Different approaches to designing, including: iterative design, intuitive design.

Design Process (Cambridge IGCSE/A‑Level 9705)

The design process is a systematic series of steps that designers follow to develop solutions that meet identified needs. In Cambridge Design & Technology (9705) students must be able to:

• explain each stage of the process,
• use appropriate design‑thinking language,
• apply different design approaches (iterative, intuitive),
• communicate ideas clearly using specialist vocabulary and standard drawing conventions,
• evaluate sustainability, health & safety and societal impact,
• recognise the role of materials, energy and emerging technologies.

1. Design‑Thinking Stages (as worded in the syllabus)

1. Empathise – identify the problem, understand user needs and constraints.
2. Define – produce a concise brief that lists objectives, performance criteria, constraints (materials, cost, time, health & safety, sustainability) and success measures.
3. Ideate – generate a wide range of ideas (sketches, mind‑maps, mood boards, concept models).
4. Prototype – develop low‑ and high‑fidelity prototypes, CAD models and calculations.
5. Test – carry out functional tests, user trials and sustainability checks; analyse results against the brief.

2. Design Principles (seven criteria required by the syllabus)

3. Design Approaches

Iterative Design

• Feedback loops – each prototype generates data that informs the next version.
• Risk reduction – problems are identified early when they are cheaper to fix.
• Evidence‑based decisions – testing results, measurements and user feedback drive changes.
• Documentation – version numbers, test data, design changes and rationale are recorded for every cycle (AO3).

Intuitive Design

• Rapid ideation – sketches and mental visualisation are produced quickly.
• Pattern recognition – designers apply solutions that have worked in similar contexts.
• Flexibility – the approach can adapt to emerging opportunities without extensive formal documentation.
• Experience‑driven – relies on the designer’s tacit knowledge and instinct.

Comparative Overview

Integrating Both Approaches

1. Begin with intuitive sketching to break conventional thinking and generate bold concepts.
2. Select promising ideas and move into an iterative prototype cycle to test assumptions, refine performance and document changes.
3. Use data from each iteration to inspire further intuitive leaps – e.g., an unexpected test result may suggest a new mechanism.
4. Maintain clear communication (standard drawing conventions, specialist vocabulary) and record sustainability and health & safety considerations throughout.

4. Communication & Documentation (AO2)

• Free‑hand sketches – include scale, annotations, line types and symbols (BS 308/BS 8888).
• Orthographic, isometric, planometric and section views – use proper projection, hidden‑line removal, dimensioning and section hatching.
• CAD models – exploded views, material call‑outs, assembly instructions, and BOM generation.
• Specialist vocabulary – e.g., “tensile strength”, “ergonomic”, “recyclable”, “risk assessment”, “feedback control”.
• All documentation should be dated, numbered and stored systematically (e.g., a portfolio binder or digital folder).

5. Design & Technology in Society

• Inclusive design – consider age, gender, ability, cultural background; use anthropometric data (e.g., 5th‑95th percentile ranges).
• Cultural & economic impact – how does the product affect local economies, employment or cultural practices?
• Examples:
  • A low‑cost water purifier for rural communities.
  • A wheelchair adapted for use on uneven terrain in developing regions.

6. Sustainable Design (AO3)

When evaluating sustainability, the syllabus expects consideration of the following life‑cycle stages:

• Raw‑material extraction (renewable vs. non‑renewable, carbon footprint).
• Manufacturing (energy consumption, waste, water use).
• Use phase (energy efficiency, maintenance, durability).
• End‑of‑life (reuse, repair, recycling, disposal, biodegradability).

Include a short sustainability statement in the final report that links back to the brief’s constraints and the seven design principles.

7. Health & Safety (AO3)

• Carry out a risk assessment at the research stage (identify hazards, likelihood, severity, control measures).
• Specify required PPE (gloves, goggles, ear protection) for each processing technique.
• Document safe workshop practices: tool handling, material storage, ventilation, emergency procedures.
• Record any statutory requirements (e.g., CE marking, REACH, ISO 45001).

