Sample case files
These files are in 2D designer and in Sketchup. They are ONE way of creating a complex case using layers. You have to adapt this techniqe to your own use and make sure that different people in your classes use different techniques otherwise you could be accused of 'leading' them by the examiners.
This technique builds up the case in layers so is expensive to produce in materials as most layers are hollow, and also needs a laser cutter for fast manufacture. You can make wonderful models using corrugated card though!
Sketchup File (See the Sketchup section in 'Free Software' for more details about this FREE 3D program)
This is the 2D Design, the actual layers that the laser would need to cut. Note, I do not have way to translate the Sketchup data to the 2D Design program. Your pupils will just have to measure in Sketchup and copy into their CAD program.

Product Design Blank page set
New June 2006
I use these with my pupils so they can lay their project work out neatly. They don't have to use them, they help them put their folder in the right order...
Click HERE to download the PDF version

LED Torch films
New October 2005
Set of 7 e-Llearning films showing how to draw the layers for an acrylic torch like the examples on this page. Films are in flash format and should play automatically in any standard web browser. If they don't work, go here to download the Flash plug in. Films are about 2.5mb each so may take a while to load on slow connections.
Film 1: Film 2: Film 3: Film 4: Film 5: Film 6: Film 7:

designed on 2D Designer and cut using a laser cutter in 3 layers of 3mm acrylic. We used high output 3mm LED's and CR2032 lithium 3v batteries and therefore we didn't need a resistor.
Click HERE for a gallery of torches made by the Yr10 Pupils
Click HERE for a 2D design file of 3 different designs ready for cutting
Click HERE for a 2D design file showing how to create the basic shapes
Click HERE for an Excel file with component codes from Rapid Electronics

Product Packaging Scans
New September 2005
A set of packaging which fitted onto my A4 scanner. These are all in 300dpi and some in 150dpi as well. They are all in .jpg format. For ideas on how to use packaging nets in your teaching, see 'BOX' in Micromodules.

150 dpi	150 dpi
300 dpi	300 dpi
Gluhwein Sachets 150 dpi	Ibuprofen 150 dpi
Gluhwein Sachets 300 dpi	Ibuprofen 300 dpi
Mini Radio 150 dpi	Kazoo 150 dpi
Mini Radio 300 dpi	Kazoo 300 dpi
Giveaway Soap 150 dpi	Mulled wine sachets 150 dpi
Giveaway Soap 300 dpi	Mulled wine sachets 300 dpi
Long Matches 150 dpi	Small Matches 300 dpi
Budget Light Bulb 300dpi	Silver Sardines Can 300dpi
Coffee sachet base 300 dpi	Dove Soap 300 dpi
Plasters Budget 300 dpi	Plasters Budget 300 dpi
Stock Cubes Budget 300 dpi	Stock Cubes Standard 300 dpi
Stuffing Budget 300 dpi	Stuffing Standard 300 dpi
Jelly 300 dpi

These files have been produced to support a standard AQA Product Design GCSE course. My pupils wished to mainly do projects which emphasised electronics.

NEW July 1st 2005. Egg Wrap idea added

NEW May 18th 2005. Pupil Help Guide as PDF file laying our the stages and the work needed for the major project

LASER CUT CASES
These two galleries show a sample case of an LED lightstick made in polypropylene and 3mm Plywood
Also some Photographs One, Two, Three, Four of a sample box case with different cutouts made in 3mm Corrugated card. The advantage of using card is its free, and if its works, it should also work in 3mm Plywood or acrylic.

LASER CUT VACUUM MOULDS
This is a new technique I believe, using layers of 3mm corrugated card to create the mould from. The moulds were supposed to be laser cut from 9mm MDF but our 50W laser cutter was makign heavy work of cutting the 3 pieces. I experiemented with corrugated card as it was free, and cut extremely quickly. Some pupils were able to design the mould, cut out the pieces and make the first vacuum forming in 45 minutes. (Some took months...). Each layer took about 1 minute so the whole mould only took 15 minutes to cut including setting up. Click here for a gallery of captioned photos.

EXISTING PRODUCTS GALLERIES
These galleries of common objects contain two types of each product. 2 toothbrushes, 2 lightbulbs, 2can openers etc.. They have been chosen as 1: they were cheap and 2: they were easy to find so you can buy your own set and use these photographs for support. If you own these brands or designs, I hope you will relish the increased exposure getting your stuff on this website brings you!

There are also galleries of existing products in the graphics section of this website. 2 different boxed novelty packs are featured

LED TORCHES

NATURAL FORM LIGHT using a MOSFET to light 4 or 5 LED's. The PCB was designed using PCBWizard and mounted on a 3mm Acrylic stand, and covered with a Polypropylene slip cover designed to appeal to children.
Click HERE for 2D Design file of stands for laser cuttig in 3mm Acrylic
Click HERE for 2D Design file of nets for making card versions of the stand and circuit, you can then use them to test the size and shape of your cover.
Click HERE for Excel file giving components Rapid Electronics order codes