📚 Year 9 CCEA Engineering: Case Study in Action | CCEA Year 9 工程：案例分析实战演练
The CCEA Year 9 Engineering course is built around the idea that students learn best by doing. Case study practicals bring together design, making and evaluation skills into one focused project. In this article, we will work through a guided case study – designing and prototyping a mobile phone stand. You will see how every stage of the engineering design cycle is applied, from a first design brief right through to testing and reflection. This mirrors exactly the type of controlled assignment you will complete in class.
CCEA Year 9 工程课程核心理念在于“做中学”。案例分析实训将设计、制作与评估能力融入一个集中的项目中。本文将通过一个引导式的案例——设计并制作手机支架原型——带你走完整个工程设计循环，从最初的设计任务一直到测试与反思。这与你在课堂上完成的可控评估任务完全对应。
1. Understanding the Design Brief: The Phone Stand Challenge | 理解设计任务：手机支架挑战
The design brief sets out what you need to achieve. For our case study, the problem is simple: design and make a freestanding phone stand that securely holds a smartphone (width 65–85 mm, thickness 8–12 mm) so it can be used hands‑free for watching videos or video calls. The stand must work in both portrait and landscape orientations, be stable on a desk, and be made primarily from a single sheet of 3 mm ABS thermoplastic (150 × 200 mm) or equivalent plywood. It should be safe, easy to use, and visually neat.
设计任务书明确了你需要完成的目标。在我们的案例中，问题很简单：设计并制作一个独立式手机支架，能稳固地放置智能手机（宽 65–85 mm，厚 8–12 mm），以便解放双手观看视频或进行视频通话。支架需同时适合竖屏与横屏使用，在桌面上保持稳定，并主要用一片 3 mm 的 ABS 塑料板（150 × 200 mm）或同等尺寸的胶合板制成。同时应安全、易用、外观整洁。
Every successful engineering project starts with a clear understanding of the constraints and user needs. Read the brief several times and underline keywords: ‘secure’, ‘both orientations’, ‘stable’, ‘single sheet’. These will be your design criteria and will later become the points you test against.
每一个成功的工程项目都始于对约束条件和用户需求的清晰理解。请反复阅读任务书并划出关键词：“稳固”“两种方向”“稳定”“单一板材”。这些将成为你的设计标准，之后也将成为你需要对照测试的要点。
2. Research and Investigation | 调查与研究
Before sketching anything, a good engineer investigates existing products and gathers information. Use a mood board to collect images of commercial phone stands – folding plastic stands, metal cradles, wooden docks. Analyse their features: what makes them stable? How do they grip the phone? Are they adjustable? Note that many successful designs use a simple angled slot or a curved backrest.
在画草图之前，优秀的工程师会先调查现有产品并收集信息。用情绪板收集商用手机支架的图片——折叠塑料支架、金属底座、木质座式支架。分析它们的特点：是什么让它们稳定？它们如何夹持手机？是否可调节？你会发现，很多成功的设计都采用简单的斜槽或弧形靠背。
You should also investigate user requirements. For our case, compile a short questionnaire or observe how people use their phones on a desk. Key findings: users want a viewing angle between 55° and 70°, they appreciate a non‑slip base, and they do not want the stand to block the phone’s charging port. Record these insights in your design journal.
你还应当调查用户需求。在本案例中，可以设计一份简短的问卷或观察人们在桌面上使用手机的习惯。关键发现：用户希望视角在 55° 至 70° 之间，喜欢防滑底座，并且不希望支架遮挡手机的充电口。将这些发现记录在你的设计日志中。
3. Generating Creative Design Ideas | 产生创意设计方案
Now the creative phase begins. Using your research, sketch at least three distinctly different concepts for the phone stand. Idea 1 might be a simple two‑piece slotted system where the phone rests in a V‑shaped notch. Idea 2 could be a curved, heat‑formed cradle. Idea 3 could be a flat‑pack style with interlocking tabs. Label each sketch with dimensions, material callouts and notes on how it would be made.
现在进入创意阶段。根据研究结果，至少画出三种明显不同的手机支架概念草图。想法一可以是简单的两件式插槽结构，手机搁在 V 形槽口中。想法二可以是热弯成型的一体式弧形托架。想法三可以是拼接式互锁平板结构。为每张草图标注尺寸、材料说明以及制作方式的注释。
Quickly evaluate each idea against your design criteria. For example, the slotted design is very easy to cut and assemble but might lack stability in landscape mode. The curved cradle looks sleek but needs controlled heating. The flat‑pack design saves material but requires precise joint tolerances. This initial screening helps you see which ideas are worth developing further.
