Lesson 1 Lesson 2 Lesson 3 Lesson 4 Lesson 5 Lesson 6 Lesson 7 Lesson 8 Assessment guidance Homework Tasks



1 PCB Housing

  • It is starting to look a lot like… we need a housing for our PCB board.
  • We can design this on Solidworks. As well as practising our skills on Solidworks we can check whether the parts will fit together.
  • Lots of the ideas are Xmas themed but you can make whatever you like but are limited in material to 100mm X 100mm.

Part 1 - Inspiration, Design movements and Sketching

  • First of all we are going to do some research into 'Design movements'.
  • Design movements...



  • Once you have found an idea, you can sketch it out on paper with a pencil and start thinking about what criteria our case/product is going to meet.
  • I've included four sketches for ideas. A good sketch should include:
  • materials, parts, dimensions (in mm), how it fits together, what the product should be do and some criteria.
  • Some important dimension are:
    • The maximum size is 80 X 80 X 100mm (length, width, height)
    • The battery is 25 X 18 X 55mm
    • The PCB is 35 X 30 X 10mm
  • Ideas for criteria are:
    • Waterproof, durable, fit three 5mm LEDs (6.8mm diameter/3.4mm radius holes), respond to changes in light, has an input or push-to-make switch, runs off 9V, is programmable, fun, educational, what the program does, functional i.e. holds a phone etc.
  • Things to remember to include when designing:
    • PCB
    • Battery
    • LEDs X 3
    • LDR X 1
    • PTM switch X 1
    • Toggle switch X 1 (if you include this)
    • Wiring to all the components, including the battery
    • How will the battery be replaced?
    • Types of joints you will use (finger joints, screws, etc)
    • Do the dimensions match the criteria. Remember the material is 3mm thick, so you will need to compensate for this.


  • Sketch one - 'Traffic Lights'  

  • Sketch two - 'Snowman'









  • Sketch three - 'Wintry Scene'




  • Sketch four - 'Elephant phone holder'



Badge It

Upload a photo of your sketch, with some criteria, to the badge on Bourne to learn.


Part 2 - Using CAD / Solidworks

  • Snowman detailed sketch views here:

  • Wintry Scene detailed sketch views here:




  • Elephant detailed sketch videos here:

Snowman/Xmas topper video:


Mating the parts together video: 


Elephant/Sleigh side video: 


Please watch this video. It will explain how to use the laser cutter.

Badge It

  • Silver - Progress ladder, Yellow - Use a CAD package to draw shapes accurately to specified dimensions.
  • Gold - Progress ladder, Green - Demonstrate the use of a 2D and 3D design package within a project.
  • Platinum - Progress ladder, Blue - Create multiple connecting parts using a CAD package.