IGCSE Design & Technology (0445) – Syllabus Notes
1. How the Syllabus Is Structured
- Common product‑design content – required for every candidate (needs, brief, specification, research, idea generation, selection, evaluation, implementation, health & safety, communication, use of technology, design & society, sustainability, control).
- One specialist option – candidates choose Resistant Materials, Systems & Control or Graphic Products. The sections below give a concise but complete snapshot of each option together with the core textile processes (pattern drafting, cutting, joining, finishing) which are common to all options.
- Assessment Objectives (AO) – AO1 (knowledge), AO2 (application), AO3 (evaluation). The mapping table (section 4) shows where each AO is assessed.
2. Common Product‑Design Content – Checklist for Component 2
Use this checklist when planning your design project. Record evidence for each point in your design folder.
- Identify a need & design brief
- Analyse the problem, target user and market.
- State constraints (resources, legal, ergonomic, environmental).
- Specification
- List measurable criteria (e.g., strength ≥ 30 N, cost ≤ £5, weight ≤ 200 g).
- Prioritise criteria (must‑have, nice‑to‑have).
- Research
- Investigate existing products, materials, technologies and sustainability issues.
- Record sources and evaluate relevance.
- Idea generation
- Sketch, mind‑map, use CAD or 3‑D modelling.
- Produce at least three distinct concepts.
- Selection & organisation
- Apply a decision‑making matrix against the specification.
- Develop the chosen concept into detailed drawings, exploded views and a bill of materials (BOM).
- Evaluation
- Test prototypes, record results, compare with specification.
- Suggest improvements (design, material, process, sustainability).
- Implementation
- Plan the manufacture (processes, tools, sequence, health & safety).
- Produce the final product and complete a quality‑check checklist.
- Health & safety
- Identify hazards, assess risk, use appropriate PPE, maintain equipment, follow safe‑working procedures.
- Reference the mandatory safety symbols (see table 2.1).
- Communication
- Use annotated sketches, technical drawings, CAD, photographs and a written report.
- Use of technology (CAD/CAM)
- CAD: 2‑D drawing, 3‑D modelling, extrusion, surface‑modelling, generation of STL or DXF files.
- CAM: laser‑cut settings, CNC milling basics, 3‑D printer material selection, tool‑path optimisation.
- Design & society / sustainability
- Consider ethical, cultural, environmental and economic impacts.
- Include life‑cycle analysis, energy‑source comparison, recycling symbols and design‑for‑disassembly.
- Control (input‑processing‑output‑feedback)
- Input devices: switches, sensors, potentiometers, keyboards.
- Processing elements: micro‑controller, PLC, logic circuit.
- Output devices: motor, solenoid, LED, speaker, display.
- Feedback: limit switch, encoder, temperature sensor, colour‑sensor.
- Provide a simple block diagram for your project showing these four elements.
3. Specialist Options – Detailed Reference
3.1 Resistant Materials
3.2 Systems & Control
- Core concepts
- Mechanisms – gears, levers, cams, linkages, belts, pulleys.
- Control systems – sensors, actuators, micro‑controllers (Arduino, PIC), PLCs.
- Energy sources – batteries (Li‑ion, NiMH), solar panels, pneumatic, hydraulic.
- Design & analysis (AO2)
- Calculate gear ratios, torque, speed, and mechanical advantage.
- Draw force diagrams and use simple kinematic equations.
- Program basic logic (if/else, loops) and calibrate sensor thresholds.
- Processes
- Mechanism design – sketch, CAD (solid modelling), generate gear‑cutting data.
- Fabrication – laser cutting acrylic, 3‑D printing PLA/ABS, CNC milling aluminium, sheet‑metal bending.
- Assembly – fastening (screws, bolts), wiring, soldering, connector blocks.
- Testing & programming – write Arduino code, use serial monitor, perform functional tests, record data.
- Safety – isolation of power sources, use of insulated tools, emergency stop circuits.
- Example project: Motor‑driven lift for a small box.
- Specification: lift 200 mm in ≤ 3 s, load ≤ 2 kg, battery life ≥ 30 min.
- Calculate gear train: 12 : 1 ratio gives required torque.
- Design gear blanks in CAD, export STL for 3‑D printing.
- Assemble with a limit‑switch (feedback) and an Arduino that stops the motor at the top.