根据设计标准快速评估每个构思。例如，插槽式设计非常容易切割和组装，但在横屏模式下可能不够稳定；弧形托架外观流畅，但需要可控加热；平板拼接式设计节省材料，但对接头精度要求很高。这一初步筛选能帮助你看清哪些构思值得进一步深化。
4. Developing and Selecting a Final Design | 深化并选择最终设计
Take your two strongest ideas and add more detail. Draw them in 2D orthographic views (front, side, plan) with final dimensions. Consider adding features like silicone feet for grip or a cut‑out to allow charging cable access. Use a design matrix to score each concept against criteria such as stability, ease of manufacture, aesthetics and material usage, weighting the criteria according to importance from the brief.
选出两个最强的方案，进一步细化。绘制二维正交视图（主视图、侧视图、俯视图）并标注最终尺寸。考虑加入防滑硅胶脚垫或为充电线留出切口等特征。使用设计矩阵，根据稳定性、制造难度、美观性以及材料利用率等标准对每个方案评分，并按任务书中的重要程度给标准设定权重。
In our case study, a decision matrix shows the heat‑formed ABS cradle scores highest on stability and aesthetics, while a simple plywood notch stand scores best on ease of manufacture. However, because the brief prioritises a ‘single sheet’ and ‘secure hold in both orientations’, the ABS cradle design is selected as the lead concept to prototype.
在我们的案例中，决策矩阵显示热弯成型的 ABS 托架在稳定性与美观性上得分最高，而简单的胶合板开槽支架在制造难度上得分最优。但由于任务书强调“单一板材”和“两种方向都能稳固夹持”，我们最终选择 ABS 托架设计作为待制作原型的主要方案。
5. Detailed Planning for Manufacture | 详细制造计划
With the final design approved, write a step‑by‑step manufacturing plan. List every operation: (1) Mark out the shape on the 3 mm ABS sheet using a try square and marker pen. (2) Cut along the external profile using a coping saw, staying just outside the line. (3) File and sand the edges smooth. (4) Drill a 5‑mm hole for the cable aperture. (5) Use a strip heater to locally heat the bend line and form the curved backrest using a wooden former. (6) Attach self‑adhesive rubber feet. Include estimated timings and highlight any quality checks, such as checking the bend angle against a template.
最终设计确定后，编写一份分步制造计划。列出每一项操作：（1）用直角尺和记号笔在 3 mm ABS 板上描出外形轮廓。（2）使用弓锯沿外轮廓切割，保留少许加工余量。（3）用锉刀和砂纸将边缘打磨光滑。（4）钻一个 5 毫米孔作为充电线口。（5）使用线加热器局部加热弯折线，并借助木制定型模具弯出弧形靠背。（6）粘贴自粘橡胶脚垫。预估每一步所需时间，并标明质量检查点，例如用角度样规检查弯角是否准确。
If the stand’s angled backrest requires a specific viewing angle θ = 60°, and the backrest slope length L = 100 mm, you can calculate the required vertical rise h with trigonometry.
若支架的倾斜靠背需要特定的视角 θ = 60°，且靠背斜边长 L = 100 mm，你可以借助三角函数计算所需的垂直高度 h。
h = L × sin θ = 100 mm × sin 60° = 100 mm × 0.866 = 86.6 mm
This height ensures the screen centre is at a comfortable eye level; your former must be built to reflect this geometry exactly.
该高度可确保屏幕中心处于舒适的视线水平；你制作的热弯模具必须精确反映这一几何关系。
6. Material Selection and Justification | 材料选择与论证
Why did we choose 3 mm ABS sheet? Engineers must justify material decisions with reference to working properties. ABS has good impact resistance, can be heat‑formed easily at around 160–190°C, and provides a smooth, matte finish that can be decorated. It is also lightweight and non‑toxic when cooled. Alternatives considered were acrylic and plywood. A quick comparison clarifies the choice.
