The Course

The exam will ask questions in line with the sections below. Links to relevant web links or quizzes are given for each section.

Each question will be based on a product such as a bicycle, a toy or a component such as a screw, or a circuit

The Core


Download specimen papers

Specimen paper 1 (foundation)

Specimen paper 2 (Higher)

Specimen paper 7 Mechanisms (foundation)

Specimen paper 8 Mechanisms (Higher)

Details of the course with links


Types of material and their uses :-

metals e.g. mild steel, copper, brass, aluminium.

plastics e.g. polythene, high impact polystyrene, nylon. web link - metals and plastics

wood e.g. pine, oak, beech

Manufactured boards e.g plywood, mdf. web link - wood and manufactured boards

composites e.g. glass reinforced plastic(fibre glass). carbon fibre composites, concrete, Web link - Composites

Materials matching

Materials multiple choice

Manufactured boards

Plastics quiz

Plastics matching 1

Plastics matching 2

Finishing Materials - to protect and improve their appearance

Varnish, paint, oil, self finish (i.e. polish), dip coat in plastic.

web link - metal finishing


Finishing metals

Finishing wood

Finishing plastics

Materials properties - ductility, plasticity, hardness, malleability,brittleness,toughness, elasticity, conductivity, insulation(thermal and electrical) strength (compression, tension, shear, bending, torsion)

Web link - material properties

Material properties

Material properties crossword

Smart and modern materials - such as electro luminescent panels and memory metal

Web link - smart and modern materials

Smart materials

Tools and processes - used to produce products that match a specification

Web link - plastic forming

Tools crossword

Tool Uses

Tool Chooser


Components - electronic, pneumatic, mechanical, standard pre-manufactured components - handles, hinges etc.

Web link - fixings and fastenings

Metal fixings

Fixings and fastenings crossword


Electronics symbols

Electronics crossword

Energy sources - storage, conversion and transmission. Energy can do useful work.

Primary - solar, wind, fossil fuels, nuclear.

Secondary sources - batteries, springs, rubber bands, compressed air.

Web link - alternative energy1

Web link - alternative energy2


Energy types


Energy sources

Core Electronics  
Use and recognise circuit symbols for common components Web link - Electronics symbols
Electronics symbols
Give examples of conductors and insulators.
Insulators & Conductors
Understand the units used in electronics. To measure current (AMPS), voltage (VOLTS), resistance (OHMS) and capacitance (FARADS). Multiples and sub-multiples of units.

Units Matching


Design/understand simple circuits in block form with input sensors - light (LDR), temperature (thermistor), moisture - process - and outputs such as lights (lamps or LEDs), motors, and solenoids.

Web link - The Thermistor

Web link - The LDR

Inputs and Outputs
Ohms law for simple calculations. Web link - Ohms Law
Power calculations. Power in Watts = Volts X Amps
Resistors in series. Easy just add them up!

Common switches - toggle switch, push switch, micro switch, SPST, SPDT, DPDT, NO (normally open), NC (normally closed)

Web link - Switches 1 Web link - Switches 2 Web link Switches 3

The diode is a component which acts as a one way conductor. Web link - The Diode
LEDs are used in circuits as outputs but have to have a current limiting resistor in series with them. Web link - Batteries and LEDs
Identify the pins on a transistor
Core Mechanisms and Structures
Mechanisms as input, process, output and feedback. Open and closed loop systems
Mechanisms Crossword

Load, effort and fulcrum. Moments (force X distance) calculations.

Web link - Forces and moments

Levers and linkages and their uses.


Simple gear ratios and transmission speed.

Velocity ratios
Types of motion - linear, rotary, oscillating and reciprocating.
Forces and motion
Crank, cam, follower and how they change motion.
Structures - frames especially triangulation to establish rigidity. reinforcement by gussets, ribs, braces and laminating. Web link - Frames
Quality Design and Manufacturing

Scales of production - one-off or job, batch, repetitive flow production.

Use of CAD and CADCAM system. CNC lathe and CNC mill. Advantages and disadvantages. Laser cutter.

Web link - CNC machines

Web link - Manufacturing

Anthropometrics and ergonomics.


Manufacturing Crossword

Signs and Symbols

Consider the safe use of all equipment and materials. Risk assessment.
Signs and Symbols

Environmental effects especially when disposing of products and materials.

Personal safety.
Mechanisms Module  

Transmission - Types of gears and their uses - spur, bevel, helical, worm, contrate, crown wheel, rack and pinion.

Web link - gears and pulleys

Web link - differential

Pulleys and belts - flat, toothed and vee belts and pulleys. Cone pulleys.

Sprockets and chains.

Splined shafts, universal joints, plain and flexible couplings.

Belt tensioners.

Gear ratios and transmission speeds. Driver and driven speeds. Direction of rotation in gear and pulley systems.

Efficiency, Mechanical Advantage and Velocity Ratios.

Wheel and axle, screw jack and compound pulley and gear systems.

Velocity Ratios

Systems & Control Crossword

Bearings and Lubrication - plain, roller and ball. Types of lubrication.

Conversion of Motion - by cranks, cam and follower, crank and slider. Rack and pinion, ratchet and pawl, eccentric and simple cams.

Web link - Mechanisms

Web link - Mechanisms (Flying Pig)


Control of Motion

Brakes - hydraulic, disc, drum and cable operated brakes (as on bicycles)

Web link - cable brakes


Clutches - single plate, dog clutches and centrifugal clutches.

Web link - centrifugal clutch