2. Context and Design Brief
Analysis of Context
Research into Existing Products
Product Analysis of PRIMARY Research
Materials and their properties
Materials and Finishes Testing
Other relevant research
User Profile
Analysis of Research
Final Specification
Initial Designs
Development
Final Design Proposal
Modeling and Testing
Evidence of CAD/CAM
Cutting List
Plan of Making – flow chart
Manufacturing Diary and Quality Control
Evaluation
Life Cycle of Product

3. A Garden centre wishes to sell products to encourage wildlife into domestic gardens.
Design and make a small product that could be sold in a garden centre.
I will be designing a small wildlife attraction which could be sold in a garden
centre. It will contain a small hole for the birds to go in and out and also it
will contain a small water bath. I will need to add protective paint to cope
with all weather conditions. And insure the product is durable. It must also
be suitable for commercial manufacture – I will use CAD/CAM when
designing & making it.

4. What will the product need to store/ how will it function?
I will be making a wildlife attraction to attract more birds into
the garden. It will need to include a birdfeeder for the birds
to eat from and also it will include a box where the birds can
nest, I will also include a water bath wear birds can clean
themselves and drink.
What environment will the product be designed for and how
will this effect the overall design?
The product I am making will be designed so it can hang on
a tree in the garden, because I am making a outdoor
product I will be Applying a protective paint to cope with all
possible weather conditions.
What materials will the product be made out of and how will
this effect the overall design?
The product will be entirely made from MDF, nut it will also
have a vacuum formed plastic bird bath attached. Withy my
product I am going to try not to waste as much wood as
possible but still get a good end product, I will be doing this
so less trees need to be cut down to provide materials.
How will you assemble the materials ? Will you use joints,
adhesives, components?
My product will be made from MDF because even thought its
not a strong material if finished right it will be durable so it
can cope wi9th the weather conditions.
How will you ensure your product is suitable for commercial
production ?
I will designing my product so that it could be batched
produced I will do this by using CAD/CAM, CAD is computer
aided design this means I will design parts of my product on
pro desktop, also I will use CAM this means computer aided
manufacture this means a computer controls the machine to
make the product a example of this is a router.
Are there any cost restrictions that will influence your design
and why?
When designing my product I will need to consider the cost
restrictions, I will need to think about what it will hang of the
tree with but also I will need to consider the cost of the MDF
and also paint and finishes.
What sort of shop / retail outlet could you see your product
being sold in?
My product will be sold in a garden centre so it will need to
match the health & safety regulations so that it can be sold
to the public.

5. This bird box is only got a nesting area so it inset as good as others on the market because others have a nesting
area, a bird feeder and a water bath .
This product will be made from wood, metal and slate there is a mix between materials on this product so it has a
better overall look.
A good point about this product is because it is made up from a variety of materials it has a attractive look, a bad
point is that it is only a nesting box and doesn't include a bird feeder or a bird bath.
This bird box is only got a bird feeder so this is at a disadvantage to others because some others include a bird
feeder and also a nesting area and a water bath.
This bird box would be made from wood and slate, there is wood because the material is strong and slate because it
is very water resistant so no water goes into where the feeder is.
A good point about this product is the slate roof this is good because this stops water getting into the bird feeder, a
bad point about this is that it doesn't include a water bath or a nesting area.
This bird box is also at a disadvantage to other because it only has a bird feeder but this product also has a little
area where birds can get shelter. This product also has wood and slate, it has wood because it is a strong material
and it includes slate because its very waterproof so the birds wont get wet.
A good point about this is it has a area where birds can get shelter, a bad point is that it doesn't include a nesting
area or a water bath.
This bird box is different than the rest because this bird box doesn't have a nesting area or even a water bath it is only a
bird feeder.
This product will have been made entirely out of wood and it would have been made using machines and parts of it
would be made by hand.
A good part about this product would be there would be lots of food for the birds to eat.
A bad point would be there is only a bird feeder attached.
This bird box has a different design to the other because this bird box doesn't include a bird feeder or a small whole for
birds to go through, but this box does include a shelter for the birds. This product is made entirely of wood because this is
a very strong material which can cope with all possible weather conditions. A advantage to this box would be there is a
large shelter area for the birds, a disadvantage to this box is because there isn't a whole for the birds any type of bird or
some animals could come in it.