我们为何选择 3 mm ABS 板材？工程师必须引用材料的加工性能来论证选材。ABS 具有良好的抗冲击性，在约 160–190°C 下易于热成型，并可获得光滑的哑光表面，便于装饰。它重量轻，冷却后无毒。备选材料还包括亚克力和胶合板。快速对比能清晰说明我们的选择。
| Material | Heat Formability | Toughness | Finish |
|---|---|---|---|
| 3 mm ABS | Excellent | High | Smooth, matte |
| Acrylic | Good (but brittle when heated) | Low (cracks easily) | High gloss |
| Plywood | Cannot be heat‑bent | Good along grain | Wood texture |
Since our design relies on a curved, springy cradle, ABS is clearly the best performer. In your project, always link material properties directly to how the product functions.
由于我们的设计依赖一个弯曲而有弹性的托架，ABS 显然是性能最优的选择。在你的项目中，务必直接将材料性能与产品功能关联起来。
7. Safe Use of Tools and Processes | 工具与工艺的安全使用
Safety is non‑negotiable in an engineering workshop. Before starting any making, you must identify hazards and control measures. For our phone stand, key risk operations include using a coping saw, filing sharp edges, drilling and operating a strip heater. Always wear appropriate personal protective equipment (PPE): safety glasses, an apron and a dust mask when sanding.
在工程车间，安全是不可动摇的底线。开始任何制作之前，你必须识别危害及控制措施。针对我们的手机支架，关键风险操作包括使用弓锯、打磨锋利边缘、钻孔以及操作线加热器。务必佩戴适当的个人防护装备：护目镜、工作围裙，并在砂磨时佩戴口罩。
When heating ABS, work in a well‑ventilated area because the thermoplastic can release fumes if overheated. Use a jig to hold the workpiece and keep hands away from the heating element. Only use cold‑setting adhesives if any bonding is needed; hot‑glue guns must be handled with care. Record a risk assessment in your planning documentation – this is a skill examiners look for in CCEA Engineering folders.
加热 ABS 时，要在通风良好的区域操作，因为热塑性塑料过热会释放烟雾。使用夹具固定工件，并使双手远离加热元件。若需粘接，仅使用冷固化胶粘剂；热熔胶枪也需小心使用。在计划文件中记录风险评估——这是考官在 CCEA 工程档案中重点考察的技能。
8. Manufacturing and Prototyping | 制造与原型制作
Now realise your design in the workshop. Follow your manufacturing plan exactly, but be prepared to adapt if a process does not work as expected. Start by securely clamping the ABS sheet and carefully sawing out the shape. Keep your cuts slightly oversized so you can file precisely to the marked line. Use a half‑round file for internal curves and a flat file for straight edges, then progressively sand with P180, P240 and P400 grit for a neat finish.
现在在车间中将你的设计变为现实。严格遵循制造计划，但也要准备好在工艺未达预期时灵活调整。首先将 ABS 板夹持牢固，小心锯出外形。切割时留出少许余量，以便后续精确锉至标记线。内弧使用半圆锉，直边使用平板锉，然后依次用 P180、P240 和 P400 砂纸打磨，以获得整洁的表面。
The most critical stage is bending the backrest. Set the strip heater to the recommended temperature and wait until the sheet becomes pliable along the bend line – you can test by gently lifting the free end. Quickly transfer to the wooden former and hold until cool. In many first attempts, the bend may spring back slightly. Over‑bending by 2‑3° compensates for this. Sand any slight scorch marks and check the final angle with a protractor or angle guide.
最关键的一步是弯曲靠背。将线加热器设定到推荐温度，等到板材沿弯折线变得柔软——可通过轻轻抬升自由端来测试。迅速转移至木制定型模具并保持直到冷却。在初次尝试中，弯曲处往往会有轻微回弹。多弯 2–3° 可以补偿。打磨掉任何轻微的焦痕，并用角度尺或角度规检查最终角度。
9. Testing Against the Specification | 对照规格进行测试
Testing is how you prove your prototype meets the design brief. Write a simple test plan with pass/fail criteria. For the phone stand, conduct at least these four tests:
测试是证明你的原型符合设计任务书的途径。编写一份包含合格/不合格判据的简单测试计划。针对手机支架，至少进行以下四项测试：
Stability test: Place a mass equivalent to the heaviest specified phone (≈250 g) on the stand in both portrait and landscape. The stand must not tip over when gently nudged. Durability test: Insert and remove a wooden phone dummy 20 times; the stand should show no cracks or loosening. Angle check: Measure the viewing angle with a digital angle finder; must be 60° ± 3°. Aesthetics and finish: Inspect under good light for sharp edges or blemishes.
