Lesson Plan

• Describe key properties of resistant materials and how they influence process selection.
• Compare cutting, shaping, joining, and finishing methods and identify appropriate applications.
• Apply safety procedures when operating workshop tools and equipment.
• Analyse a simple design problem to select suitable processes and materials.
• Evaluate the quality of a finished product using appropriate criteria.

• Projector and screen
• Whiteboard and markers
• Sample material specimens (wood, acrylic, metal sheet)
• Cutting tool examples (hand saw, laser‑cutting video)
• Bending press or manual bender (demo)
• Welding/fastening demonstration materials (or video)
• Safety goggles, gloves, hearing protection
• Worksheets with process comparison tables

Begin with a quick poll: “What everyday objects have you noticed being cut, shaped, joined, or finished?” Connect this to prior knowledge of material properties and set the success criteria – students will be able to match processes to material characteristics and demonstrate safe workshop practice.

1. Do‑now (5’) – Students list processes they have observed in common products on sticky notes.
2. Mini‑lecture (10’) – Overview of material properties and how they guide the choice of cutting, shaping, joining, and finishing.
3. Cutting demonstration (15’) – Show short videos of saw, laser, and water‑jet cutting; discuss advantages, disadvantages, and safety.
4. Hands‑on activity (20’) – In groups, examine sample specimens and complete a worksheet matching each specimen to the most suitable process.
5. Shaping & joining demo (10’) – Live demonstration of bending a sheet metal piece and a mechanical fastening example, highlighting PPE.
6. Finishing discussion (10’) – Review polishing, painting, and coating; work through a simple paint‑thickness calculation.
7. Check for understanding (5’) – Quick exit‑ticket quiz on process‑property relationships.

Recap the four main process categories and the key safety rules reinforced during the demos. Students complete an exit ticket summarising which process they would choose for a given design brief. Assign homework: research a real‑world product and create a short report outlining the cutting, shaping, joining, and finishing steps used.