Evaluation methods: testing, user feedback, cost analysis

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Cambridge IGCSE Design & Technology (0445) – Complete Study Notes

1. The Design Cycle – An Overview (8 Stages)

The design cycle is the backbone of the syllabus. Each stage links directly to the Assessment Objectives (AO) and to the two exam components.

Stage What You Do Relevant AO(s) Exam Component(s)
1. Identify the Need Research, observe, interview users, analyse market trends. AO1 – knowledge of needs & user context Component 2 (portfolio) – evidence of need analysis
2. Write a Design Brief State the problem, target users, constraints and success criteria. AO1, AO2 – clear brief & justification Component 2
3. Develop a Specification Create measurable, testable criteria (e.g., strength ≥ 30 N, cost ≤ £5). AO1, AO2 – specification formulation Component 2
4. Generate Ideas Sketch, mind‑map, brainstorm, use CAD/CAM. AO2 – creative development Component 2
5. Select a Preferred Solution Evaluate ideas against the specification (Pugh matrix, weighted decision matrix). AO2, AO3 – decision‑making & justification Component 2
6. Plan the Development Work‑record, timetable/Gantt chart, risk assessment, material list. AO2 – planning & resource allocation Component 2
7. Make a Prototype / Final Product Apply appropriate techniques (cutting, joining, shaping, programming, etc.). AO2 – practical making Component 2 (practical product)
8. Test and Evaluate Testing, user feedback, cost analysis; decide on redesign, production or stop. AO3 – analysis, evaluation, improvement Component 1 (written) & Component 2 (evaluation report)

2. Core Content – Common Topics (All Candidates)

These topics are examined in both components of the syllabus.

Topic Key Points to Cover
Need Analysis & Design Brief Problem identification, target market, constraints, success criteria; use of primary/secondary research.
Specification Measurable, testable criteria; primary vs. secondary; weighting of criteria.
Idea Generation & Development Sketches, CAD, 3‑D modelling, brainstorming, morphological charts, mind‑maps.
Selection & Decision‑Making Pugh matrix, weighted decision matrix, risk/benefit analysis, justification of the chosen solution.
Planning & Project Management Work‑record pages, Gantt chart/timetable, resource allocation, detailed risk‑assessment checklist.
Communication Technical drawings (orthographic, isometric, exploded), annotated sketches, bill of materials, presentation boards, use of standard drawing symbols.
Use of Technology CAD/CAM software, laser cutting, 3‑D printing, micro‑controllers, power tools – safety, maintenance and tool selection.
Sustainability & Ethics Life‑cycle analysis, material sourcing, waste reduction, social impact, ethical sourcing, design for disassembly.
Health & Safety (Expanded)
  • PPE: safety glasses, hearing protection, gloves, dust mask, safety shoes.
  • Workshop Safety Symbols: fire‑extinguisher, first‑aid, eye‑wash, high‑voltage.
  • Tool Safety: correct handling of saws, drills, routers, soldering irons; lock‑out/tag‑out procedures.
  • Risk‑Assessment Checklist: identify hazard, persons at risk, severity, likelihood, control measures, review.
  • Designer Responsibilities: ensure safe use for the end‑user, provide clear instructions, label hazards.

3. Specialist Options – Key Content Summaries

3.1 Resistant Materials

  • Material Properties – density, tensile strength, elasticity, thermal conductivity, moisture resistance, impact resistance.
  • Typical Materials & Key Characteristics
    MaterialKey PropertiesCommon Uses
    Softwood (e.g., pine)Low density, good workability, moderate strengthFurniture, simple joinery
    Hardwood (e.g., oak)High density, high strength, good wear resistanceLoad‑bearing furniture, flooring
    Mild steelHigh tensile strength, magnetic, weldableFrames, brackets
    Stainless steelCorrosion‑resistant, high strength, non‑magneticKitchenware, medical devices
    LDPE (low‑density polyethylene)Flexible, low melting point, water‑resistantPackaging, flexible containers
    HDPE (high‑density polyethylene)Stiff, high impact resistance, chemical resistantBottle caps, piping
    Thermosetting polymer (e.g., epoxy)Hard, heat‑resistant, non‑re‑meltableAdhesives, laminates
    Composite (fiberglass, carbon fibre)High strength‑to‑weight, directional propertiesAerospace parts, sports equipment
  • Preparation & Shaping – cutting, sawing, drilling, turning, milling, laser cutting, 3‑D printing.
  • Joining Techniques – adhesives, screws, nails, welding, brazing, mechanical fasteners.
  • Finishing – sanding, painting, varnishing, anodising, powder coating.
  • Safety – PPE, dust extraction, fire risk, tool maintenance, safe handling of chemicals.
  • Example Project – Design a lightweight wooden chair that can support 80 kg and cost ≤ £12.

