A. Design Processes and Related Skills · Design Skills: From Idea to Tested Prototype

Making the Product or Delivering the Service, and Documenting the Process

A2.6 A2.5 A2.1About 75 minutes

Learning goals

I can follow my plan, drawings and procedures to make a product or deliver a service.
I can choose suitable joining and finishing methods.
I can do quality checks during production, not just at the end.
I can keep a design log that documents my process with dates, sketches, measurements, decisions and industry terminology.

Words to know

fabrication
Making a product by cutting, shaping, joining and finishing materials.

joining method
How parts are attached: adhesives (glue), mechanical fasteners (screws, nails, bolts) or joints (tab-and-slot, butt, lap).

finishing
Final treatments that protect or improve a surface, such as sanding, painting or sealing.

quality control
Checking work against specifications during and after production to catch errors early.

design log
A dated record of a project: research, sketches, decisions, measurements, problems, fixes and reflections. Also called an engineering notebook.

specification
An exact requirement, such as a size, tolerance, material or temperature.

mise en place
A hospitality term meaning everything in its place: all ingredients and tools prepared before service begins.

From plan to real thing

All the planning pays off now. You have a user profile, criteria, sketches, a technical drawing, a cut list, a bill of materials, a schedule and a procedure. The curriculum asks you to create products or deliver services, and document the process using appropriate industry terminology (A2.6).

Two habits separate professionals from beginners: they check quality as they go, and they write things down.

A general production sequence

Prepare: gather materials and tools (check them against the BOM), set up a clean, safe workspace. In a kitchen this is mise en place.
Measure and mark using the drawing and cut list. Measure twice.
Cut and shape with the right tools, under supervision.
Test-fit before gluing or fastening. Dry fits catch most mistakes.
Join with a suitable method.
Finish to protect the surface and improve appearance.
Inspect against the specifications and criteria.
Clean up and maintain tools.

Delivering a service follows a similar shape: prepare, greet and consult, deliver the service following the procedure, check the client is satisfied, record what you did, and clean up.

Joining method	Examples	Good for	Watch out for
Adhesives	White (PVA) glue, hot glue, epoxy	Wood, card, fabric; hidden joints	Drying time; some need ventilation (check the label or SDS)
Mechanical fasteners	Screws, nails, bolts, rivets, staples	Strong joints, can often be taken apart	Splitting wood; need pilot holes
Joints (shaped parts)	Tab-and-slot, butt, lap, dovetail	Strength from shape; fewer extra materials	Must be cut accurately
Other	Sewing, welding, soldering, lashing	Textiles; metals; electronics; flexible structures	Need special training and equipment

Choosing a joining method depends on the materials, the strength needed and whether the parts must come apart.

The building sequence for the cardboard prototype. Each step ends with a quick check (flat layers, snug slots, square corners, stable feet) before moving on.

A tab-and-slot joint holds cardboard parts without tape. The slot width must match the real thickness of the part, so measure it rather than guessing (corrugated card thickness varies).

Quality control during production

Do not wait until the end. Check after each step:

Are parts within tolerance of the drawing (for example ± 2 mm for a cardboard prototype)?
Are corners square (check with a square or the corner of a book)?
Do the parts dry-fit before gluing?
In a service: is the temperature right? Is the client comfortable? Is each step done in order?

A mistake found early costs minutes; the same mistake found at the end can cost the whole project.

Documenting the process: the design log

A design log (engineering notebook) is an industry document too. Engineers, technicians and chefs all keep records. A good entry includes:

Date and time spent.
What you did, using correct terms (laminated, dry-fit, kerf, tolerance, flute direction).
Measurements and data, with units.
Sketches or photos of progress.
Problems and how you solved them.
Decisions and the reasons.
Next steps.

Write in full sentences or clear notes, and never erase mistakes: cross them out with one line so the record stays honest.

Worked example

A strong design log entry

Improve this weak entry: "Worked on stand. Glued stuff. Didn't fit so fixed it."