稳定性测试：将质量相当于要求中最重手机（≈250 g）的重物仿手机以竖屏和横屏分别放置在支架上。受到轻轻推动时，支架不得倾倒。耐久性测试：用一个木质模拟手机反复插入并取下 20 次；支架不得出现裂纹或松动。角度检查：用数显角度计测量视角，必须在 60° ± 3° 以内。美观性与表面处理：在良好光照下检查有无锋利边缘或瑕疵。
Record all results honestly in a table. If the stand fails a test – for example, if it tips in landscape – note the observation. Real engineering involves diagnosing why it failed and feeding this back into the design, not hiding problems.
将所有结果诚实地记录在一个表格中。如果支架在测试中不合格——例如在横屏时发生倾倒——记录下观察到的现象。真正的工程需要诊断失败原因并反馈到设计中，而不是掩盖问题。
10. Evaluation and Reflection | 评估与反思
Once testing is complete, write an evaluation that goes beyond simply saying ‘it works’. Compare your finished prototype against the original design specification point by point. Did you manage to make the stand from one sheet? Is it truly stable in both orientations? How close is the actual viewing angle to the specified 60°? Where possible, quantify your findings.
测试完成后，撰写一份超越“它能用”这样简单评价的评估报告。将你的成品原型与原始设计规格逐点对比：你是否真的用一张板材完成了支架？它在两种方向上是否真正稳定？实际视角与规定的 60° 之间有多接近？尽可能用数据来呈现你的发现。
Reflect on the manufacturing process itself. Which steps took longer than expected? What would you change if you built a second version? Common reflections in a phone stand project include: choosing a thicker shelf lip to prevent the phone from sliding forward, moving the cable hole to a more accessible position, or using a wooden mould with a tighter radius to achieve a crisper bend.
反思制造过程本身。哪些步骤花费的时间比预期更长？如果要制作第二版，你会改变什么？手机支架项目中常见的反思包括：选择更厚的托唇以防止手机前滑，将充电孔移到更易触及的位置，或使用半径更小的木制模具以获得更利落的弯角。
Peer feedback is valuable at this stage. Ask a classmate to use your stand and comment on its ease of use and appearance. Their suggestions – perhaps about colour or the need for wider feet – can be added to your improvement list. Document all suggested improvements with annotated sketches if time allows.
在这一阶段，同伴反馈非常宝贵。请一位同学使用你的支架，并就易用性和外观给予评价。他们的建议——或许关于颜色或需要更宽的底座——可以添加到你的改进清单中。如果时间允许，用注释草图记录所有建议改进之处。
11. Presentation and Communication | 展示与沟通
In CCEA Engineering, how you present your project is almost as important as the making itself. Your portfolio should guide the reader logically through the design cycle: brief → research → specification → ideas → development → planning → making → testing → evaluation. Use clear headings, a consistent layout and high‑quality photographs of your work in progress.
在 CCEA 工程课程中，项目展示的重要性几乎不亚于制作本身。你的档案应引导读者合乎逻辑地走完设计循环：任务书 → 研究 → 设计规格 → 方案 → 深化 → 计划 → 制作 → 测试 → 评估。使用清晰的标题、一致的版式和高质量的过程照片。
Include 2D drawings with correct title blocks and dimension lines. Label materials, finishes and safety PPE you used. If you made a CAD model, add rendered views. Good communication shows you can articulate engineering ideas professionally – a skill highly valued in STEM careers.
附上带有正确标题栏和尺寸线的二维图纸。标注所使用的材料、表面处理和穿戴的防护装备。如果你制作了 CAD 模型，添加渲染视图。良好的沟通能力表明你能专业地阐述工程构思——这是在 STEM 领域备受重视的技能。
This case study has walked you through a complete engineering project. When you tackle your own controlled assessment, remember to follow the same structured approach: keep your user at the centre, base decisions on evidence, and always demonstrate safe, iterative practice.
本案例带你走完了一个完整的工程项目。当你着手自己的可控评估任务时，请牢记遵循同样的结构化方法：始终以用户为中心、基于证据做出决策，并时刻体现安全、迭代式的工程实践。
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