Age range: 11-14
Duration: 0 - 29 mins
  • D&T
  • Engineering

Engineering processes

Understand the concept of modular design and the casting process

The ‘Engineering Process’ scheme of work provides students with an in-depth understanding of some engineering materials and how they are being developed in industry. This scheme was inspired by the casting process used to make the D3O smart material into a ‘usable’ form. This links to industrial practices such as quality control, standardisation and casting manufacture. It is designed to challenge the students by requiring them to apply the knowledge and understanding of engineering materials through a ‘batch’ production experience.  

Activity info, teachers' notes and curriculum links

An engaging activity including two short tasks to support students’ understanding of the application of the casting process and the concept of modular (repeat) design.

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

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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.

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Activity overview

Engineering Processes activity description, teachers' notes and curriculum links.



Images of a wide range of cast products.



A closer look at a range of modular products.

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