Design & Technology: Product Design - KS5

A Level D&T Product Design is focused towards consumer products and applications; their analysis in respect of materials, components, and marketability to understand their selection and uses in industrial and commercial practices of product development.

The key topics covered are:

• Identifying requirements: design contexts, stakeholders, user considerations
• Learning from existing products and practice: product analysis, work of others, product lifecycle
• Implications of wider issues: factors in design possibilities, development, manufacture, market distribution
• Design thinking and communication: graphic communciation in 2D and 3D, design and development, design strategies
• Materials and component considerations: material selection in products, when designing and in prototyping, properties of materials.
• Technical understanding: structural integrity, surface finishes, smart and modern technologies.
• Manufacturing processes and techniques: understanding materials and processes used to make iterative models, final prototypes and commercial products, scales of production and quality.
• Viability of design solutions: assessing designs for stakeholder requirements, for technical specifications and
  commercial viability.
• Health and safety: safe working practices in a workshop and implications of health and safety legislation on
  product manufacture.

The final assessment for A Level D&T: Product Design is split into two parts, 50% Non-exam assessment (NEA), 50% Written exam:

NEA 50% of the A Level:

• Iterative Design Project – 100 marks, approx 65 hours non-exam assessment (50% of total A Level)
• The ‘Iterative Design Project’ requires learners to undertake a substantial design, make and evaluate project centred on the iterative processes of explore, create and evaluate.
• Students identify a design opportunity or problem from a context of their own choice, and create a portfolio of evidence in real time through the project to demonstrate their competence.

Written exam 50% of the A Level, consisting of two written papers:

Paper 1: Principles of Product Design

• 100 marks 1 hour 30 minutes written paper (26.7% of total A Level)

This paper is set out through four sets of questions that predominantly cover technical principles within each endorsed title. Students will be required to:

• analyse existing products
• demonstrate applied mathematical skills
• demonstrate their technical knowledge of materials, product functionality, manufacturing processes and techniques
• demonstrate their understanding of wider social, moral and environmental issues that impact on the design and manufacturing industries

Paper 2: Problem solving in Product Design 

• 70 marks, 1 hour 45 minutes written paper (23.3% of total A Level)

This paper has a series of longer answer questions that require learners to demonstrate their problem solving and critical evaluation skills. Students will be required to:

• apply their knowledge, understanding and skills of designing and manufacturing prototypes and products
• demonstrate their higher thinking skills to solve problems and evaluate situations and suitability of design solutions

A Level D&T: Produce Design encourages students to think creatively and critically as they develop solutions to real-world problems. Through designing, prototyping, and evaluating products, students gain insight into market needs and the full design process—from concept to commercial manufacture. This course builds technical knowledge, problem-solving skills, and an understanding of user needs, preparing students for further study and careers in design, engineering, and related industries. Students build their skills in thinking and designing to support the requirements that they will need to demonstrate when progressing to higher education or industry. 

A Level D&T: Product Design create empathetic learners who have the ability to confidently critique products, situations and society in every walk of their lives now and in the future.

Why Choose A Level D&T: Product Design?

1. Future-Focused Thinking

This course explores how technological innovation shapes our world—historically, culturally, economically, and socially. Students develop a critical understanding of the role of design in addressing global challenges, preparing them to thrive in a rapidly evolving, tech-driven society.

2. Advanced Practical Skills

From conceptual sketches to high-fidelity prototypes, students engage in sophisticated design processes using a wide range of materials and manufacturing techniques. This hands-on experience fosters creativity, precision, and technical fluency.

3. Complex Problem Solving

Personal design briefs at A Level demand analytical thinking, iterative development, and evidence-based decision-making. Students learn to evaluate user needs, sustainability, and functionality—skills that are essential in both professional and academic contexts.

4. Pathways to Innovation

A Level D&T: Product Design provides a strong foundation for careers in engineering, architecture, industrial design, and advanced manufacturing. It also supports progression to university courses in STEM, design, and applied sciences.

5. Interdisciplinary Learning

This subject integrates principles from physics, maths, and art, encouraging students to make connections across disciplines. It promotes systems thinking and a holistic approach to design challenges.

