Year 12-13 Pathway

Unit in brief
Learners explore how processes are undertaken by teams to create engineered products or to deliver engineering services safely.

Unit introduction
The use of engineering processes is integral to the manufacture of engineered products and the delivery of engineering services. Thousands of engineering processes are used in the manufacture and service of a complex product, such as an aeroplane. To ensure that these engineering processes can be planned and carried out safely and effectively, engineers must be able to work together to get the job done. It is for this reason that so many engineering companies focus time and effort on understanding engineering processes and developing teamwork. In this unit, you will examine common engineering processes, including health and safety legislation, regulations that apply to these processes and how individual and team performance can be affected by human factors. You will learn the principles of another important process, engineering drawing, and develop two-dimensional (2D) computer-aided drawing skills while producing orthographic projections and circuit diagrams. Finally, you will work as a team member and team leader to apply a range of practical engineering processes to manufacture a batch of an engineered product or to safely deliver a batch of an engineering service. To complete the assessment task within this unit, you will need to draw on your learning from across your programme. It is important that engineers understand how engineering processes are used to safely transform ideas and materials into products and services, and how critical it is to be able to work as a valuable member of an effective team or as a team leader. This unit will enable you to apply the knowledge and understanding you gained in Unit 1: Engineering Principles. The unit will help to prepare you for an engineering apprenticeship, a higher education engineering degree or a technician-level role in a wide range of specialist engineering areas.

Unit in brief
Learners will explore engineering product design and manufacturing processes and will complete activities that consider function, sustainability, materials, form and other factors.

Unit introduction
Engineering products are part of our daily lives, from aircraft to the smallest electronic circuits found in medical devices. Engineering products are designed as a result of the identification of a need or opportunity, and then engineers using creative skills and technical knowledge to devise and deliver a new design or improvements to an existing design. For example, advances in the development of fuels led to the first internal combustion engine, and engineers have been improving its design ever since. In this unit, you will examine what triggers changes in the design of engineering products and the typical challenges that engineers face, such as designing out safety risks. You will learn how material properties and manufacturing processes impact on the design of an engineering product. Finally, you will use an iterative process to develop a design for an engineering product by interpreting a brief, producing initial ideas and then communicating and justifying your suggested solution. You will draw on and apply knowledge and understanding from Unit 1: Engineering Principles and Unit 2: Delivery of Engineering Processes Safely as a Team, for example by using calculations to demonstrate a reduction in mass, by sketching using orthographic projection drawing methods or by justifying an engineering process as its use reduces the carbon footprint of a product. To complete the assessment task within this unit, you will need to draw on your learning from across your programme. It is important that engineers use creative and technical knowledge, understanding and skills to transform ideas into viable products, and that they understand the critical importance of this activity in ensuring that products are both safe and effective. This unit will help prepare you for an engineering apprenticeship, engineering courses in higher education or for technician-level roles in a variety of engineering sectors.

Unit in brief
Learners explore commercial engineering, for example key business activities, cost control, quality systems and value management, which is used by engineering organisations to create value.

Unit introduction
Engineering organisations use a wide range of systems and methods to ensure that they are competitive. For example, organisations can develop a competitive advantage by increasing the quality of their products, innovating with new product designs or reducing the cost of their operations. Well-known brands that have successfully produced a competitive advantage in this way include Dyson, Rolls-Royce and Škoda. In this unit, you will explore how key business activities and trade considerations influence engineering organisations and are used to create a competitive advantage. You will understand why organisations need to control costs and how they make decisions, applying an activity-based costing methodology. You will also understand what is meant by quality and why it means different things to different people; you will investigate quality systems, including quality assurance and control. Finally, you will explore value management as a process to create value in an organisation. The quality systems and value management principles and processes provide a foundation for business process improvement techniques, such as Lean and Six Sigma, which many engineering organisations follow to ensure continuous improvement. It has not been possible to include these methodologies as part of this unit; however, should you encounter them in the workplace then this unit provides a basis for understanding and applying them. As an engineer, it is important that you understand some of the commercial and competitive considerations which ensure that engineering organisations thrive. You will need to apply these principles to technical engineering projects to ensure that they add value to the organisation and are profitable. This unit will help to prepare you for an engineering apprenticeship, higher education and technician-level engineering roles.

