The preparation of a design brief for a marketable product.

Quantity Production – Preparing a Design Brief for a Marketable Product

1. Why Quantity Production Matters

Designing for volume means the product must be made efficiently, consistently and at a cost that supports a competitive selling price. The design brief therefore has to address:

• Target‑market needs and preferences
• Manufacturing processes, tooling and capacity
• Cost targets, pricing strategy and profit margin
• Quality, safety, sustainability and regulatory standards

2. The Six‑Stage Design Process (Cambridge 9705) and the Brief

The brief is the final output of the Document stage. It must reference the work done in the preceding five stages, otherwise the brief is incomplete.

1. Identify a design need & research (Empathise & Define) – market research, user analysis, problem definition.
2. Generate ideas (Ideate) – sketch, concept generation, initial evaluation.
3. Develop the chosen concept (Refine) – detailed drawings, risk & sustainability appraisal.
4. Plan production (Realise) – select processes, design tooling, prototype.
5. Test & evaluate (Test & Evaluate) – functional testing, user trials, cost‑benefit analysis.
6. Document (Design Brief) – compile all findings into a concise, structured brief for stakeholder approval.

3. Design Principles (Syllabus Requirement) – Linked to Specification Items

Principle	What the brief must specify
Function	Performance criteria, load limits, operating conditions.
Ergonomics & Human Factors	Anthropometric limits, grip dimensions, reach envelope, weight limits.
Aesthetics	Style, colour palette, surface finish, branding guidelines.
Sustainability	Quantifiable targets – % recycled content, carbon‑footprint ceiling, design‑for‑disassembly.
Safety & Health	Hazard identification, compliance with relevant standards (CE, FDA, ISO), risk‑assessment summary.
Cost & Manufacture	Chosen production processes, tooling requirements, batch size, cost breakdown.

4. Communication & Documentation

• Hand‑drawn sketches – required for Paper 1; must show orthogonal views, section, and key dimensions.
• CAD output – DWG/DXF files, PDF portfolio, high‑resolution raster images for coursework.
• Drawing conventions – first‑angle projection (or third‑angle if specified), scale, dimensioning, tolerance symbols (BS 8888/ISO 129‑1), material symbols (BS 308), surface‑finish symbols.
• Revision history – date, author, change description.

5. Design & Technology in Society (AO1c / AO4d)

The brief should discuss how the product interacts with cultural, economic, environmental and social factors.

• Market trends and consumer lifestyles.
• Labour conditions, ethical sourcing and inclusive design.
• Economic impact – job creation, localisation vs. offshore production.
• Environmental impact – carbon footprint, end‑of‑life options.

6. Sustainable Design – Checklist (Explicit Syllabus Content)

• Life‑Cycle Assessment (LCA) targets (e.g., < 2 kg CO₂e per unit).
• Material selection – % recycled or bio‑based content.
• Design for disassembly – snap‑fits, colour‑coded fasteners, minimal adhesives.
• Energy‑efficient manufacturing – machines > 90 % efficiency, heat‑recovery where possible.
• Quantifiable sustainability statements in the brief.

7. Health & Safety – Required Risk‑Assessment Summary

Hazard	Potential Harm	Control Measures
Tooling & mould‑making	Sharp edges, high‑pressure injection	Guarded machines, PPE (gloves, eye protection), safe‑release valves.
Material handling	Dust inhalation, fumes, thermal burns	Local exhaust ventilation, respirators, temperature‑controlled storage.
Machine operation	Entanglement, crushing, electric shock	Two‑hand controls, emergency stop, insulated wiring, regular inspection.

8. Aesthetics & Ergonomics – From Principle to Specification

• Ergonomic specification example: Maximum grip diameter = 45 mm; handle height = 120 mm ± 5 mm; weight ≤ 250 g.
• Aesthetic specification example: Surface finish – matte‑soft‑touch, colour – Pantone 186 C, branding logo embossed 0.2 mm deep.

9. Materials & Components

Material	Key Properties	Typical Quantity‑Production Processes	Environmental Notes
Injection‑moulded plastics (e.g., Tritan®, PA‑6)	High strength, low weight, dimensional stability	Injection moulding, over‑moulding	Recyclable; up to 90 % recycled content; low VOC emissions.
Sheet‑metal (steel, aluminium)	High stiffness, excellent fatigue resistance	Stamping, deep‑drawing, laser cutting	Steel highly recyclable; aluminium high embodied energy – consider recycled alloy.
Composite laminates (glass‑fibre, carbon‑fibre)	Very high strength‑to‑weight ratio	Compression moulding, resin transfer moulding	Difficult to recycle; bio‑based resins can reduce impact.
Thermo‑formed thermoplastics	Good surface finish, moderate strength	Thermo‑forming, vacuum forming	Low material waste; can be sourced from recycled streams.

