AQA A Level Product Design – Theory Content Overview
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During the course, you will need to develop your knowledge and understanding of a broad range of materials, with emphasis on the
life cycle of products, manufacture and final disposal. You will also need to consider the broader issues of the designer, including the
environmental sustainability of products and consumer safety.
Unit Overview
Theory Topics
Unit 1: Materials, Components and
Application
Written Exam (2 hours)
25% of total A Level marks
AS
Available January and June
Three sections:
•Section 1 (all questions
compulsory)
•Section 2 (one question from two)
•Section 3 (one compulsory
question)
Section A
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Natural woods
Man-made boards
Laminates and veneers
Ferrous metals
Non-ferrous metals
Alloys
Polymers
Biodegradable polymers
Elastomers
Composites
Compliant materials
Smart materials
Modern materials
Product components
Adhesives
Section B
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Unit 3: Design and Manufacture
25% of total A Level marks
A2
Available June
Consists of two sections
Choice of three questions from six
(one from each section compulsory)
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Fabrication methods
(woods, metals & plastics)
Forming methods (woods,
metals, plastics &
composites)
Casting (metals)
Metal extrusion techniques
Polymers (moulding)
Wastage processes
CAM manufacture
Finishing materials
Health and safety
QA & QC
Theory Topics
Unit Overview
Written Exam (2 hours)
Environmental issues
Sustainability issues
Ergonomics
Anthropometrics
Inclusive design
Consumer safety
Section C
Section A
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Further development of
your knowledge and
understanding of the topics
covered in Unit 1 (Section
A)
Section B
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Major developments in Technology
Product life cycle
Design and Technology in society
Role of the designer
The marketing function
Design methods
Design process
Safety / legislation
Communication methods
Illustration (2D/3D sketching)
Enhancement (rendering, etc)
Information drawing (graphs,
flowcharts, etc)
Modelling
Use of ICT in design
Design development
Human needs
QA/QC
Past and present designers
Copyright protection
Design methods
Product development / improvement
Design in the human context
Sustainability / environmental issues
Section C
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ICT applications
Manufacturing systems
Product development /
improvement
Systems and control