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NotesDesign Technology HLTopic 3.2
Unit 3 · Product in theory · Topic 3.2

IB Design Technology HL — Structural systems

Introduction to structural systems

Higher Level students should use this topic hub as a map: start with the shared sub-topics, then follow the HL-only extensions and exam-skill links where this topic asks for deeper analysis.

Exam technique guidePractice questions

Key concepts in Structural systems

Key Idea: To analyse a structure you follow the load: what acts on it, which members carry it, and how it reaches the ground. Structures come in three kinds — frame, shell and solid — and five forces act in them: tension, compression, shear, bending, torsion. A load is static (steady) or dynamic (changing), and the dynamic peak is what you design for. The stress-strain graph carries five separate facts: gradient is stiffness, the yield point is where stretch stops recovering, the peak is strength, the area is toughness, and the length shows ductility. A structure fails in strength, in stiffness or in stability — and two of those break nothing at all. Geometry beats material. Depth, span and section change stiffness far more than a different grade of the same stuff.

Paper 1 — multiple choice

  • Name the force acting in a labelled member
  • Classify a structure as frame, shell or solid
  • Read a feature off a stress-strain graph
  • Work out a safety factor from two loads

Paper 2 — analysing a product

  • Follow the load path through a named product
  • Explain a failure that broke nothing
  • Recommend strengthening and give the mechanism
  • Justify a safety factor from the uncertainties

Carried into the design project

  • Criterion D — a structural claim must be tested, not asserted
  • Your prototype's failure mode is evidence, so record it
  • Ribs and section changes are the cheapest improvements you have
Analysing a structure is one habit, repeated

Every Paper 2 structural question is the same four steps. Doing them in order turns a blank page into an answer.

StepThe question you askWhat it gets you
1. The loadsWhat acts on it, how big, and does it change with time?Static self-weight plus a dynamic peak that is several times larger
2. The pathWhich member takes it next, all the way to the ground?The members that matter — and the ones carrying almost nothing
3. The forcesIs each member pulled, squashed, cut, bent or twisted?Tension, compression, shear, bending, torsion, located on real parts
4. The failureDoes it break, sag too far, buckle or tip over?Strength, stiffness or stability — and only one of them breaks anything

The five forces drawn as what they do to a member. Locate each one on a real part and the marks follow.

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Ask what carries the load. Discrete members meeting at joints — a frame. Cut one member and the path breaks. A curved or folded surface — a shell. Cut a hole and it loses most of its stiffness. Bulk material — a solid. It barely notices a small hole. Most products are a mixture. A bicycle is a frame with shell wheels and solid bearings, and saying so is a better answer than choosing one.
The stress-strain graph, one feature at a time
Feature of the graphWhat it isWhat a designer does with it
Gradient of the straight partYoung's modulus — stiffnessPredicts deflection. Steep means it barely moves under load
Yield pointWhere stretch stops recoveringThe load after which the product is permanently changed and must be retired
Peak of the curveUltimate tensile strengthThe breaking load on the label
Area under the curveToughness — energy absorbedDecides whether it survives an impact, which is an energy problem
Length along the strain axisDuctilityDecides whether it deforms visibly first or shatters with no warning

Five separate facts on one graph. Exam questions ask for one of them at a time.

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Important: Strength vs stiffness — the peak is strength, the gradient is stiffness. A stronger grade of plastic is almost never stiffer. Strength vs toughness — the peak is strength, the AREA is toughness. Glass is strong and shatters; a helmet liner is weak and saves a head. Breaking vs failing — a shelf that sags 40 mm has failed, and nothing is broken. A bookcase that tips over has failed, and nothing is broken.

Every one of these adds stiffness without a different material — which is what makes them the cheap fixes.

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Exam-style questions
IB-style questionAnalyse[6 marks]

A school replaces its timber music-room shelving with a wall-mounted steel system. Analyse the new shelving as a structure.

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IB-style questionExplain[4 marks]

A designer doubles the depth of a timber shelf instead of switching to a denser hardwood. Explain why this is the better decision.

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IB-style questionJustify[5 marks]

A manufacturer specifies a safety factor of 5 for a rope swing sold for garden use. Justify this figure.

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Quick check

A structure sags badly but nothing breaks. Has it failed?

Why does a slender column fail below its crushing strength?

What does the area under a stress-strain curve tell you?

What is the difference between a static and a dynamic load?

Why does a corrugated sheet beat a flat one of the same mass?

When is a safety factor of 1 acceptable?

Exam tips

  • Answer structural questions by following the load: loads, path, forces, failure. In that order, every time.
  • Locate each force on a named part. Listing the five force names earns nothing on its own.
  • Keep strength, stiffness and toughness apart: the peak, the gradient and the area are three different facts on one graph.
  • Two of the three failure modes break nothing. An answer that only discusses breaking has missed two thirds of the topic.
  • Reach for geometry before material: depth, span, section and triangulation change stiffness far more, for far less.
  • Treat a safety factor as a measure of uncertainty. Justify it from what is not known about the load and about the strength.

What you'll learn in Topic 3.2

  • 3.2.1 Structures everywhere
  • 3.2.2 Classifying structures
  • 3.2.3 Structural members
  • 3.2.4 Static and dynamic forces
  • 3.2.5 Stress, strain and failure
  • 3.2.6 Young's modulus
  • 3.2.7 Equilibrium and stability
  • 3.2.8 Strengthening techniques
  • 3.2.9 Safety factor
  • 3.2.10 Designing for overload
Suggested study order: Read the notes for each sub-topic below → test yourself with flashcards → attempt practice questions → review exam technique.

Study resources — 3.2 Structural systems

3.2.1

Structures everywhere

Notes
3.2.2

Classifying structures

Notes
3.2.3

Structural members

Notes
3.2.4

Static and dynamic forces

Notes
3.2.5

Stress, strain and failure

Notes
3.2.6

Young's modulus

Notes
3.2.7

Equilibrium and stability

Notes
3.2.8

Strengthening techniques

Notes
3.2.9

Safety factor

Notes
3.2.10

Designing for overload

Notes

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Topic 3.2 Structural systems forms a core part of Unit 3: Product in theory in IB Design Technology HL. Mastering these concepts will strengthen your understanding of connected topics across the syllabus and prepare you for exam questions that require analysis, evaluation, and real-world application.

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