Unit in brief
Learners apply project-management principles to undertake a 30-hour individual project and will produce a product, system or process relevant to their specialist area of study.

Unit introduction
Project management, and understanding the project life cycle, is a fundamental part of all engineering disciplines, from aerospace and computing – which may involve the development of new products and services – to the manufacturing sector, which may involve refurbishing or installing equipment. The output from a project is varied and could be a product/service, system or process that is relevant to your specialist area of study. There are many approaches to project management, and in this unit you will understand and apply one project-management approach over the life cycle of a project to solve an engineering-based problem on a given theme or idea. This will involve you researching an engineering-based problem and using your creative skills to generate a range of solutions to the problem. You will produce a feasibility study to select the most appropriate solution given the known constraints. Over the life cycle of the project you will make use of project-management processes, such as monitoring progress and managing risks, to design and develop a solution that is fit for audience and purpose. You will demonstrate high-standard behaviours during the development of your solution and will present your solution in a portfolio of evidence. In this unit, you will draw on your learning from across your programme to complete assessment tasks. The purpose of the specialist engineering project is for you to consolidate and build on the knowledge and skills gained throughout your BTEC National programme of study. The completion of this unit will help you to progress to employment as an engineering technician, or to an apprenticeship or higher education.

Unit in brief
Learners explore how programmable devices and electronic components are developed systematically to form physical systems controlled by computer code.

Unit introduction
Programmable devices are already used in numerous systems and products, such as car engine control, wearable and health technology products, environmental control and process control systems. A popular programmable device is a microcontroller, it contains all the internal components of a computer on a single chip and it runs a stored computer program to achieve the intended purpose. The advantages of microcontrollers are that they are cheap, small, have low power consumption, are readily available and can be programmed to control products and systems, making them economical for developing products and systems. Microcontrollers and their programs form an important part of the rapidly growing ‘Internet of Things’ (IoT), a network of billions of interconnected physical objects, which is bringing the next information revolution with it. In this unit, you will investigate how microcontrollers are applied to solve engineering problems and learn how to program or code them. You will explore the hardware used to create a physical microcontroller system or product and consider the interfacing between the microcontroller and the input/output devices. You will develop an understanding of the constructs (instructions or commands) used to program a microcontroller and how to represent both hardware and logical instructions in diagrammatic format. You will design and develop a prototype microcontroller system to solve a problem. As technology trends evolve there is an increasing demand for more complex, connected systems that interact seamlessly together, providing enhanced features and benefits for customers. It is important for all types of engineer to understand how physical systems are developed. This will involve gaining knowledge, understanding and practical skills that are transferable to many other programmable devices, such as programmable logic controllers (PLC) and/or computers, such as the Raspberry Pi™, as well as developing computer programs and apps. This unit will help prepare you for an engineering apprenticeship, engineering courses in higher education or for technician level roles in a variety of engineering sectors.

Unit in brief
Learners use differential (rates of change) and integral (summing) calculus to solve engineering problems and develop a mathematical model of a local and relevant system.

Unit introduction
Many of the products, components and systems that we use have been subject to a rigorous design process that will have involved the use of calculations including mathematical calculus. During the design stage, it is important to be able to predict how a product will perform in service, for example the handling characteristics of a car or the power output from an electrical power supply. Also, investing time and resources in setting up manufacturing machinery and supply chains is very expensive – working with formulae and numbers on paper or using a computer involves a lot less cost and allows engineers to determine optimal (or near-optimal) solutions. In this unit, you will investigate how to apply differential and integral calculus methods to solve engineering problems. You will learn about the rules and procedures of calculus mathematics to obtain solutions to a variety of engineering problems. You will solve a complex problem from your specialist area of study and perhaps from a local organisation by breaking it down into a series of linked manageable steps. Each step will be solved using calculus methods learned through investigation and practice. These mathematical skills are transferable and will be used to support your study of other topics in the BTEC Nationals engineering programme, for example in mechanical principles and electrical systems. As an engineer you need to understand and develop the skills required to solve problems using calculus and other mathematical procedures. This unit will prepare you well for progressing to higher education to study for an engineering degree or a Higher National Diploma (HND). It will also help prepare you for an apprenticeship or for employment in a range of engineering disciplines as a technician, and will help you work with professional engineers as part of a team working on cutting-edge products and systems.

