Lesson Plan

• Describe the four main categories of production processes (forming, machining, joining, finishing).
• Compare at least three specific processes within each category regarding suitability, advantages and limitations.
• Apply a decision‑making framework to select an appropriate manufacturing process for a given product brief.
• Evaluate cost, tolerance and volume considerations using a comparative table.
• Communicate the chosen process rationale in a brief written report.

• Projector or interactive whiteboard
• PowerPoint/slide deck summarising process categories
• Handout with comparative process table
• Sample material specimens (metal rod, plastic piece)
• Worksheet for process‑selection activity
• Calculator or spreadsheet software

Begin with the question, “How would you make a component that needs to be produced 5,000 times with tight tolerances?” Students recall prior knowledge of material properties and basic shaping methods. Explain that today they will learn to match product requirements to the most suitable manufacturing process and will be assessed on their ability to justify that choice.

1. Do‑now (5 min): Quick quiz on the four process categories.
2. Mini‑lecture (10 min): Overview of forming, machining, joining, and finishing with real‑world examples.
3. Case‑study activity (15 min): In groups, analyse the aluminium engine‑bracket brief, complete a decision‑matrix comparing casting, die‑casting, extrusion + CNC, and metal SLM.
4. Guided discussion (10 min): Groups present findings; teacher highlights why die‑casting is optimal for the brief.
5. Worksheet practice (15 min): Each student selects a process for a new product brief, justifying choice using cost, tolerance, volume and sustainability criteria.
6. Recap & exit ticket (5 min): Students write one key factor that most influences process selection on a sticky note.

Summarise how systematic evaluation of material, tolerance, volume and cost leads to an optimal process choice. Collect exit tickets to gauge understanding and assign homework: research a commercial product, identify its manufacturing process, and write a brief justification linking the product’s requirements to the chosen process.