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Modelling allows designers to explore, test and refine ideas before committing to full manufacture. This lesson covers 2D and 3D modelling methods — both digital (CAD) and physical — as required by AQA GCSE Design and Technology (8552), Section 3.3. These are tested on Paper 2 and are essential skills for your NEA.
Modelling serves several purposes in the design process:
| Purpose | Explanation |
|---|---|
| Test form and proportion | Does the product look right? Is it the correct size? |
| Test function | Does the mechanism work? Do the parts fit together? |
| Communicate ideas | Show clients and stakeholders what the product will look like |
| Identify problems early | Discover issues before expensive tooling and manufacturing begin |
| Refine the design | Make changes quickly and cheaply on a model rather than a finished product |
Physical modelling involves creating tangible, three-dimensional representations of a design using materials such as card, foam, clay, MDF or 3D-printed plastic.
| Model Type | Material | Purpose |
|---|---|---|
| Card model (mock-up) | Card, paper, tape | Quick shape and proportion check; packaging net testing |
| Foam model | Styrofoam, blue foam (high-density polyurethane) | Form exploration; can be carved and sanded to shape |
| Clay model | Modelling clay, Plasticine | Ergonomic testing; automotive design (full-size clay models) |
| Breadboard model | Breadboard, components, wires | Electronic circuit prototyping (temporary, no soldering) |
| Toile | Calico or muslin fabric | Textile prototype to test fit and pattern before cutting expensive fabric |
| 3D-printed model | PLA, ABS, resin | Accurate representation of the final form; functional testing of mechanisms |
| Advantages | Disadvantages |
|---|---|
| Can be handled, held and tested physically | Time-consuming to make |
| Gives a realistic sense of scale and form | Materials cost money |
| Users can test ergonomics directly | Difficult to modify (may need to start again) |
| No specialist digital skills required | Only one version exists (unless duplicated) |
AQA Exam Tip: In your NEA, photograph your physical models and annotate the photographs. Explain what you tested, what you learned, and how it informed your next design iteration. This demonstrates the iterative design process.
CAD (Computer-Aided Design) software allows designers to create precise 2D drawings and 3D models digitally. CAD models can be modified easily, shared electronically and used to drive CAM (Computer-Aided Manufacturing) equipment.
| Software | Type | Use |
|---|---|---|
| 2D Design | 2D | Schools — laser cutter files, simple drawings |
| Techsoft Design V3 | 2D | Schools — CNC routing, laser cutting |
| Google SketchUp | 3D | Free modelling tool; architectural and product visualisation |
| Tinkercad | 3D | Free, browser-based; simple 3D models for 3D printing |
| Fusion 360 | 3D (parametric) | Industry-standard; product design, engineering, simulation, CAM |
| SolidWorks | 3D (parametric) | Professional engineering design; widely used in industry |
| Blender | 3D (surface/mesh) | Free; organic modelling, rendering, animation |
| Circuit Wizard | Schematic | PCB design and circuit simulation |
| Adobe Illustrator | 2D vector | Graphic design, packaging, logos |
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