6. This is a attractive bird box so that it will attract birds into the garden because of the colours used on this product.
To make this product it would need a protective paint so that the product can cope with all weather conditions but also It has
to be bright so that birds will easily recognise it and bring more birds into the garden.
This product will of been made of wood so that it is strong and durable also this product will have been made entirely using
machines.
A good point about this product would be because of the way the top is going over the sides there wont be any water getting
into the nesting area,
A bad point to this would be it would be very hard to hand in the garden because of the shape of the product.
This bird boxes main function is for birds to nest, this product has less to offer because it doesn't include anywhere for the
birds to eat from and doesn't include a bath for the birds. This product will also have to have a protective coating so that it Can
cope with the weather conditions.
This product would be made out of wood so it is very durable.
A good point is the design is very attractive and looks like a real house, a bad point is that this product will be very heavy.
This bird box is only for nesting, it doesn't have a bird feeder or a bird bath for the birds to use.
This product will need to have a protective paint so that it can cope with all weather conditions.
This product will be entirely made from wood and will have been made using machines but also parts would be done by hand.
A good part about this product is it is light but also very strong, a bad point would be because it is only quite small it might not
attract as many birds into the garden.
This bird box also has a disadvantage because its only a nesting box, it also has a very unique design as a minurcture garden
shed this would appeal to more of a humorous person.
This product would be made from wood it would be made using machines but also parts of it could be hand made.
A good point about this product is it’s a very unique design a bad point about this is it is only a nesting box and doesn't include a
bird feeder and a water bath.
This bird box has a very unique design because it includes a large area of shelter for birds, but also it also includes a bird
feeder for the birds to eat, because of these features this is my favourite design. this box would be made from wood because
of its strength and slate because it is a very good material to use for a shelter because water doesn't soak into it and go damp.
A advantage to this box is it has a very large shelter, a disadvantage to this box it doesn't include a water bath which others
have.

7. MDF
MDF is a relatively cheap board to make, but it is also a quality board, This
board is composed of fine wood dust and resin pressed into a board. I think
this could be a key part of my design as I will be making a mould out of MDF
which I will then use the vacuum former to make the bird bath I will be
adding to my design.
Plywood
This is made from veneers of timber with each grain layer being at right
angles to each other and bonded together by resin and pressure. This will
be a key part of my design because I will be making my product almost
entirely using plywood and flexi-plywood because it is a very good material
to work with.
.
HIPS plastic
This material is Strong and resists weathering, flexible, Can withstand
sunlight for long durations and also acrylic is a very good material to work
with because it can be cut easy and moulded into any shape you may
what. This would be useful for my design as I will be including a bird bath
so that has to be very water resistant an I will be able to mould it into any
shape required.
Metal Bracket
This material is very strong and can hold a lot of weight which is essential for
my product, it is also very easy to attach to my product and also you can buy
it ready made so this saves time, and it will be to a high quality. This material
will be essential to my product because this will be what I attach my bird
feature to a tree in a domestic garden, I have choose this material because of
the strength, durability and ease of attaching.

8. Cuprinol shades
Cuprinol shades is a wood stain, this will be the finish I will
apply to my product this is because it is very weather
resistant so it will cope with harsh weather conditions, but
also it is a very bird friendly finish, this means that if the bids
are inside the box they wont be inhaling the fumes of the
finish.
Danish oil
Danish oil is also a finish that could be applied to my
product to give the whole product a nicer finish and
appearance, a good point about this finish is that it gives a
shinny finish so it looks better overall, also this finish is bird
friendly so the birds will not be inhaling any fumes.
Eco varnish
Eco varnish is a varnish that could be applied to my product
because it can be used outside it will be able to protect my
bird feature but also because this product is eco friendly I
will be able to use this on my bird feature because it won’t
harm the birds in any way.

9. Ergonomics needs to be taken into consideration so that the wildlife attraction is made to the correct size and is comfortable for the birds
to nest inside and possibly eat from.
Anthropometrics also needs to be taken into consideration because I will need to collect all the relevant measurements of a wildlife
attraction, so I will have a idea on what size my wildlife attraction will be, Anthropometrics means the study of humans and animals and its
movements.
I gathered lots of information from the RSPB about different sizes needed for different birds. The bird feature that I will be making will
need to be an appropriate size; such as the entrance hole should be big enough, but not too small to attract certain birds. I have found
this list below of a wide range of birds with their required entrance size, this is very helpful to me because now I am able to see the wide
range of birds with the entrance whole size they require to enter the nesting box.
Also below I have included the measurements for a wildlife attraction all these measurements have been collected my myself so I am
positive that these results are correct. I will make sure I use these when designing and making my birdhouse so that it is safe and
accessible for the right birds and not their predators.
195mm
28mm
160mm

10. Name: Pauline Owen
Age: 72
Occupation: retired
Interests: gardening, shopping and bird watching.
I am a 72 year old woman who enjoys being out in
the garden watching the wildlife. I live in a very
natural house in a small town. Because of this I
enjoy watching the birds in there habitat which is
why I try to keep my garden as tidy and suitable to
there needs as possible. I could use a bird feature
where the birds can come and nest in the winter
and also feed, drink and clean. I would be willing to
pay up to £30 for a feature which includes all of
these features. I would like this product to include all
the features named all in one simple product, I
would like it to have something to do with great
Britain as it is where I was born and have always
lived.

