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.
  • Ideas could be Christmas themed but you could choose any religious theme that suits you. 
  • You could do some research into different religious festivals and design your product on these.
  • You could also make whatever you like but are limited in material to 80mm 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 (this will need to be a 8mm diameter hole)
    • Toggle switch X 1 (if you include this - this will need to be a 7mm diameter hole)
    • 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 in the finger joints.


  • Sketch one - 'Traffic Lights'  

  • Sketch two - 'Snowman'









  • Sketch three - 'Wintry Scene'




  • Sketch four - 'Elephant phone holder'



Client/User feedback

It is always good practise to get your clients/users feedback of your initial ideas before making a product.

Now that you have produced your initial idea, you will hand this idea to the person sitting next to you. 

  1. In a different colour pen/pencil, you will look at the design and check that it fulfils all of the criteria that was decided at the beginning of the page (dimensions and parts that need including) making notes of any missing criteria. 
  2. Looking at the design, can you make any suggestions for improvements - these need to be helpful - please be respectful of other peoples work.
  3. Once you have completed this, hand the image back for changes to be made.

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.