OCR A Level Design Engineering Paper 2 Question Paper

Download the official OCR A Level Design and Technology: Design Engineering H404/02 Problem Solving in Design Engineering question paper for the June 2025 examination series. This examiner-authentic OCR PDF contains the complete set of design-engineering assessment tasks focused on autonomous vehicles, robotics, pneumatics, manufacturing systems, control systems and engineering problem solving.

The paper uses a detailed disaster-response robotics scenario involving autonomous rescue vehicles, the Magirus Aircore TAF35 fire-fighting robot and a miniature tracked search robot named Scout. Students are required to apply mathematical calculations, engineering analysis, systems thinking and manufacturing knowledge to realistic industrial design-engineering challenges.

Questions include evaluating the technical and ethical issues surrounding autonomous vehicles during disasters, analysing collaboration between engineers in the development of complex robotic systems and calculating rubber-track length, mass and drive-system speed for the Scout robot. The assessment also includes gearbox velocity-ratio calculations, pneumatic force calculations, mechanical linkage design, programmable-control-system flowcharts and ultrasonic sensor integration.

Manufacturing tasks require students to propose suitable batch-production methods for aluminium robot chassis components using cutting, forming, jigs, dies and joining techniques to ensure structural integrity. Extended-response questions assess analytical reasoning, technical communication and engineering decision-making using OCR’s quality-of-written-response criteria.

This OCR H404/02 June 2025 question paper is ideal for timed exam practice, mock examinations, robotics revision and OCR A Level Design Engineering preparation. It helps students understand OCR question structure, command words, mathematical requirements and examiner expectations across the Problem Solving in Design Engineering specification.

Perfect for students preparing for the 2026 OCR examination series, teachers creating classroom assessments and tutors supporting OCR Design Engineering revision. Pair this paper with the official OCR H404/02 June 2025 mark scheme for complete examiner-guided preparation and assessment practice. Fully compatible with desktop, tablet and mobile PDF viewing.

This document is designed for OCR A Level Design Engineering students preparing for the 2026 examination series, especially candidates studying robotics, mechanisms, manufacturing and engineering systems. It is particularly useful for learners aiming to improve technical problem solving, mathematical accuracy, engineering analysis and extended-response exam technique.

It is also highly valuable for teachers, tutors, revision-course providers and independent learners who require authentic OCR exam material for classroom assessment, mock examinations, robotics projects, pneumatic-system design exercises and targeted OCR Design Engineering revision.