3.2 Systems & Control

Key Content for All Systems & Control Candidates

  • Structures
    • Static equilibrium, load paths, stress & strain basics.
    • Trusses, frames, beams, buckling criteria.
  • Mechanisms
    • Levers, gear trains, cams, linkages, bearings.
    • Motion ratios, gear ratio calculation, mechanical advantage.
  • Electronics
    • Basic circuit symbols, series & parallel circuits, Ohm’s law (V = IR).
    • Sensors (e.g., limit switches, potentiometers), actuators (motors, solenoids).
    • Micro‑controllers (Arduino, Raspberry Pi) – input‑output programming basics.

Specialist Focus Areas (Examples)

  • Structures – design a load‑bearing frame for a portable table.
  • Mechanisms – calculate gear ratios for a toy car that reduces motor speed from 5000 rpm to 500 rpm.
  • Electronics – program an Arduino to control a temperature‑regulated fan.

3.3 Graphic Products

  • Technical Drawing Standards – line types, lettering, dimensioning, scale, drawing symbols.
  • Projection Methods – orthographic (front, top, side), isometric, axonometric, perspective.
  • Exploded & Assembly Drawings – part relationships, bill of materials.
  • Layout & Presentation – grid systems, colour theory, typography, branding.
  • Digital Tools – vector software (Inkscape, Illustrator), raster software (Photoshop, GIMP), 2‑D CAD.
  • Example Project – Design a packaging label for a sports drink, including logo, nutritional table and barcode, produced in Adobe Illustrator.

4. Project Workflow – Checklist for Component 2 (Portfolio)

Use this checklist to ensure every required piece of evidence is included and clearly linked to the seven marking criteria.

Stage Evidence Required Typical Page Count Marking Criterion
Need Analysis Observations, interviews, market research, problem statement. 1–2 pages Identification of need
Design Brief & Specification Brief (max 150 words), specification table with measurable criteria. 1 page Specification development
Idea Generation Sketches, mind‑maps, CAD screenshots, idea log. 2–3 pages Idea generation & development
Idea Selection Pugh matrix or weighted decision matrix, justification. 1 page Selection & justification
Planning Work‑record, timetable/Gantt chart, risk assessment, material list. 2 pages Planning & project management
Making / Prototyping Step‑by‑step photos, process notes, tools used, safety checks. 3–5 pages Making (practical product)
Testing & Evaluation Test plan, data tables, user‑feedback forms, cost analysis, evaluation report. 3–4 pages Testing & evaluation (AO3)
Final Presentation Conclusion, improvements, reflection, bibliography. 1–2 pages Overall presentation & reflection

5. Evaluation Methods – Testing, User Feedback & Cost Analysis

5.1 Testing

Testing measures the product against the performance criteria set out in the specification. It can be quantitative (numeric data) or qualitative (observational).

  1. Identify the relevant criteria (e.g., durability, accuracy, speed).
  2. Choose appropriate test methods and equipment (force gauge, stopwatch, digital caliper, etc.).
  3. Carry out tests under controlled, repeatable conditions.
  4. Record results in a clear data table (include units, number of trials, average, standard deviation where relevant).
  5. Compare results with target values from the specification.
  6. Draw conclusions – does the product meet, exceed, or fall short of each criterion?

5.2 User Feedback

Gathering opinions from intended users provides insight into usability, aesthetics and overall satisfaction.

  1. Define the user group (age, skill level, physical abilities).
  2. Select a feedback method – questionnaire, interview, observation, focus group.
  3. Develop concise questions that link directly to the specification (e.g., “Rate the comfort of the handle on a scale of 1–5”).
  4. Collect responses from a representative sample (minimum 5–7 participants for reliability).
  5. Analyse data – look for trends, common comments and rating averages.
  6. Use findings to suggest specific improvements (e.g., “increase grip width by 5 mm”).

5.3 Cost Analysis

Cost analysis checks whether the product can be produced within the budget and highlights high‑cost items.