11. Existing products
For my research I have collected primary research where I have gone on collected them
myself and also secondary research where I have collected images from the internet.
They are all light and cheap to make, they are all made from wood and include some slate
for shelters. All these boxes are suitable for the birds to nest, eat or drink. Most of these
bird boxes don’t need a large base because they are designed to hang off tree’s etc, but
two of these bird features have a large base because they will have a stand which will
support the feature, this is a option that I will have to consider when I am designing my
bird feature. Also a lot of the bird features don’t include nesting areas, bird baths or bird
feeders this will also be a option which I will consider when designing my bird feature.
Materials research
I have collected some research about all different materials that I will be including in my
bird feature. All of these materials are appropriate to add to my design, all of these
materials are very light and cheap, also point is that all of them are very easy to work
with and will get a good end finish. There are a different range of materials on this page
such as wood, metal and plastic, I will be including all of these materials in my bird
feature to show that I have shown a wide range of materials.
Ergonomics and Anthrometrics
I have collected all the measurements and dimensions of a bird feature which is
relative to mine I have done this so I will have a idea of what size my bird feature, also
I have included a table of a wide range of birds with there required entrance whole.
This is helpful to me because when I will design my bird feature I will be able to tell
what size entrance whole I will need for certain birds.
Finishes and components
On this page I can done some research on finishes and components, all of the
research that I have done are all appropriate for my outdoor product, this is because I
have only researched eco products so they will be able to cope with the possible
weather conditions and also so they wont cause any harm to the birds. All of the
products are cheap and wont effect the environment this was a key feature that the
finish that I will use will need to have. This will help my because I now know what
finishes there are that are ideal for the product I will be making.

12. My design must;
 my design must be targeted at the right audience, this will be to both men and women from the ages 30 upwards
 my design must not be able to offend anyone in any way, such as if there could be any offending messages on it
 my design must be able to attract birds into the garden and nest, feed, drink and bath in my bird feature
 my design must be designed to fit into any garden and it will have to be able to hang from a tree for the birds to access easily
 my design must be able to fit certain types of birds in such as blue tit’s, but at the same time keep certain types of birds out
such as crows. So my design must have the required entrance hole size to do this = no larger than 28mm in diameter
 my design must be a certain size it will have to be light so that the feature will be able to be free hanging off a tree but it will
also have to be slightly heavy so that it will not break or fall off in very windy conditions
 my product must be able to last at a minimum of 6years and would be expected to last for around 15 years so will have a
protective finish and be well made / assembled with strong joints and glue
 my product must be able to look nice in the garden to attract the birds, but also it must attract the customer in the garden
centre
 my product must be waterproof so that it can keep the birds dry when they are using the feature. I plan on using some flexible
ply wood this is so I can mold it into any shape I need and it is very strong and easy too use and is waterproof with a finish
 my design must be cheap but even though the materials will be cheap they will still have to be very strong and durable
 my design must be environmental friendly because I will be making a bird feature so it must not harm the birds in anyway,
because of this I will be only using environmentally friendly materials
 my design must be able to be mass produced, this is so it will be able to be sold in a garden centre, so that the product will be
able to be bought by customers all around the world
My design must have a good water tight finish such as cuprinol shades to keep all water out and the birds dry

