Start of main content
Age Range: 11-14
Duration: 60 or more mins
  • D&T
  • Engineering
  • Mathematics

Investigating batch production

Using the casting process to make a batch of a product

In this activity students will use the casting process to create a small batch of identical products.

The lesson is part of a series of resources designed to challenge students by requiring them to apply the knowledge and understanding of engineering materials through a ‘batch’ production experience. It followed on from our CAD design project. Also included in the series are Engineering design processes and Investigating cast products.

It’s one of a set of resources developed to aid the teaching of the secondary national curriculum, particularly KS3, supporting the teaching in engineering and design and technology (D&T).

Activity: Using the casting process to make a batch of a product

In this activity, students will use a prepared mould to create a small batch of identical products through a casting process.

Students will mix the casting material (like plaster of Paris), pour it into the moulds, and allow the products to dry. Once complete, they will then carefully remove the products from the moulds. Students will need to record the dimensions of each product to identify any variations and explain why these might have occurred..

Download our activity overview for a detailed lesson plan on batch production.

The engineering context

Casting is a commonly used by engineers as a form of batch production, which is way of manufacturing many different forms of goods in an efficient way on a large-scale offering benefit such as mass production and quality control.

Suggested learning outcomes

This lesson will teach students how to carry out a basic batch manufacture of a cast product. At the end of the activity, students will be able to describe the advantages of batch production.

Download our activity sheet and other teaching resources

The activity sheet includes teachers’ notes, useful web links, and links (where appropriate) to the national curriculum in each of the four devolved nations; England, Northern Ireland, Scotland and Wales.

All activity sheets and supporting resources are free to download, and all the documents are fully editable, so you can tailor them to your students’ and your schools’ needs.

Download our classroom lesson plan and presentation below.

Please do share your highlights with us @IETeducation.


Related resources