Design and Technology KS3 / GCSE: How to assemble the wing of the world's largest airliner

The production of this revolutionary wing design is revealed.

It is a massive task to form the 30 tonne wing which takes 25 days.

We see two key sub assemblies, one forming the wing's exterior skin and the second the skeleton.

A mixture of graphics and footage from inside the actual factory bring this story to life.

We see the main assembly jig, automated machines and lifting devices as the wing is skilfully crafted.

Teacher Notes

Could be used to illustrate the use of moulds and jigs to ensure consistency in production.

The class could discuss why consistency is important when manufacturing repeat products and how it is achieved, for example through the use of computer controlled machines, the bed (mould) used to form the wing and the assembly jig.

Students could then carry out an activity to cut pieces of paper to a specified length using a scalpel within a set time limit of one minute - firstly using an engineering rule, then using a simple jig.

They could then compare the consistency of the measurements and the number of pieces produced.

They could also design a simple jig for a repeat application, such as drilling two holes in a metal wall bracket.

Curriculum Notes

This clip will be relevant for teaching KS3 and KS4/GCSE Design and Technology, materials.

This topic appears in OCR, Edexcel, AQA, WJEC in England and Wales, CCEA in Northern Ireland and SQA National 4/5 and Higher in Scotland.