13. This is a very simple design, it will be made out of MDF because MDF is a cheap material and is easy to work
with. This design will include a entrance whole for the birds to go in and out of. It will also include a perch and
fat ball this is so the birds can stand on the perch and eat from the fat ball, this would be cut by hand and the
roof would be cut out using the router.
This design has a clear theme, which is it will be designed after a royal mail box, this will be made from
plywood this is because with plywood I will be able to steam bend the material so that the whole box is
circular. This box will include a entrance whole for the birds to go into and nest it will also have a fat ball, a
perch and a place where you can insert a apple for the birds to eat from. This design will be made by hand for
cutting the base and also the laser cutter for the water bath and also the router for cutting the bottom and top.
This design is a very unique design because will be designed as a CCTV camera, this design would be
made from plywood and MDF, it will be made from plywood for the actual camera head this is because it is
a cheap material and I will be able to steam bend it into the required shape I need. I will be using MDF for
the other parts on the design this is because MDF is durable and strong which is a key factor because this
will be what is keeping the camera head up. This design would be mainly made by hand but the bracket
and the camera head would be cut using the router.
This design has a very unique design because I have never seen anything like this before, this design
would be entirely from plywood this is because the two main parts of this design this would be the two eye
pieces, these would be made from plywood because I would be able to steam bend the material into the
two shapes, this design would be made using the router but the connecter in between the two eye pieces
would be cut by hand.
This design is a very simple design which would be made from MDF this is because MDF is a cheap
material to buy and is very easy to work with so I would be able to get the finish that I need. This design
would be mostly cut by hand the only parts that would be cut on the router would be the roof, and I would
also need to use the laser cutter to cut out the windows to give it a better look and overall appearance.

14. This is a very quirky design because it is designed after a pumpkin, this design would be entirely made with
plywood this is because plywood is very flexible so I would be able to steam bend it into the circular shape.
this design would be entirely cut using the router, but some of the details on the face of the design would be
cut on the laser cutter.
This design is also very quirky because by looking at it you wouldn't know what it was but this is in the design
to look different to others. This would be made out of plywood and MDF because the main part of the design
would be made out of MDF because it is a strong material and also is very easy to work with, also the food
stick would be made out of plywood because it will be circular and by using plywood I would be able to get this
shape, this design would be mainly made on the router but the food stick would be made cut by hand.
This design is different to all my others because of one main reason this is because this design wont be hung
off a tree, this will have a stand and would be placed on the floor. This design would be made entirely out of
MDF this is because it will need to be strong because it will have to hold the various layers on the stand, also
this will be made from MDF because it is a easy material to work with and is a cheap material to buy. This
would be cut by hand for the most of it, the only parts which would be cut on the router would be the stand.
This design is inspired by the company ALLESI this is because all of ALLESI’S designs are all very quirky
and different, so this is designed as a old phone and is also very quirky and different to other products iv
seen. This would be made using plywood and plastic, the whole design would be made from plywood as
that it is a very shapely design plywood would be able to be shaped to that shape, the only part which
would be made from plastic would be the feet and this is because plastic is a strong material and would
support the box. This would be entirely made on the router and laser cutter.
This design is very different to other designs because you wouldn't except this to be a bird box, this would
be made entirely from MDF because it will need to be very strong and would need to be easy to work with
because of the range of different joints which would be needed to join all the different parts of this design.
this design would be made up of all different methods such as the main part of the box would be cut all by
hand but the smaller parts such as where the speakers would be including the entrance wholes for the birds
to do in would be cut using the router.

16. This is my first design of my bird box product, for this design
I have followed the style of a classic post box, this includes a
nesting area, a fat ball hook, a standing perch and it also
includes a bird bath. This design is a basic box shape which
can look slightly like other boxes on the market. This design
has a lot of certain parts which I like and will want to include
in my final product.
This is my second developed design this shows some of the
same features which my first design has but I have taken out
some of the features which are included on my first design,
on this design I have changed the shape to a semi-circle
this is because it makes the design unique. I believe this
design doesn't have enough features to be features on my
final product.
This is my third developed design, this shows features from
both the above designs and I have developed it further, in
this I have taken all the features from the first design and
included them into this design also I have used the shape
from the second design but I have slightly modified it by
making it fully spherical, I believe that by doing this I have
made my design unique and I haven't seen another product
like it on the market.

17. The sides will be made using flexible plywood
and will be cut using the jigsaw and tacked into
place, it will all be put together using a butt joint
because this is a strong and durable joint and
will be able to cope with the weight of the
whole structure.
The top of the bird box will be a circular shape with
a whole in the middle for the bird bath to sit, this will
be made from flexible plywood and cut on the
jigsaw this will be made like this because it is strong
and durable, The bird bath will be made from HIPS
and I will make a MDF mould and I will vacuum form
the HIPS over, this will then slot into the top part of
the bird box and fit in nicely and will be able to slot
out when I will be cleaning the bird box.
The base of the bird box will be made from MDF
and will slot into the bottom of the sides an I will
glue into place with PVA , I will be making the
bottom from MDF because it is a sturdy material to
use and It will be cut using the router so that I can
get the exact shape required. I will be using PVA
to glue the bottom in place because it is the best
way to glue wood to wood which will be the
strongest and be able to stay in place
permanently.
I will be using MDF to make the entrance
whole to the nesting area I will be using
this because it will be strong and wont
morph into a different shape in the various
conditions, I will be cutting this out by hand
using a coping say I will be using this
method because I can get the exact shape
required band will be able to make the cut
very precise.
I will be making the apple holder and the fat
ball holder out of MDF this will be cut out by
hand using a coping saw this is because I can
get the exact cut I need and very precise.
Also the standing perch will be made from a MDF
dowel an I will be cutting this down to the exact size
required by hand using a coping saw and I will be
using the drill to make two small indented whole
into the side of the sides and gluing it in with PVA
glue so that it can stick into place easily and will be
very strong and will be able to with stand any
weight that could be on it.