Unit in brief
Learners develop two-dimensional (2D) detailed drawings and three-dimensional (3D) models using a computer-aided design (CAD) system.

Unit introduction
Computer-aided design (CAD) spans most areas of engineering, as well as aspects of other disciplines such as construction and media. Engineering is a multi-disciplinary vocational subject that uses CAD as part of other processes to develop (design and manufacture), improve and maintain cutting edge products and systems. For example, Formula 1® racing teams test all their cars on bespoke CAD packages to analyse performance and stresses, and make modifications to the cars as a result. In this unit you will use CAD software and hardware to produce 2D and 3D drawings. You will acquire the skills to produce models of products, editing and modifying these, and exploring materials and their properties. You will output a portfolio of drawings, for example orthogonal, 3D shaded or solid model, and detail view drawings, to an international standard. As an engineer it is important to be able to interpret and produce engineering drawings that help individuals and organisations to communicate ideas, design and manufacture products and improve product performance. Studying this unit will help you to progress to employment as a draftsperson and gain other technician level roles in engineering. It also prepares you for an engineering-based apprenticeship, and for higher education.

Unit in brief
Learners explore the safe operation of pneumatic and hydraulic systems, including simulation of circuits using software and practical system assembly and testing.

Unit introduction
Pneumatic and hydraulic systems are an important part of many modern engineering products and systems. For example, aircraft landing gear relies on hydraulics, as do the robotic machines that are used in vehicle assembly plants. Pneumatic systems are widely used in the manufacturing industry and pneumatically operated tools are commonplace in garages and engineering workshops. You will study the safe operation and maintenance of pneumatic and hydraulic power systems by investigating industrial case studies. You will learn how to use computer-aided design (CAD) software to create circuit diagrams of pneumatic and hydraulic systems and then simulate their function before gaining practical experience of assembling and testing a physical system. As an engineer you may need to operate, maintain and repair pneumatic and/or hydraulic systems safely. This unit helps to prepare you for an engineering apprenticeship, for higher education and for technician-level roles, such as in plant maintenance or as a hydraulic/pneumatic technician

Unit in brief
Learners explore the principles and the design of the transmission and distribution infrastructure that supplies electricity to organisations and domestic households.

Unit introduction
The electricity supply is a fundamental part of everyday life that is often taken for granted. For example, people rarely pay much attention to the electricity pylons running across the country that provide much of the power we use every day for domestic devices and industrial processes. In this unit, you will explore the operation and construction of nuclear and fossil fuel power stations, which are still the most common methods for generating electricity. You will identify where the responsibility passes from the power to the transmission companies, and the methods they use to transfer high-voltage electricity over long distances safely. Finally you will investigate the methods used to reduce the electrical voltage and distribute it safely to customers. As an electrical engineer you may work for one of the large electricity distribution network operators or transmission companies where you could be involved in the design or maintenance of a national grid, or similar infrastructure. This unit prepares you for an electrical power-based engineering apprenticeship, for higher education and for a technician-level role in an electrical power company.

Unit in brief
Learners will explore and develop the design and manufacture of electronic printed circuit boards (PCBs). This unit does not cover the design of circuits.

Unit introduction
Electronic products are everywhere, from toasters to computer tablets, and at the heart of these devices are ever more complex electronic circuits. To make these products function as intended (reliably and safely), the circuits need to be connected effectively; and this is the job of a PCB. As well as making all of the required electrical connections that join the components together, a PCB must also physically support the components. PCBs might also comprise some user controls or a display, and can be designed to help protect the circuit from excess heat or interference. In this unit, you will understand and explore the industrial processes involved in designing and manufacturing sustainable PCBs. You will gain an understanding of the different types of PCB and the design considerations for an electronic product or system. You will experiment with software tools to design and simulate the PCB, before safely producing a PCB that you will then examine to assess its functionality and build quality. Finally, you will reflect on the skills and understanding you have acquired while designing and manufacturing a PCB, and the behaviours applied. It is the role of electronic design engineers to examine and analyse the diverse product and system requirements and then to develop effective, efficient and sustainable solutions, ensuring optimal performance. This unit will help to prepare you for employment and apprenticeships in electronic and electrical engineering and, in particular, electronic product design and manufacture. You may also be interested in this unit if you want to progress to higher education to study engineering.