- Test for speed, repeatability and battery consumption; evaluate against specification.
3.3 Graphic Products
- Key skills
- Formal drawing – orthographic, isometric, planometric, exploded views.
- Layout – grid systems, hierarchy, colour theory, typography.
- Digital production – vector (Illustrator, Inkscape), raster (Photoshop, GIMP), 3‑D visualisation (Cinema 4D, Blender).
- Processes
- Hand drawing – sketching, tracing, use of French curve, technical pens.
- Digital design – creating editable vector files, setting DPI, colour‑mode (CMYK vs RGB), preparing production files (PDF/X‑1a, EPS).
- Production – screen printing, digital printing, embossing, die‑cutting, laser‑cut engraving.
- Example project: Reusable coffee‑cup label.
- Brief: label must survive 100 washes, be biodegradable, cost ≤ £0.10 per unit.
- Research: biodegradable polymers, water‑based inks.
- Design: hand sketch → vector layout in Illustrator (300 dpi, CMYK).
- Prototype: laser‑cut label from 0.2 mm biodegradable film, print with water‑based ink.
- Evaluation: test wash durability, assess legibility, calculate carbon footprint.
4. Assessment Objectives (AO) Mapping
| Topic / Skill |
AO1 (Knowledge) |
AO2 (Application) |
AO3 (Evaluation) |
| Identify need, write brief & specification | ✓ | | ✓ |
| Research & analyse existing products | ✓ | | ✓ |
| Generate and select ideas (including decision matrix) | ✓ | ✓ | ✓ |
| Technical drawing & CAD (orthographic, exploded, 3‑D) | ✓ | ✓ | |
| Pattern drafting (textiles) – allowances, grain line, notches | ✓ | ✓ | |
| Cutting techniques – hand scissors, rotary cutter, electric cutter | ✓ | ✓ | |
| Joining methods – sewing, adhesives, thermal bonding, mechanical fasteners | ✓ | ✓ | |
| Finishing – hemming, binding, over‑locking, surface treatments | ✓ | ✓ | |
| Health & safety – hazard ID, risk assessment, PPE, safety symbols | ✓ | ✓ | |
| Control – input, processing, output, feedback devices | ✓ | ✓ | |
| Calculations – fabric requirement, gear ratios, material strength, energy use | ✓ | ✓ | |
| CAD/CAM – 2‑D/3‑D modelling, STL/DXF export, laser‑cut settings, 3‑D printer parameters | ✓ | ✓ | |
| Sustainability – life‑cycle stages, energy‑source comparison, recycling symbols, design for disassembly | ✓ | ✓ | ✓ |
| Evaluation of prototype against specification & sustainability | | | ✓ |
5. Health & Safety – Detailed Checklist
5.1 Hazard Identification & Risk Assessment
- List each operation (cutting, drilling, soldering, etc.).
- Identify associated hazards (sharp blades, moving parts, electricity, fumes).
- Assess likelihood (Low/Medium/High) and severity (Minor/Serious/Critical).
- Determine control measures (PPE, guards, ventilation, isolation).
- Record in a risk‑assessment table and review before each session.
5.2 Mandatory Safety Symbols (12 standard symbols)
| Symbol | Meaning |
|---|
| ⚡ | Electrical hazard |
| 🔧 | Tool – wear protective gloves |
| 🧯 | Fire risk – keep extinguisher nearby |
| 👓 | Eye protection required |
| 🧤 | Hand protection required |
| 🦺 | Wear high‑visibility clothing |
| 🚫 | Do not eat/drink |
| 🔊 | Hearing protection needed (loud equipment) |
| ⛑️ | Hard hat – overhead work |
| ♻️ | Recycle waste material |
| ☢️ | Chemical hazard – use fume extraction |
| 🛑 | Emergency stop – ensure access |
6. Sustainability – Core Concepts
6.1 Life‑Cycle Stages
- Raw‑material extraction
- Manufacturing / processing
- Distribution & retail
- Use phase
- End‑of‑life (reuse, recycle, landfill)
6.2 Energy‑Source Comparison (example)
| Source | Renewable? | CO₂ (g kWh⁻¹) | Typical applications in DT |
|---|
| Battery (Li‑ion) | No | ≈ 150 | Portable electronics, small robots |
| Solar panel | Yes | ≈ 0 | Outdoor sensors, solar‑powered chargers |
| Grid electricity (UK mix) | Partial | ≈ 230 | Laser cutter, CNC mill |
| Pneumatic air | No | ≈ 250 (compressed) | Air‑driven tools, actuators |
6.3 Recycling Symbols & Design for Disassembly
- ♻️ 1 – PET (polyethylene terephthalate)
- ♻️ 2 – HDPE (high‑density polyethylene)
- ♻️ 3 – PVC (polyvinyl chloride)
- ♻️ 4 – LDPE (low‑density polyethylene)
- ♻️ 5 – PP (polypropylene)
- Design tip: use snap‑fits, screws instead of permanent adhesives to enable easy separation of material groups.
