OCR A Level Design Engineering Paper 1 Question Paper

Download the official OCR A Level Design and Technology: Design Engineering H404/01 Principles of Design Engineering question paper for the June 2025 examination series. This examiner-authentic OCR PDF contains the complete OCR Design Engineering assessment covering polymers, mechanisms, embedded systems, electronics, manufacturing, sustainability, ergonomics and engineering mathematics.

The paper includes detailed engineering questions based on electric toothbrushes, 3D printing, flexible plywood structures, embedded microcontroller systems and programmable LED head torches. Students are required to apply engineering calculations, materials knowledge, design analysis and manufacturing understanding to realistic industrial design-engineering scenarios.

Questions cover thermo softening polymers, thermoplastic elastomers (TPE), rechargeable-battery power calculations, charging-system efficiency, mechanisms converting reciprocating motion into oscillating motion, ergonomic product design and additive manufacturing using PLA filament. Mathematical engineering tasks include hollow-sphere calculations, probability calculations for manufacturing faults, arc-length and chord-length calculations for flexible beams and histogram-based statistical analysis.

The assessment also explores social, ethical and environmental issues linked to cobalt mining for electric-car batteries and asks students to evaluate responsible sourcing practices used by manufacturers. Additional sections examine surface mount technology (SMT), pick-and-place machines, reflow soldering ovens, embedded microcontrollers and programmable LED control systems using flowcharts and logic analysis.

Extended-response questions require technical discussion of ergonomic design, ethical material sourcing and the use of SMT and embedded systems to streamline manufacturing of multiple product variants. The paper tests both engineering knowledge and structured analytical communication using OCR’s level-of-response assessment style.

This OCR H404/01 June 2025 question paper is ideal for timed exam practice, mock examinations, engineering revision and OCR A Level Design Engineering preparation. It helps students understand OCR question structure, command words, mathematical requirements and examiner expectations across the Principles of 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 H404/01 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 materials, mechanisms, electronics, embedded systems and manufacturing. It is particularly useful for learners aiming to improve engineering calculations, product-analysis skills, technical communication 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, manufacturing analysis, embedded-systems programming and targeted OCR Design Engineering revision.