Key Stage 3 A suggested Year 9-10 Project:

To Manufacture a Pocket Torch

RA Moffatt WELB

A Pocket-Pen Torch Design

RA Moffatt WELB

Key Stage 3

Shown is a design for a pocket – pen torch. It was envisaged by the designer that this product would become useful in certain situations.

Design Tasks:

You are about to make such a torch just like this! However you will have theopportunity to personalise your pen-torch, by designing the following parts: -

The clip is to be of your own design. The end of the torch is to be made from brass or aluminium and turned on the centre lathe.

a) What materials could the clip be made from?b) Why do you think these materials are suitable?c) Show by means of a sketch how the clip may be fitted to the body of the pen torch?

Investigation:

You now need reference material to help with ideas?

Before manufacturing start by making a study of the following: -

• Different designs of torches to see how the different parts fit together• The shape and style of pen clips

Homework 1:

Make a collection of five different clip designs from old catalogues,

brochures, magazines, Internet, etc

Can you thing of any other item or product that may be carried in ones pocket that would require some type of clip?

From the materials you have collected design a suitable clip that could be attached to the cylindrical torch. Use notes along with your sketches to help explain your ideas.

A Pocket-Pen Torch Design

Task 1:

Write a problem identification for this product. In other words list or describethree situations that this product would be helpful in?

Design Brief: (Remember a design brief is a short statement describing the task)Your teacher will help you write the design brief

Design Tasks:

• Design a clip suitable for the pen-torch that can easily be attached to the main

body of the pen.• Select your best design and make a paper or card template (full size)• Show clearly using sketches and notes two different methods of securing

the clip to the pen body• Design a simple cylindrical end plug that will protect the bulb should the

torch drop. • Show how this plug is to be fitted to the main body of the torch?

A Pocket-Pen Torch Design

Shown below are some of the main components used to make the torch work. This is a simple electric circuit or electrical system and it is important that youUnderstand how this circuit works?

Push-to-Make switch

2 AAA Batteries

a) Draw the simple electrical circuit using the Crocodile Technology software and test this circuit. b) Re-Draw this circuit using the correct symbols and explain how this circuit works?

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