Unit 1 – Materials Technology & Science

Aim and purpose

The purpose of this unit is to develop learners understanding of the materials used in engineering products and the scientific principles engineers use to identify which materials are the most suitable for use in a given engineering context.

Unit introduction

When designing products, engineers have to select appropriate materials and components for the application. In this unit, learners will develop knowledge and understanding of a range of engineering materials and their properties. They will also consider several of the scientific principles that can affect the choice of material or components in various engineering contexts. In particular, the learner will develop knowledge of:

  • properties of materials
  • engineering materials
  • engineering chemistry
  • electricity and electronics
  • transfer of energy

Assessment 

This unit is assessed by an external examination set and marked by AQA. The examination takes place under controlled examination conditions.

Unit 2 – Mechanical Systems

Aim and purpose

The purpose of this unit is to give learners a practical understanding of mechanical systems. This includes different types of mechanical systems and their typical applications, how these systems are designed, and how they and their component parts function.

Unit introduction

Mechanical systems are used to carry out tasks that involve forces and movement. They typically involve some form of power source that generates force and movement, functional elements that change the magnitude or direction of this force or movement, a means of transmitting this force or movement to where it is required and some form of control system.

In this unit learners will explore different types of mechanical systems and their typical applications, how these systems are designed, and how they (and their component parts) function. They will also assemble and test mechanical systems and identify the preventative maintenance requirements.

Assessment 

This unit is assessed by an AQA set and marked assignment.

Unit 3 – Mathematics for Engineers

Aim and purpose

The purpose of this unit is for learners to model and solve engineering problems across a range of practical engineering contexts through the use of mathematics.

Unit introduction

When designing engineered products, or solving engineering problems, engineers frequently have to select and apply mathematical techniques and methods. In this unit, learners will develop knowledge, skills and understanding of a range of standard mathematical techniques, enabling their selection and use in practical engineering situations. In particular, the learner will develop the ability to:

  • solve problems using the practical application of mathematics
  • use arithmetic to solve engineering problems
  • use algebra to solve engineering problems
  • use trigonometry and coordinate geometry to solve engineering problems
  • use statistics to solve engineering problems
  • use calculus to solve engineering problems.

Assessment 

This unit is assessed by an external examination set and marked by AQA. The examination takes place under controlled examination conditions.

Unit 4 – Engineering Design

Aim and purpose

Learners who complete this unit will develop an understanding of the engineering design process and will use industry standard tools and techniques to deliver an engineering design from start to finish.

Unit introduction

Design is the essential creative process of engineering, which distinguishes it from science, and which calls for imagination, creativity, the knowledge and application of technical and scientific skills, and skilful use of materials. The teaching of design has an integral place in the formation of all engineers. The unit will prove the key knowledge and skills needed to be a design engineer:

  • strong problem-solving skills
  • a creative approach for generating new ideas
  • a sound knowledge of computer assisted design (CAD) software
  • an excellent grasp of engineering and design principles
  • knowledge of the qualities of manufacturing parts and materials used in designs
  • communication skills
  • an understanding of manufacturing processes and construction methods
  • an awareness of the environmental impact of design ideas.
  • This unit will assess learners understanding of the engineering design process (including all of the considerations and constraints a design engineer will face) and their ability to produce an engineering design using industry standard tools and techniques.
  • This unit provides an opportunity to evidence achievement of the transferable skills of communication (oral and written) and problem-solving.

Unit 5 – Production & Manufacturing

Aim and purpose

The purpose of this unit is to provide learners with an understanding of the range of manufacturing processes and systems relevant to the production of multiple components. The learner will develop a production plan, schedule the production and work as part of a team to manufacture the batch of products.

Unit introduction

In many engineering contexts, products are manufactured in quantity. Engineers specify which manufacturing processes are required to convert the available forms of material into the finished products, and the systems to be used to support the production of consistent products.

In this unit, learners will develop knowledge and understanding of a range of manufacturing processes and use these processes to plan and manufacture a batch of products. In particular, the learner will develop knowledge of:

  • manufacturing processes
  • engineering manufacturing systems
  • quality control and quality assurance
  • engineering production planning
  • performing production processes.

This unit provides an opportunity to evidence achievement of the transferable skill of teamwork.

Assessment

This unit will be assessed through a centre set and marked assignment.

Unit 6 – Design Visualisation

Aim and purpose

This unit focuses on the use of 3D parametric modelling software in the design process, and how it can then be used to create the different outputs such as 2D drawings and animations. The unit will allow learners to develop skills in using the latest in CAD technology and CAD techniques for design engineering.

Unit introduction

This unit enables learners to develop the knowledge and skills needed to set up and operate a 3D parametric computer-aided drawing (CAD) system to produce fully detailed models and drawings for engineering activities, in accordance with approved procedures.

The drawings produced will include detailed component drawings for manufacturing, assembly and sub-assembly drawings.

Learners will follow a design brief and carry out concept development to produce design solutions. They will then need to capture all of the relevant design requirements and necessary information in order to carry out the drawing operations. They will select and use the appropriate equipment and software, based on the type and complexity of the drawing functions to be carried out, to produce 3D models and 2D drawings, including the use of rendering and animation in their designs.

Learners will be expected to work to appropriate and current British Standards (BS) to produce fully detailed drawings to enable the manufacture and assembly of the product to take place.

The unit will provide the underpinning knowledge needed to enable learners to take an informed approach to applying computer-aided design procedures for engineering. Learners will understand the computer system and software used, and its application. They will know about the various tools and techniques used to produce the drawings, in sufficient depth to provide a sound basis for carrying out the activities to the required specification.

Learners will understand the safety precautions required when working with the computer drawing system and will be fully aware of any health, safety and environmental requirements, and the appropriate legislative and regulatory frameworks applicable.

Unit 7 – Advanced Design for Manufacture

Aim and purpose

This unit develops the knowledge and skills learners need to be able to produce a final build plan for the manufacture and/or assembly of a new product design. They will be required to follow a systematic approach to design for manufacture (DFM) and design for assembly (DFA) analysis.

Unit introduction

The aim of this unit is to enable students to develop a thorough understanding of engineering design and manufacturing, and apply that understanding to the design for manufacture of products at an overall and detailed level. Learners will gain an understanding of modern design techniques and manufacturing technologies.

Unit 8 – Design Engineer Project Management

Aim and purpose

This unit will give candidates experience of completing an industrially sourced design project for an external industrial client.

Unit introduction

The specific aim of this unit is to train the learner to project manage an engineering design. This unit will draw on the knowledge and expertise gained while studying the other units of the Technical Level in Design Engineering, plus the knowledge gained from within this unit, to tackle a real engineering industrial, or commercial, problem thereby integrating design and engineering practice to tackle a real need or problem.

On successful completion of this unit learners will be able to:

  • apply project management and design methodology to engineering problems
  • generate ideas related to designing new or appropriate solutions, systems, components or processes
  • apply appropriate science and engineering tools to the analysis of unfamiliar problems
  • coordinate a creative and innovative design solution with the effective use of appropriate design and project management methodologies
  • understand the links between technical design and commercial risks
  • design a component, system or process using appropriate design techniques and be able to describe key elements of those processes
  • use of appropriate computer based design and project management tools to solve problems.

Assessment 

In this unit learners must complete a project relating to the development of an engineering design.