6. Robust and Reflective Assessment

Assessment combines rigorous written analysis with practical project work. Students receive regular feedback to refine their ideas, improve outcomes, and build confidence in their design capabilities.

What's the Big Picture?

Studying A Level D&T: Product Design equips students with a powerful blend of creative, technical, and strategic skills. Whether they aspire to design sustainable products, engineer innovative solutions, or simply understand the mechanics behind everyday objects, this course empowers them to make a meaningful impact.

For students to be successful in D&T: Product Design you must be interested in the subject, have passion, creativity and inquisitive nature to solve real-world problems.

Entry Requirements:

• A minimum of a grade 6 in GCSE Design and Technology (Graphics or Materials) if studied.
• If you have not studied Design and Technology at GCSE: 
  • You should ideally have achieved a Grade 6 in Mathematics, as this demonstrates the required level of problem-solving ability.
  • You will also be required to bring a portfolio of work upon enrolment.

Portfolio Guidance:

We are looking for students who can demonstrate a passion for Product Design. Your portfolio should showcase your creativity, curiosity, and ability to develop and communicate ideas through a range of projects and experiences.

Ideas for work that we would like you to produce include (but are not limited to) the following:  

• a range of hand sketches showing a variety of products and objects in different drawing styles (ie. Isometric, Orthographic, Exploded, Sectional, Perspective, Shaded, Tonal, Textured, Rendered).
• examples of modelling using card/recycling and/or CAD software such as SketchUp, TinkerCAD (iPad version available) and Onshape.
• production of scale models/dioramas to show attention to detail and accuracy.
• investigations into a product's manufacture and assembly by taking it apart, photographing and labelling its component parts & structure.
• examples and explanations of modifications made to a product/object to aid either an older, younger or disabled people.
• a research piece on an existing designer, from any field of design, that you admire or are inspired by.
• user trips and experiences that show in depth analysis of products when in use (videos of these would be an appropriate recording of this).
• a product analysis of an object you find interesting inc. materials, function, manufacturing, aesthetics, safety considerations etc.
• a review of a television program/episode/series or short film which explores an aspect of the design industry (ie. Grand Designs, George Clarke’s Amazing Spaces, Mega Factories, Inside the Factory, The Repair Shop, How do they do it?, How it’s made)  
• a career or pathway you are currently heading towards (if it isn’t in the ‘Design’ industry, it’ll need to showcase how Product Design can benefit it)

We are looking for your passion, your creativity and your inquisitive nature but in addition to this, we are keen to see your current ability, skill level and depth of DT knowledge. The portfolio of work (preferably collated in PowerPoint or PDF) will also be valuable to gauge your current approach to presentation.

Exemplar of work presentation:

A Level D&T: Product Design is an excellent stepping stone to further study and careers such as:

• Product and Industrial Design
• Manufacturing
• Engineering: civil, mechanical, applied, aeronautical, electronics
• Environment: architecture, interior design, landscape design
• Graphic Design: packaging, publication 
• Marketing and Advertising
• Material science
• Media

In addition to university, many of our students at SJB have gone on to apprenticeships with organisations such as British Airways, Transport for London, and Rolls-Royce.

Enrichment in our department plays a vital role in helping students think creatively and solve real-world problems beyond the classroom. We endeavour to provide opportunities that develop essential skills for future careers and everyday life. Please see our opportunities that we offer at KS5:

• SATRO Problem Solving Challenge – Each year, we host and compete in this exciting engineering challenge, with KS3, KS4, and KS5 teams going head-to-head against schools from across the South East. Students work collaboratively to solve real-world engineering problems, gaining valuable hands-on experience while strengthening their teamwork, problem-solving, and creative thinking skills. The event also offers students the chance to connect with professionals from the engineering industry, broadening their horizons and inspiring future careers.
• DT Industry in conversation – All KS5 Design and Technology students attend this dynamic event, featuring interactive sessions led by top designers, engineers, and innovators. Students explore the latest in sustainable materials, digital prototyping, and design thinking, gaining real-world insights and inspiration for their own projects. The event brings technology and creativity to life, connecting students with industry experts and the journey from concept to reality.