7. CAD/CAM Mini‑Guide (Core Technology)
7.1 CAD Workflow
- 2‑D sketch → define dimensions & constraints.
- Extrude / revolve to create 3‑D solid.
- Apply fillets, chamfers, holes as required.
- Check for interferences (assembly simulation).
- Export:
- STL for 3‑D printing (binary, 0.1 mm tolerance).
- DXF/DWG for laser cutting or CNC milling.
7.2 CAM Basics
- Laser cutter: set power (W), speed (mm/s), focus height; use vector files (DXF, SVG).
- CNC mill: choose tool (e.g., 3 mm end‑mill), define spindle speed (RPM), feed rate, step‑over; generate G‑code.
- 3‑D printer: select material (PLA, ABS, PETG), layer height (0.1–0.2 mm), infill % (20 % typical), nozzle temperature, bed temperature.
8. Textile Processes – Detailed Notes
8.1 Pattern Drafting
Creating a two‑dimensional template that guides fabric cutting.
- Analyse the brief and take accurate body or object measurements.
- Select a drafting method:
- Flat‑pattern (traditional).
- Drape method (muslin mock‑up).
- Computer‑aided design (CLO, Optitex, AutoCAD).
- Draw the basic shape on pattern‑drafting paper, adding:
- Seam allowance – 10 mm (woven), 15 mm (knit).
- Hem allowance – 20 mm.
- Notches, grain lines, placement marks.
- Label each piece (front, back, sleeve, etc.) and indicate grain direction.
- Produce a muslin prototype; check fit and adjust the pattern.
Common Tools
- Pattern‑drafting paper or tracing paper
- French curve, hip curve
- Metal ruler, flexible ruler, L‑shaped ruler
- Compass, protractor
- Pencils, erasers, drafting pens
8.2 Cutting
Transferring the pattern onto fabric to obtain ready‑to‑sew pieces.
Preparation
- Lay fabric flat on a clean, stable cutting surface (cutting mat or board).
- Align the fabric grain line with the pattern grain line.
- Secure pattern pieces with pins, pattern weights or double‑sided tape.
- Mark darts, pleats or placement lines with tailor’s chalk, fabric markers or washable pens.
Cutting Techniques
| Tool | Best for | Key tip |
|---|
| Hand scissors | Small, delicate pieces, trims | Keep blades sharp; cut on the right‑hand side of the pattern. |
| Rotary cutter | Straight cuts on medium‑weight woven fabrics | Use a metal ruler as a guide; replace blade regularly. |
| Electric fabric cutter (e.g., CNC‑controlled) | High‑volume or repetitive cuts | Check blade alignment; clean debris after each run. |
Safety Considerations
- Keep fingers clear of blade edges; use a cutting mat to protect both work surface and blade.
- Store scissors and rotary blades in protective covers when not in use.
- Wear safety glasses when operating electric cutters.
- Ensure good lighting and a stable work surface.
8.3 Joining
Assembling cut pieces into a finished textile product.
Primary Joining Methods
| Method | Suitable Fabrics | Advantages | Disadvantages |
|---|
| Sewing (hand or machine) | All woven, knit and non‑woven fabrics | Strong, flexible, decorative possibilities | Hand stitching is time‑consuming; machines need regular maintenance |
| Adhesive bonding | Lightweight synthetics, interfacing, some knits | Fast, no visible stitching | Less durable, may affect breathability |
| Thermal bonding (heat‑seal) | Thermoplastic fabrics (polyester, nylon) | Water‑proof seam, smooth finish | Requires specialised equipment; unsuitable for natural fibres |
| Mechanical fasteners (screws, rivets, snaps) | Heavy‑weight fabrics, leather, technical textiles | Very strong, detachable | Can create bulk, may damage fabric |
Common Stitch Types (Machine)
- Plain (running) stitch – basic seam, low strength.