Formula:

$$\text{Total Cost} = \text{Material Cost} + \text{Labour Cost} + \text{Overheads}$$

  1. List every component and raw material required.
  2. Calculate the quantity of each component per finished product.
  3. Obtain current unit prices (include bulk discounts where applicable).
  4. Estimate labour time for each operation and apply an hourly wage rate.
  5. Include overheads – utilities, equipment depreciation, packaging, transport.
  6. Summarise the figures in a cost table (showing per‑unit and total cost).
  7. Compare the total cost with the target budget; identify items that could be reduced or substituted.

5.4 Comparison of Evaluation Methods

Method Purpose Strengths Limitations
Testing Measure performance against objective criteria. Quantitative, repeatable, directly linked to specification. May need specialised equipment; can be time‑consuming.
User Feedback Assess usability, aesthetics and user satisfaction. Captures real‑world experience; highlights issues not evident in tests. Subjective; depends on sample size and question quality.
Cost Analysis Determine financial viability and identify cost‑saving opportunities. Links design decisions to budget; essential for commercial products. Relies on accurate price data; may overlook intangible costs (e.g., brand value).

5.5 Integrating Evaluation Results

  • Summarise findings in a concise evaluation report (include tables, graphs and photographs).
  • State clearly which specification criteria have been met and which need improvement.
  • Prioritise changes using an impact vs. feasibility vs. cost matrix.
  • Decide on the next step: proceed to production, redesign, or conduct further testing.

6. Health & Safety, Sustainability & Ethics – Expanded View

  • Health & Safety
    • Risk assessments for each process – hazard identification, persons at risk, severity, likelihood, control measures, review.
    • PPE requirements (gloves, goggles, hearing protection, respirators, safety footwear).
    • Workshop safety symbols and their meanings.
    • Safe use of tools: hand tools, power tools, soldering equipment, laser cutters.
    • Emergency procedures – fire extinguishers, first‑aid kits, eye‑wash stations.
    • Designer responsibilities – providing clear user instructions, labelling hazards, designing for safe operation.
  • Sustainability
    • Life‑cycle assessment (raw material extraction → manufacture → use → disposal).
    • Selection of recyclable, biodegradable or low‑impact materials.
    • Design for disassembly and re‑use.
    • Minimising waste – off‑cut utilisation, efficient manufacturing processes.
  • Ethics
    • Fair‑trade and ethical sourcing of raw materials.
    • Labour rights and safe working conditions in the supply chain.
    • Social impact of the product (accessibility, inclusivity).
    • Responsible marketing – avoiding misleading claims.

7. Assessment Overview & Examination Objectives

The IGCSE Design & Technology assessment is split into three papers (if the specialist paper is taken) and a coursework component.

Component Weight Format Assessment Objectives (AO)
Component 1 – Paper 1 (Common Content) 25 % 2‑hour written exam (questions on need analysis, specification, idea generation, etc.) AO1 20 % – knowledge & understanding
AO2 40 % – application of knowledge
AO3 40 % – analysis, evaluation & justification
Component 2 – Paper 2 (Specialist) 25 % 2‑hour written exam (questions specific to the chosen specialist option) Same AO distribution as Paper 1.
Component 3 – Coursework (Portfolio) 50 % Portfolio (max 1500 words) + practical product AO1 20 % – knowledge of the design cycle and specialist content
AO2 40 % – planning, making and communication
AO3 40 % – testing, evaluation and reflection

Common Command‑Word Guide

Command Word What It Asks You to Do Relevant AO
Describe Give a factual account of a process, material or feature. AO1
Explain Give reasons or causes; link theory to practice. AO2
Analyse Break down information, identify trends or relationships. AO3
Evaluate Judge the merit of a solution using criteria; suggest improvements. AO3
Justify Provide a logical argument supporting a choice or design decision. AO3
Design Produce a detailed plan or drawing that meets a brief. AO2

8. Quick Revision Checklist

  • Can you write a clear, measurable specification with primary and secondary criteria?
  • Do you know at least three idea‑generation techniques and can you produce a Pugh matrix?
  • Are you comfortable recording a test, plotting the data and drawing a conclusion?
  • Can you design a simple questionnaire, collect responses and analyse the feedback?
  • Do you understand how to calculate total cost (materials + labour + overheads) and compare it with a budget?
  • Have you reviewed the health & safety symbols, PPE requirements and risk‑assessment checklist?
  • Can you explain the key properties of the main resistant materials and the basic principles of structures, mechanisms and electronics?

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