Lesson 55 · Unit 7

Process, Research &
Prototyping

Connect research, ideation, drawing, modelling, CAD and model–test–refine as one iterative design process.

80 minutesA2.1 · A2.2 · B2.1 · B2.2

Guiding question: How does evidence move through the design process instead of appearing only at the beginning?01

Today’s destination

By the end of class, you should be able to…

Track research

Explain how evidence remains active across all five stages.

Choose representations

Match drawing/model fidelity to the design question.

Use digital tools

Distinguish CAD, FEA, VR/AR and rapid prototyping purposes.

Iterate with evidence

Use data + user feedback to drive model–test–refine.

Success check: Use accurate terminology, then apply it to unfamiliar design contexts.

SYNTHESIS · Process02

Empathize

Understand user, task, product and context.

Define

Problem statement + specifications.

Ideate + model

Distinct feasible approaches + evaluation.

4–5

Design + present

Model–test–refine, formal communication, intended solution.

Iterative, not linear: new evidence can send a designer back to research, specifications or ideas.

B2.1.1 · five sections03

Primary

First-hand evidence: observation, interviews, surveys/questionnaires, focus groups, material tests, product analysis.

Secondary

Third-party evidence: internet research, government data/statistics, university research, literature.

Qualitative

Descriptive evidence—why, how, perceptions, behaviour, experience.

Quantitative

Numerical evidence—dimensions, counts, time, force, ratings, performance data.

B2.1.2–2.1.4 · research types04

Stage	Research question	Possible evidence
Empathize	What is the real problem?	User observation, interview, product analysis.
Define	What must success look like?	Primary + secondary data → specifications.
Ideate	Is this idea feasible / preferred?	Additional research, sketches, quick models, user feedback.
Design solution	Does the solution perform?	Fidelity models, performance data, end-user tests.
Present	Can others understand the solution?	Formal drawings, virtual representations, comparison evidence.

B2.1.2 · research throughout the process05

Informal drawing

Fast exploration/refinement: free-hand sketches, iterative sketches, rough digital drawing. Advantage: speed and idea volume. Limitation: lower precision/ambiguity.

Formal drawing

Precise communication: isometric, orthographic, assembly, exploded and detailed drawings. Advantage: interpretation/manufacture. Limitation: slower and less useful for rapid divergent exploration.

A2.2.2 / B2.2.1 · choose drawing by purpose06

	Low fidelity	High fidelity
Best for	Early exploration, task flow, broad form, fast changes.	Later testing of detailed form/function/interactions.
Advantages	Fast, cheap, encourages change.	More realistic feedback; can expose detailed issues.
Limitations	May not represent final performance.	More time/cost; users/designers may resist changing polished work.

A2.2.1 · fidelity trade-offs07

Scale

Size relationships

Test fit, reach, clearance or spatial relationships.

Aesthetics

Visual/form qualities

Gather feedback on shape, proportion, surface and appearance.

Materials

Material behaviour

Explore feel, weight, stiffness, finish or suitability.

Function + performance

Does it work?

Generate measurable data and user evidence.

A2.2.3–2.2.4 · physical prototype purpose08

Geometry

surface modelsolid modelgenerative design

Human interaction

digital humansmotion capturehaptic technology

Simulation / experience

VRARfinite element analysis (FEA)

A2.2.5 · CAD/virtual prototypes09

FEA shows a high-stress region near a bracket joint.

What should the designer do next?

Interpret the output relative to loading assumptions/material/model limits, then refine geometry/material or test physically as appropriate. FEA is evidence from a simulation—not automatic proof of real-world performance.

B2.2.4 · interpret FEA output10

SLA

Uses photopolymer resin cured by light; useful for detailed forms, with material/process limitations.

FDM

Builds layers from extruded thermoplastic; accessible and fast, but layer quality/anisotropy can affect prototypes.

SLS

Fuses powder using a laser; supports complex geometry, but equipment/material costs are higher.

Emerging technologies: designers should evaluate advantages and limitations instead of assuming “newer = better”.

A2.2.6 · SLA / FDM / SLS11

Construct CAD

Surface/solid/virtual model.

Check geometry

Scale, wall thickness, fit and manufacturability for the RP process.

Prototype

Create the physical model quickly.

Gather evidence

Data + user feedback → iteration.

B2.2.3 / B2.2.5–2.2.612

A bottle grip slips during wet-hand testing.

What makes the next step an iteration rather than a random change?

The refinement should be traceable to evidence: identify the failed requirement, change a relevant feature (geometry/material/texture), then retest the same requirement to see whether performance improves.

B2.1.12–2.1.13 · iterative development13

A designer wants to communicate exact component dimensions and how three parts assemble. Which representation is most appropriate?

A2.2 / B2.2 · representation purpose14

Redesign a folding laptop stand.

The current stand wobbles, pinches fingers and packs poorly.

Build a four-step evidence plan from research to refined prototype.

One strong sequence: observe users folding/setting up the stand → write specifications for stability, pinch risk and folded size → create distinct ideas and quick models → build/test/refine a higher-fidelity model using measurable stability/clearance data and user feedback.

Cross-topic application · Process15

Exit ticket

Before you leave…

1. Name one point after empathize where research still matters.

2. Give one advantage and one limitation of high-fidelity prototyping.

3. Choose one CAD/virtual tool and state the design question it can answer.

Next lesson

Materials, Selection & Sustainable Systems — Synthesis

Keep the retrieval loop moving: recall → apply → check → correct → revisit.

Curriculum alignment
Cumulative synthesis of A2.1, A2.2, B2.1 and B2.2, including primary/secondary and qualitative/quantitative research, the five-stage design process, ideation, informal/formal drawing, physical/virtual prototypes, CAD tools, FEA, rapid prototyping, fidelity and model-test-refine.

Lesson complete16 slides

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IB Design Technology SL · Lesson 5516

Process, Research &Prototyping