1. BTEC First Engineering
Learning aim A Know about engineering processes used to produce modern engineered products

2. BTEC First Engineering
The first engineers
The earliest evidence of engineering is from around 4,000 years ago. Since then, things have changed a little…
Teacher notes (PS 1):
The great step pyramid in Egypt was constructed c. 2125bc. This is one of the earliest examples of a large engineering project.
The Romans built the Pont du Gard aqueduct in France around 2,000 years ago to transport water 50km to the city of Nimes.
Vikings used long boats to travel the seas of Northern Europe and even across the North Atlantic between the 9th and 11th centuries.
In 1712 Thomas Newcomen invented a steam engine for pumping water out of mines.
The principles behind the construction and operation of all these are still used for engineering today.
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3. BTEC First Engineering
Engineering sectors
Engineered products are designed and produced by companies who specialise in different sectors.
Aerospace
Automotive
Communications
Electrical/Electronic
Mechanical
Biomedical
Chemical
Teacher notes (PS 2):
Ask learners to suggest to which sectors a bicycle, a mobile phone and a satellite would belong.
Outline the types of products associated with each sector.
An aeroplane would be aerospace; solar panels would be electrical/electronic; a fairground ride would be mechanical.
Learners to use AS 1 to consider the sectors that produce a range of different products.
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4. Engineering processes
BTEC First Engineering
Engineering processes
Processes can be divided into groups, which are linked by the features of the processes.
Machining
Forming
Fabrication
Electrical/ electronic
Turning
Milling
Drilling
Casting
Forging
Welding
Shearing
PCB manufacture
Surface mount
Teacher notes (PS 3):
Items such as car lock nuts could be turned, while milling is used to get a smooth finish to a casting.
Casting is used for things such as making car engine blocks; forging is used for products such as spanners and crankshafts.
Welding is used to join sheet steel, such as in a structure, or for making products such as skips.
PCB manufacturing and surface mounting can be associated with almost all electronic products.
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5. Scales of production One-off
BTEC First Engineering
Scales of production
One-off
Where just one product is made for a customer.
Could be a prototype.
Batch
A set number of identical products.
Some flexibility to individualise designs.
Mass
Products produced in large quantities.
Often involves automation.
Continuous
Automated production can continue for months.
Often produces low-cost products.
Teacher notes (PS 4):
One-off – designs are made individually (bespoke) for the customer. They are often craftsman made, using hand tools and light equipment. High-cost, high-value products.
Batch – a set number are produced, but with flexibility to increase production or individualise designs (e.g. cars produced with different trim levels). Also, a requirement for a repeat amount made at another time, on a regular or irregular basis, time, and quantity.
Mass – products made in large numbers, possibly until demand ceases to exist. Little human involvement in production as much is done by automated equipment.
Continuous (or flow) – production is indefinite. Commonly associated with liquid products (oil, fizzy drinks etc.) but could be for high-demand items (bottle tops, nails etc.). As with mass production, little to no human involvement in manufacture.
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6. Modern production methods
BTEC First Engineering
Modern production methods
Uses of robots
Robots can be used for:
remotely operated vehicles
manufacturing
welding
painting
quality control
packaging
CNC equipment
Computer Numerical Control
Machines are controlled by a computer.
Drawings are produced using a computer (CAD) and transferred to a machine (CAM).
Teacher notes (PS 5):
Robots – Repeatedly perform a programmed task, and can do so almost indefinitely. They can be used in dangerous situations, such as for bomb disposal, or underwater for long periods of time (ROVs – remotely operated vehicles – for both), or in environments which could cause harm to humans, such as paint booths. They are only as accurate as the program that has been written for them, but are generally highly efficient.
CNC – designs are produced using a CAD (Computer Aided Design) package which is converted in the software into machine code, which includes information about coordinates, feed speeds, spindle speeds etc. The CNC machine then uses this information to undertake a task, such as move a cutter head or a workpiece to produce a product – Computer Aided Manufacture (CAM).
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