18. The function of this design is to be a bird feeder, a water bath and be a nesting box. In this design I
have included all of these aspects and so that it is appropriate for the birds. This design will have
strong string attached the main body compartment which will then hang off a tree in a stable position.
My design wont need a large base because it will hang of but on my design I have included a larger
base because of the theme which I am using. In this design I will be including a fat ball holder this is
to provide the birds with food, also I will be including a standing perch for the birds to stand on and I
will also be including a holder which you can insert a apple or fruit into for the birds to feed off.
The finish on the product that I will be making will be cuprinol shades this is required because as I
am making a product which will be outside I will need it to be suitable for all weather conditions, also
I will need it to be environmentally friendly because as I am making a bird box the birds are part of
the environment so I need to make sure the birds cannot be harmed in any way.
The product will be made in three separate pars these would be the top, the base and the main side
panel, I will construct the three parts and then tack them together this is because this will be very
strong and stable. For my design the only joint which I will be using is a tack joint this is because it
will be very durable and will be stable when and when not in use.
The materials I will be using for my product is plywood and flexi-plywood this is because I am making
a product which will be used outside so I will need a material which can handle the conditions which
may be outside. For part of my design I will need to bend the flexi-plywood and this will be done by
soaking the wood in water overnight so that I can bend it into the correct shape I will need.
Part
Side
bottom
Smaller bottom
perch
Smaller top
top
Circle top outer
Circle top inner
Circle top
Food holder
Material
Flexi-plywood
plywood
plywood
dowel
plywood
plywood
Flexi- plywood
Flexi- plywood
plywood
Bright Drawn mild
steel
Thickness
6mm
12mm
12mm
12mm
12mm
12mm
6mm
6mm
12mm
4mm
Materials cutting list
Size (mm)
250 x 700mm
270 x 270mm
210 x 210mm
65mm
210 x 210mm
270 x 270mm
20 x 820mm
20 x 645mm
270 x 270mm
140mm
quantity
1
1
1
1
1
1
1
1
1
1
Finish to be applied
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades
Cuprinol shades

19. At this part of designing my product I have created a card model of my design so I can get a feel of how the
product will look and work and I will also be able to see everything that will work and everything that won’t
to then go on further and change anything that needs to be improved on or fixed to give the product a better
overall standard. It meets all points given on the specification apart from having a hole which will be added.
I have modelled my card model using card and I have stuck it
together using masking tape, I have used this method because
my using card I will be able to get a very clear view of that my
product will look like when finished and I have used masking
tape because it is strong and will be able to keep the model
together.
I believe that the prototype was very successful
because I can see where everything will be placed
and how it will look so I know if I need to make any
alterations or improvements. I believe that from
seeing my card model that I do not need to make
any alterations to my design because everything
works as it should and everything fits where it is
supposed to no I don not think I need to make any
changes to the design or the measurements.
My card prototype shows that my product will be
very easy to use as I have included string which
you will be able to easily hang it from a tree, so
by doing so it shows that my end product will be
able to hang from a tree easily and effectively.
Overall I think that the style of the product is very unique
and I have never seen any other product like it so this is
why I would purchase this in a store for around the price
£25-30. I think that the main advantages to this product are
that it is different and quirky which appeals to the public
and would convince them to prefer my product.
Because I have made my card model to scale I
am able to see if everything will work as it
should , and by doing this I am able to see that
there will be no changes to my design before
manufacture.
After questioning my Nan (The User Profiled)
she thinks that the shape is a little too short and
needs to be taller to give it the post box feel.
Additionally there would be no need for the
perch on the left as there is nothing to access
where the perch is. So this will be removed.