When specifying a material in the brief, use the correct BS 308 symbol and reference the material data sheet.

10. Manufacturing Strategy – Process Families (Cutting, Forming, Joining, Finishing)

• Cutting – laser, water‑jet, CNC milling; high precision, low waste, suitable for prototypes and low‑volume runs.
• Forming – injection moulding, stamping, extrusion; high repeatability, low per‑unit cost at large volumes.
• Joining – welding, adhesives, mechanical fasteners; choice influences disassembly and recyclability.
• Finishing – painting, anodising, powder coating; affects aesthetics, corrosion resistance and environmental load.

All four families must be listed in the brief’s “Manufacturing Strategy” section, together with a simple process‑flow diagram.

11. Stages in Materials Processing for Quantity Production (Syllabus Point 9)

1. Design of tooling / mould
2. Tooling manufacture (mould making, die cutting)
3. Material preparation (drying, granulation, sheet cutting)
4. Primary forming (injection, stamping, extrusion)
5. Secondary operations (assembly, machining, surface finishing)
6. Inspection & quality control

12. Energy & Control Systems in Large‑Scale Manufacturing

• Machine power rating (kW) × annual operating hours = energy consumption (kWh).
• Automation level – PLC‑controlled cycles reduce labour but raise capital cost.
• Energy‑recovery systems (e.g., heat exchangers on injection moulders).
• Carbon‑footprint targets set by the company or legislation must be reflected in the brief.

13. Emerging Technology (A‑Level Focus)

• Hybrid manufacturing – additive (3‑D printed) + subtractive machining for complex tooling.
• Industry 4.0 – IoT sensors for real‑time monitoring of temperature, pressure, cycle time.
• Digital twins – virtual simulation of the production line to optimise layout and throughput.

14. Cost Estimation for Quantity Production

Per‑unit cost formula:

$$C_u = \frac{C_f + C_m}{N} + C_v$$

• $C_f$ – Fixed costs (tooling, set‑up, design, prototyping)
• $C_m$ – Material cost for the whole batch
• $N$ – Number of units produced
• $C_v$ – Variable cost per unit (labour, energy, overhead, consumables)

Example – 5 000 units

Cost Item	Amount (£)	Notes
Tooling & Set‑up	12 000	Fixed – mould design & manufacture
Material (plastic)	15 000	£3 per unit
Labour (assembly)	10 000	£2 per unit
Energy & Overhead	5 000	£1 per unit
Total Cost	42 000
Cost per Unit	£8.40	(£42 000 ÷ 5 000)

15. Selecting the Appropriate Production Method

Method	When to Use	Key Advantages	Key Limitations
Injection moulding	Large volumes, high repeatability	Very low per‑unit cost after tooling, excellent dimensional control	High upfront tooling cost, limited design changes
Sheet‑metal stamping	Metal components, high‑speed production	Fast cycle times, high material utilisation	Tooling cost, limited to relatively simple geometries
3‑D printing (Additive)	Low‑volume, highly customised or complex geometry	Low set‑up cost, design freedom	Higher per‑unit cost, slower build rate, limited material options
Assembly line (sub‑assembly + final integration)	Products with many components	Efficient labour utilisation, easy automation	Requires detailed process planning, higher initial capital
Hybrid processes (e.g., 3‑D printed moulds for short‑run injection)	Short‑run, high‑quality plastic parts	Reduced tooling cost, retains injection quality	Limited to low‑volume runs, mould durability lower

16. Step‑by‑Step Development of the Design Brief

1. Conduct market research & user analysis.
2. Write a concise Product Overview (use & market segment).
3. Define functional, ergonomic, aesthetic, safety, sustainability and cost specifications – link each to a design principle.
4. Select production processes and justify tool‑making requirements.
5. Perform a detailed cost breakdown and set a pricing strategy.
6. Complete a risk‑assessment summary and check legal/regulatory compliance.
7. Prepare communication artefacts – hand‑drawn sketches, CAD views, BOM, revision history.
8. Review the brief against the syllabus checklist (see Section 18) and obtain stakeholder sign‑off.

17. Market Research – Foundations for the Brief

Typical sources: surveys, focus groups, competitor analysis, trend reports, statutory regulations.

• Who is the target customer (demographics, psychographics, buying behaviour)?
• What problem does the product solve and how is it currently addressed?
• What price range is acceptable and which value‑added features are expected?
• Which materials, finishes and sustainability attributes are preferred?
• What cultural, legal or economic constraints exist in the target market?