Add the date and time: Oct. 20, 2026, 50 min.
Say exactly what was done, with terms: Laminated the base, back and brace (3 layers each, flutes running lengthwise), pressed under books for 2 h. Cut two slots in the base for the brace tabs.
Record measurements: Measured laminated thickness with a ruler: 12 mm. Planned slot width was 10 mm.
Describe the problem and fix: Dry-fit failed: tabs would not enter the 10 mm slots and crushed the card. Widened the slots to 12 mm to match the measured thickness. Re-tested: tabs now fit snugly.
Decision and reason, plus next step: Lesson: measure the real material before cutting joints. Next: assemble and check with a protractor that the back meets the base at about 37° (the angle the 24 cm base and 18 cm brace give).

The improved entry is dated, specific, measured, honest about the problem and explains the reason for each decision.

Hands-on activity

Build your tablet stand prototype

You need: corrugated cardboard from delivery boxes, white glue, a steel ruler, a pencil, a protractor, clothespins or heavy books, rubber bumpers or small pieces of rubber (from an old glove or a jar opener), a cutting mat or thick scrap board, and an adult to do or supervise all cutting with a utility knife. If you prefer, use sturdy scissors on single layers before laminating.

Use the cut list from the last lesson (or your own design). Mark all parts with flute direction arrows.
Cut the pieces. Adult supervision for every knife cut: steel ruler as a guide, fingers behind the edge, blade retracted when set down.
Laminate 3 layers for each part. Press and let dry (at least 2 hours).
Measure the real thickness, then cut a test slot in scrap to check the fit before cutting the real slots.
Dry-fit, then glue the assembly. Check the back angle with a protractor.
Add the ledge and rubber feet.
Keep a design log entry for every work session (at least three entries).

What to look for: parts within about ± 2 mm of the drawing, snug joints, the stand holding a tablet or a book of similar size, and log entries that are dated, measured and use correct terms.

Alternative without a stand to build: design and deliver a simple service at home, such as preparing and serving a snack plate for your family with mise en place, a timed plan and a satisfaction check, and log it the same way. An adult should supervise any knife or stove use.

Just for fun

Funny-but-true: many professional kitchens shout "Behind!" when walking behind a co-worker and "Corner!" before turning a blind corner. It sounds funny, but it is a real safety system to prevent collisions with hot pans and sharp knives.

Your turn

Put in order: finish, test-fit, measure and mark, join, cut, prepare.

Why dry-fit before gluing?

Name one advantage of mechanical fasteners over glue.

A tolerance is ± 2 mm on a 150 mm part. The part measures 147 mm. Accept or reject?

List five things a strong design log entry includes.

What does mise en place mean, and why does it help service?

Why should you never erase mistakes in a design log?

More practice: warm-up

What is fabrication?

Give two examples of adhesives.

Give one example of a finishing process.

What is quality control?

What is a design log?

More practice: on your own

Three cardboard layers each measure 3.8 mm thick. How wide should the slot be for a snug fit?

Choose a joining method for each and explain: (a) a birdhouse roof that must be removed for cleaning (b) a paper model.

Describe a quality check for each stage of serving hot chocolate at the booth.

Rewrite with industry terms: "I cut the wood too short because the saw ate some of it."

Why should parts be measured after laminating instead of using the planned thickness?

Challenge

A stand needs the back at 37° ± 3° to the base. After assembly it measures 32°. Give two possible causes and fixes.

Explain how a design log could help a different student rebuild your project a year from now.

Compare producing 1 prototype with producing 30 copies for a school fundraiser. What changes in the process?

Check your understanding

Quiz

Which step should come right before gluing parts together?

Which joining method allows parts to be taken apart easily?

A part should be 200 ± 1 mm. Which measurement is acceptable?

What is the main purpose of a design log?

Which entry uses industry terminology best?

Why do quality checks during production rather than only at the end?

For parents and teachers

Big idea: Expectation A2.6 asks students to create products or deliver services and to document the process using industry terminology. A2.5 (using documents) and A2.1 (following a planned process) are applied here.

Supervision: the build activity uses a utility knife. An adult should do or directly supervise every cut: use a steel ruler, a cutting mat or scrap board, keep fingers behind the blade and retract it when it is set down. If you prefer, your teen can use scissors on single layers. Hot glue can burn; white glue is a safe alternative. The service alternative (a snack plate) needs supervision for any knife or stove use.

How to help: ask to read the design log after each session and ask, "Why did you make that decision?" Encourage honest records of mistakes.

Common difficulties: rushing past dry-fits, guessing slot widths, and log entries with no dates or measurements.