for electrical equipment, correct use of ventilation when cutting plastics.
• Work‑area organisation – keep aisles clear, store tools safely, label hazardous substances, maintain clean surfaces.
• Emergency procedures – location of fire extinguishers, first‑aid kits, eye‑wash stations, evacuation routes.

7. Sustainability & Environmental Impact

Examiners expect a whole‑life‑cycle perspective.

• Materials – prefer renewable, recycled or low‑impact options; justify choices in the portfolio.
• Manufacturing processes – select low‑energy or waste‑reducing methods (e.g., CNC machining vs. hand‑cutting, water‑based paints).
• Use phase – design for durability, easy maintenance, energy efficiency.
• End‑of‑life – plan for reuse, recycling or safe disposal; include a brief Environmental Impact Assessment (material choice, carbon footprint, waste generated).

8. Control & Systems (Relevant to Specialist Option – Systems & Control)

• Control concepts – open‑loop, closed‑loop, feedback, PID control.
• Components – sensors (temperature, proximity, light), actuators (motors, solenoids), micro‑controllers (Arduino, Raspberry Pi), PLC basics.
• Diagramming – circuit schematics (ISO 7010 symbols), ladder diagrams, block diagrams.
• Testing & measurement – multimeters, oscilloscopes, data‑logging software; record results in tables and graphs.

9. Assessment Overview

9.1 Assessment Objectives (AOs)

9.2 Mapping of Notes to AOs

• AO1: Sections 2 (Product Design stages), 6 (Health & Safety), 7 (Sustainability), 8 (Control & Systems), and the material lists in Section 5.
• AO2: Sections 3 (Portfolio items & marking criteria), 4 (Communication of ideas), 5 (Specialist option content), and the testing & evaluation guidance.
• AO3: Section 4 (drawing techniques, CAD software), Section 5 (practical activities), Section 6 (health & safety procedures), and the realisation record guidance.