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Torch

infoWhy this? Combining task and product analysis with CAD, acrylic forming, laser cutting, and basic electronics demonstrates how different disciplines contribute to a functional product. Designing, making, packaging, and evaluating a torch develops precision, creativity, and informed decision-making across the complete design process.

scheduleWhy now? Building on introductory design and workshop practice, we extend our experience to thermoplastics, digital manufacture, and a simple electrical circuit. This establishes knowledge of CAD, laser cutting, and LEDs that is developed further through soldered electronic manufacture in the later Lamps unit.

neurologyYou need to know

  • A task analysis involves breaking down a task into its component steps, considering the intended use and scenarios for the product.
  • Product analysis is the detailed examination of a product's features, functions, and suitability for purpose.
  • ACCESS FM stands for Aesthetics, Cost, Customer, Environment, Size, Safety, Function, and Materials, and is used to analyse and compare products.
  • Torches can be made from a variety of materials, including acrylic, and have different design features depending on their intended use.
  • Acrylic is a rigid thermoplastic that is available in sheets and softens when heated.
  • Acrylic can be laser cut because the laser heats and removes the material to create precise shapes.
  • Acrylic must be laser cut using suitable power and speed settings, an operating extraction system, and supervised safety procedures.
  • Acrylic can be formed by line bending with a strip heater, joined using solvent cement, and finished by filing, sanding, and polishing its edges.
  • Isometric drawing is a method of visually representing three-dimensional objects in two dimensions, using 30-degree angles.
  • 2D Design is a computer-aided design (CAD) software used to create precise digital drawings for manufacturing.
  • Key tools in 2D Design include line, shape, text, dimension, and editing tools such as trim, copy, and delete.
  • A laser cutter is a machine that uses a laser to cut materials, and has specific advantages such as precision, speed, and the ability to cut complex shapes, and disadvantages such as cost, material limitations, and safety considerations.
  • The acrylic casing forms the outer body of a torch, while the internal material positions and supports the electrical components.
  • A torch requires a complete circuit with an uninterrupted conductive path between the two terminals of the battery.
  • The battery supplies electrical energy to the torch circuit.
  • An LED converts electrical energy into light.
  • An LED is polarised and must be connected the correct way round for current to flow through it.
  • A switch closes the circuit to turn the torch on and opens the circuit to turn the torch off.
  • A current-limiting resistor, if used, limits the current flowing through the LED to prevent damage.
  • Product evaluation involves assessing a product against its design criteria and intended purpose.
  • Packaging serves to protect, contain, and promote a product, and must be designed with both function and aesthetics in mind.

rocket_launchYou must be able to

  • Complete a detailed task analysis for a torch, considering intended uses and scenarios.
  • Carry out a product analysis of two different torches using the ACCESS FM framework.
  • Generate four distinct design ideas for an acrylic torch, showing creativity and consideration of user needs.
  • Produce an accurate isometric drawing of the final torch design by hand or using appropriate tools.
  • Create a digital version of the final torch design using 2D Design software, correctly using key tools and functions.
  • Identify and explain the advantages and disadvantages of using a laser cutter for manufacturing the torch.
  • Laser cut acrylic using suitable power and speed settings, an operating extraction system, and supervised safety procedures.
  • Form acrylic by heating it along a line with a strip heater, bending it accurately around a former, and holding it in position until it cools.
  • Join acrylic parts using solvent cement safely and accurately under supervision.
  • Finish acrylic edges by filing, sanding with progressively finer abrasive paper, and polishing them to produce a smooth surface.
  • Assemble the final torch product so that the casing supports and protects a complete circuit containing a battery, an LED connected with the correct polarity, a switch, and a current-limiting resistor if required.
  • Test the torch circuit by using the switch to open and close the circuit and checking that the LED lights when the circuit is complete.
  • Conduct a thorough product evaluation, referencing the original design criteria and user feedback.
  • Design and construct suitable packaging for the torch, considering protection, presentation, and sustainability.


Revision Quiz

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