Resistant Materials

Year 7

Banksy Box
Students explore small personal items that can be stored in a small wooden box. An isometric projection drawing is produced and basic hand tools are used to make the boxes. Students use lap joints to join the sides of the box and cut a base from plywood. Graffiti style graphics are engraved onto the lid using a laser cutter with the designs reflecting what the boxes are to store.

Year 8

Pewter Cast Key Fob
Students explore a fun theme to shape the pewter cast key fob. CAD is used to design a mould which is then laser cut from plywood. The mould is then used in the pewter casting process. If appropriate to the design, plastics are engraved and embedded into the pewter cast key fobs.

Year 9

USB LED Desk Lamp
Students design make an LED desk lamp using a USB port as the power supply.  Wood, plastics and electronic circuits are incorporated in the desk lamp product. Before manufacturing takes place a working drawing including dimensions are produced. The desk lamps are then made and tested. As an extension task students explore the use of more advanced electronics so that the desk lamp automatically switches the lamp off.

BCA Smart Product Design and Manufacture (SPDM)
Level 2 Technical Award

Year 10 & 11

What will I learn?

The purpose of the course is to provide you with practical technical knowledge, understanding and skills in designing and manufacturing products using contemporary technologies. SPDM integrates 3D printing, CAD/CAM, coding and microcontrollers.

Course Overview

Unit 1: Product Design

Unit 1 teaches design and modelling techniques plus 2D and 3D CAD. Learners apply these skills semi-independently in their own project, which is to design and develop a Smart product prototype.

Unit 2: Product Manufacture

Product Manufacture teaches the use of 3D printing and other Computer Aided Manufacture (CAM) tools to produce prototypes rapidly. The unit also shows learners how to embed physical components into a design so that they can prototype an integrated Smart product.

Unit 3: Smart Electronics

Unit 3 covers microcontrollers, digital and analogue inputs, outputs, and sensors. Students learn how to design and program a simple Smart system with an input and an output which they can integrate within a Smart product.


Potential further 70 Marks Students take an exam leading to A*-C GSCE equivalent grades. Alternatively, students not evidencing the ability to pass at this level are able to sit the level 1 paper and still obtain an accredited qualification.

For more information on the specification please visit the Course Website

Students Work