Lesson Plan

• Describe the principles, key steps, advantages and disadvantages of blow moulding, steam bending, laminating, press forming and spinning.
• Compare typical materials, applications and process limitations for each forming method.
• Analyse which forming process best meets a given design brief based on criteria such as geometry, material, volume and cost.
• Identify health and safety considerations associated with each process.

• Projector and screen
• PowerPoint slides covering each process
• Handout with comparison table and key points
• Sample pieces: PET pre‑form, wood strip, laminated panel, sheet metal, metal disc
• Safety goggles and heat‑resistant gloves
• Steam‑bending demonstration kit (or video)
• Whiteboard and markers

Begin with a quick visual hook showing a bottle, a curved wooden chair back, and a spun metal lamp shade to spark curiosity. Recall students’ prior knowledge of basic forming methods and highlight today’s focus on five specific processes. State the success criteria: students will be able to describe, compare and select appropriate forming techniques for design problems.

1. Do‑now quiz on previous forming concepts (5 minutes).
2. Teacher outlines lesson objectives and agenda (5 minutes).
3. Interactive presentation of each process with diagrams and short video clips (20 minutes).
4. Group activity: using the handout, compare two assigned processes and fill in advantages, disadvantages and typical applications (15 minutes).
5. Whole‑class discussion to synthesise findings and address misconceptions (10 minutes).
6. Formative check – exit ticket: “Which forming process would you choose for a lightweight, hollow automotive component and why?” (5 minutes).

Recap the key characteristics of each forming method and how they influence design decisions. Collect exit tickets to gauge understanding and clarify any lingering questions. Assign a brief homework: research a real product that uses one of the discussed processes and prepare a one‑page summary.