Lesson Plan

• Describe the main forming, removal, and joining commercial processes used for resistant materials.
• Compare the advantages and disadvantages of at least three processes for a given design brief.
• Select an appropriate manufacturing method based on material properties, production volume, tolerance and cost.
• Apply a basic stress calculation to evaluate a machined component.
• Explain key safety and quality‑control measures in commercial manufacturing.

• Projector or interactive whiteboard
• Printed handouts of the process comparison table
• Sample material specimens (metal rod, plastic sheet)
• Access to CAD software or drawing paper
• Calculator
• Safety goggles and gloves for the demonstration

Begin with a quick image of a factory floor to spark interest and ask students what they think shapes a product from raw material to finished part. Review prior knowledge of material properties and remind them that today’s success criteria include identifying processes, justifying choices, and performing a simple stress check.

1. Do‑now (5') – 3‑question quiz on basic material properties and previous lesson content.
2. Teacher input (10') – Concise overview of forming, removal, and joining commercial processes with visual examples.
3. Group comparison activity (15') – Teams use the handout table to evaluate three processes against a sample design brief; each team presents one advantage and one disadvantage.
4. Design task (15') – Students design a simple bracket, select a material, choose the most suitable process, and sketch a brief process plan.
5. Stress calculation exercise (10') – Using the provided formula, calculate the axial stress in a machined pin and discuss the result.
6. Safety & quality control demo (5') – Demonstrate PPE use and a quick visual inspection of a sample joint.
7. Plenary / Exit ticket (5') – Students write one key takeaway and one question they still have.

Recap the three process categories and how the chosen method aligns with material, volume, tolerance and cost considerations. Collect exit tickets to gauge understanding, and assign homework: research a real‑world product and outline the commercial processes used to manufacture it.