AS91611 Hub | Page 3: Testing, Feedback & Synthesis

1. Empirical Physical Testing Methods

To produce authentic portfolio evidence for AS91611, testing must be repeatable, measurable, and documented with quantitative data rather than subjective visual checks.

⭐ Excellence Requirement: Data-Driven Trialling

Record specific units of measurement (e.g. drop height in metres, breaking force in Newtons, deflection in millimetres, or print time in minutes). Combine numerical testing data with photo/video evidence of failures to justify your subsequent CAD modifications.

Testing Method	Objective & Setup	Quantitative Metric Captured	Design Refinement Action
Drop Impact Test	Drop physical outcome from increasing heights onto hard concrete.	Failure height threshold (m) & crack initiation zone.	Add fillets to internal corners; switch to high-impact eSUN PLA+.
Deflection Under Load	Apply known weights to cantilevered sections of the prototype.	Millimetres of bending deflection per kg applied.	Increase perimeter wall loops or add structural ribbing in CAD.
Clearance & Fit Test	Assemble sliding or snap-fit parts across multiple 3D prints.	Clearance gap (mm) required for smooth operation.	Adjust CAD offset tolerances between 0.2mm and 0.3mm.

2. Synthesising Technical Data with Stakeholder Voice

Excellence in AS91611 requires you to synthesise—meaning you merge physical testing data, stakeholder feedback, material performance, and broader context into a unified evaluation.

Step 1 (Physical Result): The drop test showed the lower mount cracked at 1.5m due to stress concentration at sharp 90-degree corners.
Step 2 (Stakeholder Feedback): Key user noted: "The clip holds securely, but the sharp edges catch on my gloves when releasing it outdoors."
Step 3 (Synthesised Solution): Added 2.5mm CAD fillets to eliminate stress concentration points and rounded exterior edges to improve user ergonomics while retaining structural integrity.

🔄 Synthesis Matrix Generator

Select a scenario to view how to combine physical testing data with stakeholder feedback for your final report:

Select a scenario above to load synthesis breakdown...

3. Evaluating Fitness for Purpose in the Broadest Sense

📋 Final Checklist for Evaluation Writing

Your final portfolio conclusion must explicitly address:

Functional Fitness: Does the physical outcome meet all specifications in the initial brief?
Contextual Fitness: Does it perform safely and reliably in its intended real-world environment?
Sustainability & Future Potential: Was resource use minimised, and can parts be recycled or repaired?

4. Module 3 Interactive Workbook & Final Tasks

Complete these final activities to finalise your evidence portfolio for AS91611 submission.

Task A: Testing & Refinement Matching (Drag & Drop)

Drag each physical test result on the left to its corresponding synthesised design modification on the right:

Physical Test Results:

1. User reported thumb pain when pressing the release tab during cold outdoor testing.

2. Cantilever arm deflected 6mm under 2kg load, causing gear misalignment.

3. Part snapped along print layer line when twisted during torque testing.

4. Full 12-hour print failed halfway due to warped bed adhesion on sharp corners.

Synthesised Design Modifications: Enlarge tab contact area and add ergonomic curved chamfers:

Add vertical structural ribs and increase wall count from 2 to 4:

Re-orient CAD print direction flat on bed to align strength with torque:

Add 10mm brim in slicer and implement partial feature testing:

Task B: Dynamic Multi-Choice Assessment (8 Questions)

Select a question from the drop-down menu or click 'Next Question' to work through the assessment bank:

Jump to Question:

Task C: Written Synthesis & Final Evaluation

Scenario 1: Quantitative vs Qualitative Testing Analysis

Describe one physical test you conducted on your outcome. State both the quantitative metric (e.g., millimetres, Newtons, grams) and the qualitative user feedback gathered, and explain how they informed your next build iteration.

Scenario 2: Failure Analysis & CAD Modification

Identify a failure mode or flaw encountered during trialling (e.g. delamination, cracking, excessive flex). Explain the root technical cause and detail the specific CAD change made to resolve it.

Scenario 3: ⭐ Excellence Push - Synthesised Final Evaluation

Write a comprehensive final evaluation paragraph for your portfolio. Synthesise your testing results, stakeholder feedback, material properties (eSUN PLA+), and environmental considerations to prove your prototype is fit for purpose in the broadest sense.

Module 3 Glossary

Term	Definition in Technology NCEA Level 3
Synthesis	Integrating multiple streams of evidence (physical test data, stakeholder feedback, material science) to justify design decisions and evaluations.
Quantitative Data	Numerical, objective measurement data collected during testing (e.g. force thresholds, flex distance, drop height).
Qualitative Data	Descriptive, subjective user observations regarding comfort, aesthetics, ease of use, and overall user experience.
Stress Concentration	A localized area in a design (like sharp 90° internal corners) where stress concentrates, leading to premature structural failure.