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OCR A-level Design & Technology: Product Design (H406) · Material and Component Considerations
Mini-Lesson

Material and Component Considerations

This mini-lesson covers Material and Component Considerations for OCR A-level Product Design: the material families, the properties that drive selection, and standard components.

You will distinguish thermoplastics and thermosets, match properties to jobs, sort materials, and calculate a component cost. Press Start to begin.

Material families

Choosing from the material families

Selection means matching a material family and form to the job:

  • Metals — ferrous (steels, cast iron), non-ferrous (aluminium, copper) and alloys (stainless steel, brass).
  • Polymers — thermoplastics (re-mouldable: ABS, PET, PP) and thermosets (cross-linked, permanent: epoxy, melamine).
  • Timbers — hardwoods (oak, beech), softwoods (pine) and manufactured boards.
  • Composites and smart/modern materials for enhanced or responsive performance.
Quick check

Thermoplastic or thermoset?

?Which statement correctly distinguishes thermoplastics from thermosetting polymers?
Properties

Properties that drive selection

Match the property to the demand:

  • Mechanical: tensile/compressive strength, hardness, toughness, ductility, malleability, elasticity.
  • Physical: density, electrical/thermal conductivity, corrosion resistance.

Selection is a balance: function, aesthetics, cost, availability and environmental impact together decide the choice.

Quick check

Which property matters?

?A tool that must survive being dropped without shattering needs a material that is above all...
Components

Components and standardisation

Products combine materials with bought-in components:

  • Standard components — screws, bolts, bearings, hinges and knock-down (KD) fittings made to agreed sizes.
  • They are cheap, available and interchangeable, speeding assembly and easing repair.
  • KD fittings allow flat-pack furniture to be assembled and disassembled with simple tools.
Sort it

Sort the materials

Tap a material, then the family it belongs to.

🔩 Ferrous metal

♻️ Thermoplastic

🌳 Natural timber

Quick check

Why standard components?

?Why do designers specify standard components rather than custom parts wherever possible?
Match it

Match each material to its stand-out property

Tap an item on the left, then its match on the right.

Material
Stand-out property
Calculate

Your turn — component cost

1A 2 m aluminium extrusion costs 24. Each product uses a 250 mm length. Cost of extrusion per product = cost per length x length used, i.e. (24 ÷ 2000 mm) x 250 mm. Calculate the extrusion cost per product.
Hint: 2 m = 2000 mm; 24 ÷ 2000 = 0.012 per mm; x 250.
Recap

The big ideas to know

Families: metals (ferrous/non-ferrous/alloy), polymers (thermoplastic/thermoset), timbers, composites

Thermoplastic = re-mouldable; thermoset = cross-linked, permanent

Properties: strength, hardness, toughness, ductility, density, conductivity, corrosion resistance

Selection balances function, aesthetics, cost, availability and environment

Standard components and KD fittings cut cost and ease assembly/repair

You have covered how to select materials and components and justify the choice.

🏆

Mini-lesson complete!

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