20. no
20-25mins
start
Gather all plywood for base
and top of
product
2mins
no
Glue a piece of
dowel into the two
pieces of plywood
for base of product
to keep in place.
2mins
Have they been
drilled in the right
place
no
Mark out where
will be cut on
base and top of
product.
no
10mins
Using the pillar
drill, drill out the
holes marked out
yes
Has it been
marker out
correctly
Is the size of
plywood the
right side
no
Cut out the
shape marked
out on ply-wood
using the
jigsaw
no
Has it been
cut correctly
yes
5mins
Next mark out
holes to show
where you will
drill out
7mins
Mark out centre
of each circle on
top and bottom
no
yes
On 2D design,
design the holes
which will be cut
into the side piece
of flexi-ply which
will be cut using the
router
15mins
no
Make sure its
bent into the
correct shape
no
30mins
Tack the sides
into the base and
top
no
Make sure it’s
the correct
shape
yes
yes
Finish
2mins
Slot the bird bath
into place and glue
into place.
yes
Using 2D design
mark out the top
piece of ply
15mins
no
Are all the
sizes correct
yes
Has the HIPS been
heated to the right
temperature
no
10mins
Use the wood mould and
using the vacuum former
To melt the piece of HIPS
over the mould to create
the bird bath
yes
Now send the
design to router to
cut out the top
piece of plywood
20mins
Bend the flexiplywood into the
correct shape
Have the sizes
been added up
correctly
no
Has it sent
the right
shape
no
5mins
Has it sent
properly
yes
no
Has it been
soaked for long
enough
4hr
Now cut the MDF which
has been gathered to
the correct shape which
the bird bath will be
Soak the side
made from flexiply in water
overnight
yes
Tack the top piece
into the side piece
of flexi-ply
15mins
Is it the
correct
shape
30mins
yes yes
Send design to
router to cut
holes out the side
piece of flexi-ply
no
2-4 hr
Now gather the top
piece of flexi- ply
and soak it over
night in water
yes
Has it been
marked out
proper
yes
no
yes
Make sure it has
been soaked for
long enough time
Gather the side
piece of flexi- ply
yes
yes
15mins
30mins
yes
Do you have
enough
materials
7mins
Is there
enough glue
Repeat last step
for top of product
Now bend the top
piece of flexi-ply into
the correct shape
no
Make sure
enough tacks
are used yes
no
Is there
enough MDF
to use
5mins
Gather MDF to
create a mould for
bird bath

21. Here showing is me making each part of my product, this shows how I use tools to make my product at each stage
and show what my product looks like at each stage and how I will then continue to make my product.
This is showing my two
pieces of plywood
which I had cut out into
the correct shape using
the jigsaw. I had
marked out the exact
shapes so I knew
where to cut..
This is showing me
setting up the
software for the
Boxford router. I
needed to do this
correctly so my
designs was not cut
out wrong.
This is showing me
sticking the top
circle to the lid of
the product which I
had lined up
perfectly so it was
all centred so that it
didn't ruin my
overall product.
This is showing me
drilling holes into my
pieces of plywood
using the pillar drill
which I had marked
out the holes where
I would drill.
This is showing the
software for the
Boxford router
recognising the
designs for the top
circle which had
earlier designed on
2D design
This is showing
my clamping the
lid of my product
together so that it
sticks together
properly without
moving.
This is showing how I will
fit the two pieces of
plywood together using
dowel for the top and the
bottom of the product. I
had accurately marked
out how long each piece
of dowel would need to
be.
This is showing
the plywood after
I had drilled the
holes which I had
marked out in a
earlier stage.
This is showing the
router preparing the
design to be cut
using the designs I
had checked over
that they are all the
correct sizes.
This is showing me
setting up the
vacuum former to
make the plastic
bath which I needed
to make sure that
temperature was
correct to get the
required shape.
This is showing
the router cutting
my design into the
piece of 12mm
plywood for the
top circle of my
product..
This is showing me
putting the HIPS
onto the vacuum
former which I had
checked that the
temperature of the
HIPS was correct so
that it would mould
it properly and fit
into my product.
.
This is showing my
two pieces of
plywood stuck
together using a
combination of
dowel so they don’t
slide and PVA glue
to keep together.
This is showing my
piece of plywood after
it had been cut by the
router after this I
measured all the sides
which had been cut to
make sure it would fit
on my product.
This is showing the
vacuum former
moulding the HIPS
over the wood after
I had checked the
temperature
because if I didn't it
may of not moulded
over my template of
wood to make the
bath.
This is showing
me clamping the
base together so
that is doesant
move and sticks
together correctly.
This is showing the
two circles which I
used the router to
cut out which I had
measured and they
was all the correct
sizes.
This is showing my
work after I had
used the vacuum
former to for the bird
bath which I had
placed centre on the
vacuum form bed so
that it would be the
best possible quality
that it could be.
This is showing
me designing my
top circle which
had the bath
glued into it. I
designed this on
2D design..
This is showing me
putting PVA glue onto
my top circle to stick it
to the lid of my product
which I lined up
perfects so that it didn't
fit together out of
centre.
This is showing
my soaking my
flexi plywood in
the sink so that it
would be able to
bend into the
correct shape.