8. Aesthetics & Ergonomics

• Visual elements – line (straight, curved), colour theory (primary, complementary), form (geometric, organic), texture, pattern.
• Ergonomic data – key anthropometric measures (standing height, seated elbow height, hand breadth, grip strength). Use tables from the syllabus or the “Human Factors” handbook.
• Apply the “form‑function‑user” triangle to balance appearance with usability.

9. Materials & Components

Major material families and typical uses (as listed in the syllabus):

10. Stages in Materials Processing (AS Level)

1. Measuring & marking – use calibrated tools, reference dimensions.
2. Cutting – shearing, sawing, laser cutting, CNC milling.
3. Shaping – bending, forming, turning, milling, 3‑D printing.
4. Joining – adhesives, screws, rivets, welding, brazing, ultrasonic welding.
5. Finishing – sanding, polishing, coating, painting, anodising.

11. Materials Processing Techniques (required list)

• Manual: hand‑saw, coping saw, hacksaw, hand drill, files, sandpaper.
• Power tools: jigsaw, bandsaw, drill press, rotary tool, bench grinder.
• Computer‑controlled: CNC milling, laser cutting, water‑jet cutting, CNC turning.
• Forming: press brake, roll forming, vacuum forming, injection moulding.
• Joining: soldering, brazing, TIG/MIG welding, spot welding, adhesive bonding, mechanical fastening.
• Finishing: spray painting, powder coating, electro‑plating, anodising, heat treating.
• Rapid‑prototyping: 3‑D printing (FDM, SLA, SLS), resin casting.

12. Energy & Control Systems

• Energy sources – fossil fuels (petrol, diesel), nuclear, renewable (solar, wind, hydro, tidal, geothermal).
• Forms of energy – mechanical, electrical, thermal, chemical, light, sound.
• Control system basics – input, processing (micro‑controller, PLC), output, feedback loop.
• Examples:
  • Thermostat‑controlled heating element (temperature sensor → controller → heater).
  • Speed‑controlled DC motor using PWM (pulse‑width modulation).

13. Emerging Technologies (A‑Level relevance)

• Computer‑Aided Design (CAD) and Computer‑Aided Manufacturing (CAM) – parametric modelling, tool‑path generation.
• Rapid‑prototyping & additive manufacturing – 3‑D printing of polymers, metals and composites.
• Robotics & automation – programmable manipulators, CNC routers, pick‑and‑place machines.
• Artificial Intelligence (AI) & Machine Learning – generative design, optimisation algorithms.
• Virtual & Augmented Reality (VR/AR) – immersive prototyping, ergonomic simulation.
• Internet of Things (IoT) – sensor‑enabled products, remote monitoring.

14. A‑Level Extensions (if teaching the full 9705 syllabus)

15. Assessment Tips for Students

• Show iteration clearly – version numbers, test data tables, and a brief commentary on how each change improves performance.
• Justify intuitive choices – reference previous projects, design principles, or pattern‑recognition reasoning.
• Use design‑thinking labels (Empathise, Define, Ideate, Prototype, Test) where appropriate to demonstrate terminology knowledge.
• Maintain a well‑organised portfolio – sketches, CAD screenshots, calculation sheets, risk assessments, sustainability checklist and a reflective log.
• Balance creativity with systematic evaluation – examiners look for originality **and** reliable, evidence‑based development.
• Address all seven design principles in the final report and link each back to specific evidence (e.g., test results, material data, user feedback).

Suggested Diagrams (for classroom or exam preparation)

• Flowchart of the iterative loop: Concept → Prototype → Test → Refine → … linked to the five design‑thinking stages.
• Mind‑map illustrating intuitive idea generation branching into possible solutions, material choices and manufacturing methods.
• Lifecycle diagram showing raw‑material extraction → manufacturing → use → end‑of‑life, with sustainability checkpoints highlighted.