Unit in brief
Learners investigate and conduct tests on the mechanical properties of metals, consider suitable applications and explore failure modes to improve component design.

Unit introduction
Selecting the most appropriate material and processing method for an engineered product or system is critical to ensure that it is fit for purpose. The materials used in the airframe of an aeroplane, car body pressings, cast components in domestic appliances and the ‘T’-shaped electricity pylons (in the UK) all require careful selection and testing of appropriate metallic materials. In this unit, you will investigate and research the microstructures of ferrous and non-ferrous metallic materials, some of which will have been processed, for example heat treated. You will inspect the microstructures of the materials you are investigating. You will also undertake destructive and non-destructive tests on the materials and use the results of the experimentation and research to determine the mechanical properties of, and suitable applications for, the materials. Finally, you will examine the reasons why components have failed in service and consider possible design improvements that could prevent failure. As an engineer it is important to know about and understand the capabilities of a range of metallic materials to create products and systems that are suitable for application. This unit will help to prepare you for an apprenticeship or a technician-level role in industry. It will also help to prepare you for a range of higher education courses, such as a Higher National Diploma (HND) or a degree in any engineering discipline.

Unit in brief
Learners explore the mechanical properties of non-metallic materials (polymers, ceramics and composites), consider their suitable applications and explore their component failure modes.

Unit introduction
Selecting the most appropriate material for an engineered product is of prime importance if it is to be fit for purpose. A design engineer must know about the range of non-metallic materials available to them and how they will behave in service. In this unit, you will investigate the structures of common materials from three non-metallic material groups, specifically polymers, ceramics and composites. You will gain practical experience of testing the mechanical properties of these materials and an understanding of how and why they are used in a range of applications. You will also investigate how components made from these materials can fail in service, the reasons why they fail and design changes that would help prevent future problems. As an engineer, you will need to understand non-metallic materials so that you can create and optimise the performance of products and systems you are working on. This unit will prepare you for an apprenticeship or higher level course, such as Higher National Diploma (HND), or a degree in any engineering discipline that requires an understanding of materials and their applications.

Unit in brief
Learners explore and carry out fabrication processes to safely manufacture products from sheet metal.

Unit introduction
Fabrication processes are used to manufacture sheet metal products and components in a wide range of industries and applications. For example, sheet metal products and components are found in oil rigs, ships and aircraft, desktop computer cases, fridges and filing cabinets. In this unit, you will cover the four main stages of manufacturing a sheet metal product: preparation, cutting out blank components, forming up the components and joining them into an assembled product. You will learn the safe use of a range of industrial hand tools, machinery and other equipment associated with fabrication processes. You will apply this knowledge in the manufacture of a sheet product, for example tool box, desktop computer or console casing, or a portable wood-burning stove. Finally, you will reflect on how your skills, knowledge, behaviours and organisational skills were applied during the fabrication of a product. It is important that engineers have an appreciation of the materials and processes involved in manufacturing sheet metal products, and are capable of creating solutions to engineering-based problems. This unit will help prepare you for a mechanical or manufacturing engineering apprenticeship, higher education and for employment in a technician-level role in the sheet metal fabrication industry.

Unit in brief
Learners cover the principles and practical methods used in additive manufacturing (AM) and develop a component using additive processes.

Unit introduction
Additive manufacturing (AM) processes are set to revolutionise the manufacturing industry and provide mass customisation of products and components for consumers. For example, a human jawbone can be manufactured to the exact specification of a patient needing a transplant. In addition, additive processes are more sustainable than traditional subtractive manufacturing processes, such as computer numeric controlled machining. In this unit, you will examine the technology and characteristics of the additive and finishing processes that are needed to manufacture a product or component. You will investigate design changes required to move from a traditional manufacturing process, such as machining and casting, to an additive process and the additional finishing processes that may be needed as a result. Finally, you will design a component that is suitable for manufacture using an additive process and manufacture your component using a 3D printer. Technology is transforming our lives; therefore as an engineer it is important that you understand the new manufacturing processes that are providing opportunities in product design, mass customisation and sustainability. In the United Kingdom, additive AM processes have been estimated to be worth around £6 billion per annum and are expected to employ 63 000 people by 2020. This unit helps to prepare you for employment, for example as a manufacturing engineering technician, for an apprenticeship, or for entry to higher education to study, for example, manufacturing engineering.