22. This is showing me
drilling the entrance hole
for the birds to go into
and out of this was done
using the pillar drill and
was marked out in the
exact place needed.
This is showing how
my product will look
with the bird bath in
place I needed to do
this because I needed
to make sure that they
both fitted together.
This is showing me spraying my
product with a second coat of
lacquer to make sure the paint is
ceiled into the product...
This is showing the setting
of the laser cutter which I
set up to cut out and
engrave the pieces of
plastic to give my product
the full effect of the design.
This is showing my
flexi ply and the
base and top which
I would then go onto
tack them together .
This is showing when I was
bending my flexi ply around the
base of my product I had to do
this fast because the wood was
starting to dry out and the flexi
ply would not of bent round my
base for the correct shape.
This is showing me
painting my product to the
colour which i designee it
as and also I used this so
that you could still see the
grain of the wood to make
the appearance look
better.
This is showing me
adding Danish oil onto the
side pieces for my product
which I have made using
layers of plywood I did
this because it would
bring out the grain out of
the wood.
This is showing how
my lid bath will fit into
the lid of my product.
This is showing is also
showing how the bird bath
will fit into the lid of my
product.
This is showing my
pieces of plastic
when the laser
cutter had finished
making them.
This is showing my
fully finished
product with all my
features added onto
it.
This is showing my product
after it had been tacked to
the base and I had tacked
the top inside circle to get
the lip in the correct place.
This is showing me using
the hand drill to drill two
holes where I will screw my
side features onto my
product I had marked out
where these holes would be
cut so that all the features
would fit on correctly
This is showing the
product with the chain
which will be hooked
onto my product to
hang it from a tree..
This is showing Me filling the gap
where the flexi ply meets with wood
filler to give it a better overall finish I
needed to be carful doing this
because if I had got any of the wood
filler onto the main side then the
finish on the whole product wouldn't
look as good.
This is showing me
gluing one of the
side pieces to my
product and lining it
up so that I had
screw it in to make it
stronger..
This is showing that
there is no hook yet
on the product and
where I will be
hooking the chain
onto..
This is showing how the lid will
fit into the hole at the top of the
product I needed to test this
because if it didn't fit correctly I
would of needed to sand the
inside of the lid down to make it
fit together.
This is showing me
screwing my side feature to
the main part of the product
this needed to be screwed
and glued to keep the
pieces from not moving.
This is showing
where I have tacked
a piece of flexi
plywood I have
done this because it
gives the product a
better overall look.
This is showing my
product with the lip into
the product I had got to
this stage after I had to
sand down the inside of
my lid to they would fit
together.
This is showing me
spraying lacquer
onto my product to
keep the paint from
wearing off over
time.
This is showing my
top after I have
painted my product,
this is because it
looks better overall
and more
professional.

23. This is showing how I have used CAD/ CAM in the development of my product, this part is showing where I have used CAD which means computer aided
design for this part I have used 2D design and his was to design the top circle where the bah will sit, this part of my design needed to be designed using
CAD because otherwise the bath would no of fitted in correctly because it needed to be a perfect circle.
This is also showing how I have used CAM this is computer aided manufacture and this means where you send your CAD design to the Boxford Router
which can cut the materials to the exact same shape I have used his method using the router, I have chosen to do this because the shape I need would
have to be cut into the ext shape required to fit the bath in so I used CAM for this stage of production.
There are advantages to this and disadvantages, one advantage to this would be that because it is all cut precisely you get a very accurate cut and its cut
exactly how you may require it, plus it’s faster.
One disadvantage to this would be is that if you do not get all the measurements correctly then you could not only break the wood and the machine but you
could also hurt yourself if you haven't taken all the safety precautions
I also used the laser cutter to cut out the post box decoration using 3mm thick
acrylic. Again, the designs were easy to cut getting a high quality finish.
Acrylic
Cut – Speed 1.7%, Power 100%
Engrave – Speed 90%, Power 10%
HIPS (High Impact Polystyrene)
Cut – Speed 2.2%, Power 100%
Engrave – Speed 2.0% Power 100%
Thin card
Cut – speed 65%, power 100%
Engrave – Speed 100%, Power 20%
flexible plywood
Speed 0.8%
Power 85%

24. I have now finished making my product completely and at this stage I will be evaluating my finished product. Here is the original
Specification that I set out to achieve. I think that my product has met all of these points of my specification.

