For each project:-

• A log book recording progress is to be kept. A photographic record of your activities should be included.
• A production plan using a flow chart is to be produced for each project – include estimated times, materials, processes and tools.
• Health and safety issues must be noted in the logbook.
• A service plan must be completed for all equipment and machines used.
• A risk assessment must be completed for each activity.
• Evaluate each project against the specification

The following projects are to be made as a recommended minimum:-

Printed Circuit Board Manufacture

• An eltronic alarm circuit is to be produced using a photo resist method
• Etching to be done using a bubble etch tank
• Circuit board to be well prepared with no broken tracks.
• Tracks to be tinned to aid soldering
• Holes to be drilled for components ( Diameter 1mm – 1.5 mm)
• Fixing holes to be drilled (Diameter 4mm)
• Circuit to be assembled and tested.
• All Health and Safety precautions to be taken.
• All equipment to be service checked before use.

Door Plaque/Number

• A plaque is to be produced suitable for attaching to an outside door or gate.
• Plaque to be sand-cast in aluminium.
• Mould to be machined from modelling foam using 3D CNC router.
• Finish is to be sand blasted, spray painted and polished where appropriate.
• Fixings are to be included in the finished product.
• The plaque is to be carefully fettled to remove excess metal; cut edges to be blended in.
• All Health and Safety precautions to be taken.
• All equipment to be service checked before use.

Screwdriver

• A screwdriver is to be designed and made which will be tested using standard slot head screws
•The handle should be comfortable to use.
• Handle to be designed and manufactured using CADCAM.
• Aluminium to be used to machine the handle (diameter 25mm)
• Centre hole to be drilled using a manual centre lathe.
• Screwdriver blade to be made from silver steel. (Practice blade to be made from mild steel and case hardened)
• The blade is to be forged.
• The blade is to be hardened.
• The blade is to be tempered (to straw).
• The blade is to be annealed as necessary when forging (due to work hardening).
• The blade finish should be satin as a result of going through the grades using wet and dry paper (silicon carbide paper).
• The handle finish is direct from the lathe with any sharp points or edges fettled.
• The parts are to be joined using a screw thread and secured using two part epoxy adhesive (Araldite).
• All Health and Safety precautions to be taken.
• All equipment to be service checked before use.

The Copper Pot

• A small trinket box is to be made from copper tube and sheet.
• The parts are to be soft soldered together.
• The top and bottom of the box are to be joined using the pill box method.
• Surplus metal is to be trimmed away with tin snips.
• The edges are to be filed back to level and then polished.
• The box may be personalised by etching, lining, spray painting, sand blasting with a resist etc.
• The bottom of the box should have felt attached to protect polished surfaces.
• All Health and Safety precautions to be taken.
• All equipment to be service checked before use.

Each project is to be evaluated aganst these specifications