18. Full Design Brief Template (Recommended Structure)

Section	Content Required (Key Points)
Product Overview	One‑sentence description, intended use, market segment, design intent.
Target Market	Demographics, psychographics, buying patterns, estimated market size.
Functional Requirements	Performance criteria, dimensions, weight limits, durability, operating environment.
Aesthetic Requirements	Style, colour palette (Pantone/RYB), surface finish, branding guidelines.
Ergonomic & Safety Requirements	Anthropometric limits, grip comfort, hazard identification, relevant standards (e.g., EN 71, ISO 13485).
Manufacturing Strategy	Chosen processes (cutting, forming, joining, finishing), tooling needs, batch size, process‑flow diagram.
Materials & Components	Selected material(s) with BS 308 symbol, justification (properties, cost, sustainability), component list.
Cost & Pricing	Target unit cost, detailed cost breakdown (fixed, material, variable), pricing strategy, profit margin.
Quality & Standards	Applicable ISO/BS standards, inspection methods, tolerances.
Sustainability	Recycled‑content %, carbon‑footprint target, design‑for‑disassembly plan, LCA scope.
Risk & Legal	Risk‑assessment summary table, IP status, regulatory compliance (CE, FDA, RoHS).
Communication & Documentation	Hand‑drawn sketches, CAD file list, Bill of Materials, revision history, drawing conventions.

19. Example Design Brief – “Eco‑Smart Water Bottle”

Section	Key Extract (Illustrative)
Product Overview	Reusable 750 ml water bottle with integrated UV‑LED sterilisation, aimed at eco‑conscious urban commuters.
Target Market	Adults 18‑35, middle‑income, active lifestyle, UK & EU markets; estimated 1.2 M potential users.
Functional Requirements	UV‑LED must deliver ≥ 99.9 % bacterial kill in ≤ 60 s; bottle must survive 5 m drop from 1 m; temperature range 0‑40 °C.
Aesthetic Requirements	Matte‑soft‑touch finish, colour: Pantone 286 C, laser‑etched logo 0.2 mm deep.
Ergonomic & Safety	Grip diameter 45 mm ± 3 mm; BPA‑free material; CE‑marked UV module; risk‑assessment completed (see Section 7).
Manufacturing Strategy	Injection moulding (Tritan®) for body, CNC machining for UV housing, assembly line with robotic pick‑and‑place; batch size 10 000.
Materials & Components	Body – Tritan® (≥ 80 % recycled content, BS 308 symbol “PL‑T”); UV module – aluminium alloy (100 % recyclable).
Cost & Pricing	Total cost per unit £9.20; target retail price £24.99; profit margin 58 %.
Sustainability	Carbon‑footprint ≤ 1.8 kg CO₂e per unit; design‑for‑disassembly – 4 snap‑fit joints; end‑of‑life recycling scheme.
Risk & Legal	Risk‑assessment summary (see Section 7); complies with EU REACH, RoHS, and CE Low‑Voltage Directive.
Communication & Documentation	Hand‑drawn orthogonal sketches (Fig 1‑3), CAD assembly model (DWG), BOM, revision log (R1‑2025‑01).

20. Quick‑Reference Checklist (Before Submission)

• All six design‑process stages referenced in the brief?
• Each design principle linked to a specific specification?
• Hand‑drawn sketches included (Paper 1 requirement)?
• Correct drawing conventions (projection, scale, symbols) used?
• Market, cultural, economic, environmental and social impacts discussed?
• Quantifiable sustainability targets stated?
• Risk‑assessment summary table present and signed?
• Materials specified with BS 308 symbols and justification?
• Manufacturing strategy lists cutting, forming, joining, finishing processes?
• Energy use and carbon‑footprint estimates included?
• Cost formula applied and breakdown shown?
• All required sections (Table 18) completed and logically ordered?
• Revision history and stakeholder approval signatures attached?

21. References to the Cambridge International AS & A Level Design & Technology (9705) Syllabus

• Design process – Section 2.
• Design principles – Section 3.
• Communication – Section 4 (including hand‑drawn sketches).
• Design & technology in society – Section 5 (AO1c / AO4d).
• Sustainable design – Section 6 (checklist).
• Health & safety – Section 7 (risk‑assessment box).
• Aesthetics & ergonomics – Section 8 (linked to specifications).
• Materials & components – Section 9.
• Manufacturing strategy – Sections 10‑12.
• Cost estimation – Section 17.
• Emerging technology – Section 13.
• Full brief format – Section 18.

22. Final Note

When writing the brief, keep it concise (≈ 1 500‑2 000 words for the coursework) but ensure every syllabus requirement is explicitly addressed. Use the tables and checklists above as a scaffold – they map directly onto the assessment objectives and will help you achieve the highest marks.