25. I have now finished making my product completely and at this stage I will be evaluating my finished product, my product does meet all the
design specifications which are noted in my specification. My product is easy to use for the user and this is because if it was difficult for the
user they wouldn't want to use my product because they might not be able to use the product correctly. Each of the products functions work
the way which that was intended I made sure I would make these features precisely to the way which they would work and fit onto the
product this is because if I had made any changes which didn't follow the same specifications it may not fit onto the fit and maybe of not
worked correctly.
USER OPINIONS
I have asked other people what they think of overall product and all feedback was positive results it has been said that my finished product is
very unique and will appeal to my target audience. The people who I have presented my product to they have all liked all the features on my
product and they have said that each feature has a purpose and that they are all essential for the bird feature which is in the criteria for my
product. My nan says “A great overall finish which meets all that you set out to complete. I would have this in my garden and I’m sure the
birds would enjoy using it. Maybe add a different colour to the door step in future s o it matches the black plastic on the front”.
The intended user for this product would purchase it because it includes everything in the specification and also some added features, my
intended user would pay £30 for my product which is my estimated price for my product. Consumers would buy this product from others
because it includes a number of varied features which other bird features do not which I researched whilst doing my primary existing
products, so because my product offers that bit more this is why consumers should buy product. The environmental impact which it has made
during making the product has been kept to a minimum this is because as I have made a bird feature I have made sure that the product
doesn't have any materials which could harm the birds using the product and also the environment.

26. During product I encountered two main problems so from these problems I
have made modifications and overall improved my product because of these,
one of these modifications which I have made is in my initial design I had
added a feature on the left side of the product which would clap in fruit, but
whilst in production I realised that I would have been able to add this feature
without the birds been harmed so because of this I modified my product and
added a standing perch at the front of the product.
My second problem that occurred was whilst I was cutting
out the small inside circle the plywood started pealing off
due to the hard shape so to fix this I designed the shape on
2D design and cut it out using the Boxford router. This
happened when peeling the MDF base off the plywood, it
splintered and damaged the surface which I had to cover up
when gluing to another piece of plywood. I was lucky I had
something to glue it to.
If I was to make my whole product again I would try to make it so that the whole centre piece doesn’t leave a small
gap which is displayed to the right, I would do this by soaking the plywood in the water for a longer period of time so
that each part of the plywood was able to bend, this would improve the overall look of the product and would give it
a more professional look.
If I was to make my whole product again I would try to make more features onto it by adding something onto the
right side of the product, this would help more customers to buy my product because it would include more in the
product but by adding this it could increase the price of the product.
If I was to make my whole product again I would also maybe change the size of the entrance whole for the birds
so that a wider variety of birds would be able to use this product buy I would need to do this carefully because if
one particular bird is preyed by another I would not make the whole big enough to let these certain birds come in
so that all the birds are safe inside my product.
If I was to make my whole product again I would change the shape of the perch, I would do this so that maybe more
birds would be able to stand on it, this might increase the amount of people who would by my product.
As well I would add a groove in the base that would sit against the tree so it doesn’t blow about in the wind as I
think this will be a problem after seeing it roll against the tree when testing it.

27. Name
Style
Function
Improvements
Michael Kelly
Its very unique
Works very well
with the
environment
Add multi access
holes for the
birds to enter the
box
Anthony Stevens
Its very
interesting
It functions with
ease
Include more
features
Lee O’Neill
It looks like it was It does
designed like
everything that
the specification
says.
Make sure all
tacks where
covered with filler
so you cannot
see them from
the surface.
Most people questioned think the style is interesting and unique and it functions well. They do say that they want multi access
holes for the birds to go in and out but this is not what nesting boxes should have. Especially when young chicks are in the
nest as they might get eaten by other birds or animals and it might be too cold with 2 holes because the wind might fly
through.
I do agree with Lee though that the tacks should be covered up so they cannot be seen. When I looked at most birdhouses in
the garden centre they all had screws, nuts, bolts, nails on show so I though this would be OK, but I now realise that some
people don’t like them showing. So I would fill them with filler if I did this again.

28. Trees are cut from a
sustainable forest using
either a chain saw or a
machine.
This is when the product is
at the end of its life cycle or
is broken it is sent to a
recycling plant to be stripped
and made into sawdust then
crushed into a manmade
board such as MDF.
Then the wood would
be sent to schools or
other factories and
made into a product,
in this case it’s for a
bird box.
Trees
then
cut
down into smaller
pieces
to
be
transported easier.
Then the wood is
sent to a factory to
make each individual
board.