Lesson Plan

• Describe the four main categories of fabrication processes and their typical applications.
• Compare the advantages, disadvantages and suitability of cutting, forming, joining and additive manufacturing.
• Apply a decision‑matrix to select the most appropriate fabrication method for a design brief.
• Explain the key health, safety and environmental considerations for each fabrication technique.
• Analyse how process selection impacts geometry, waste, cost and production volume.

• Projector and screen
• PowerPoint presentation / digital slides
• Printed worksheets with decision‑matrix case study
• Sample material specimens (metal sheet, plastic sheet)
• Safety goggles and gloves
• Video clips of laser cutting and 3‑D printing
• Whiteboard and markers

Begin with a 30‑second video of a complex component being fabricated to spark curiosity. Ask students what processes might have been used, linking to prior knowledge of cutting and joining. State that by the end of the lesson they will be able to evaluate and justify the most suitable fabrication method for a given design brief.

1. Starter – Quick Kahoot quiz on fabrication categories (5’).
2. Mini‑lecture – Overview of cutting, forming, joining and additive manufacturing with real‑world examples (15’).
3. Group activity – Using a decision‑matrix worksheet, teams select a process for a provided component brief and justify their choice (20’).
4. Demonstration – Show short video clips of laser cutting and a 3‑D printer in action; discuss observed advantages (10’).
5. Safety focus – Identify hazards for each process and match appropriate PPE; brief discussion (5’).
6. Plenary – Recap key points, students complete an exit ticket stating one new thing learned and one question remaining (5’).

Summarise how the choice of fabrication method balances performance, cost, waste and sustainability. Collect exit tickets and assign a homework task: research a commercial product, describe the fabrication process used, and justify its suitability.