- Backstitch – high strength, used where stress is expected.
- Overlock (serger) stitch – finishes raw edges while joining.
- Blind stitch – concealed hem, ideal for visible garment edges.
- Buttonhole stitch – reinforced opening for buttons.
Hand‑sewing Techniques
- Running stitch – simple seam.
- Backstitch – reinforcement.
- Slip stitch – invisible hem.
- Whip stitch – edge joining for knits.
8.4 Finishing
Final treatments that improve appearance, durability and comfort.
Edge Treatments
- Hemming – fold edge (usually 20 mm) and stitch to prevent fraying.
- Binding – sew a fabric strip over raw edge for decorative effect.
- Over‑locking – serger trims and finishes edge in one operation.
Surface Treatments
- Pressing with an iron – set temperature according to fabric type.
- Applying fabric stiffeners or softeners to achieve the desired hand.
- Decorative finishes – embroidery, appliqué, screen printing, digital printing.
Quality Checks (Final Inspection)
- Seam tension and stitch length are even.
- All allowances (seam, hem, ease) match the pattern.
- No fabric defects (holes, pulls, colour variations) remain.
- Product meets every specification criterion (size, strength, aesthetics, cost, sustainability).
9. Example Calculations
9.1 Fabric Requirement for a Simple Skirt
Formula (rounded to one decimal place):
\[
\text{Fabric length (cm)} = \frac{(\text{Waist} + 2 \times \text{Ease})}{\text{Fabric width (cm)}} \times 100 + \text{Allowances}
\]
Given:
- Waist = 68 cm
- Ease = 5 cm
- Fabric width = 140 cm
- Allowances (hem, seam, waste) = 30 cm
Calculation:
\[
\text{Fabric length} = \frac{(68 + 2 \times 5)}{140} \times 100 + 30 \approx 71.4\ \text{cm}
\]
9.2 Gear Ratio for the Lift (Systems & Control)
Desired lift speed: 200 mm in 3 s → 66.7 mm s⁻¹.
Motor speed (no‑load) = 3000 rpm (50 rev s⁻¹).
Required output speed = 0.33 rev s⁻¹ (for a 60 mm lead screw).
\[
\text{Gear ratio} = \frac{\text{Motor speed}}{\text{Output speed}} = \frac{50}{0.33} \approx 150\!:\!1
\]
Use a two‑stage reduction (e.g., 10 : 1 × 15 : 1) to achieve the required torque.
9.3 Energy‑use Comparison (Sustainability)
Laser cutter – 120 W for 30 min = 0.06 kWh → CO₂ ≈ 14 g (using UK grid factor 230 g kWh⁻¹).
3‑D printer (PLA, 60 W) for 5 h = 0.30 kWh → CO₂ ≈ 69 g.
10. Quick‑Reference Tables
10.1 Safety Symbols (re‑listed for fast access)
| Symbol | Meaning |
|---|
| ⚡ | Electrical hazard |
| 🔧 | Tool – wear gloves |
| 🧯 | Fire risk |
| 👓 | Eye protection |
| 🧤 | Hand protection |
| 🦺 | High‑visibility clothing |
| 🚫 | No eating/drinking |
| 🔊 | Hearing protection |
| ⛑️ | Hard hat |
| ♻️ | Recycle waste |
| ☢️ | Chemical hazard |
| 🛑 | Emergency stop |
10.2 Seam & Hem Allowances (Textiles)
| Fabric type | Seam allowance | Hem allowance |
|---|
| Woven (cotton, linen) | 10 mm | 20 mm |
| Knit (jersey, interlock) | 15 mm | 25 mm |
| Technical (nylon, polyester) | 8 mm | 15 mm |
10.3 Material‑Selection Matrix (Resistant Materials)
| Criterion | Weight (1‑5) | Wood | Aluminium | ABS Plastic | Carbon Fibre |
|---|
| Strength | 5 | 3 | 4 | 3 | 5 |
| Weight | 4 | 2 | 5 | 4 | 5 |
| Cost | 3 | 5 | 3 | 4 | 2 |
| Machinability | 3 | 4 | 5 | 5 | 2 |
| Environmental impact | 2 | 4 | 3 | 3 | 2 |