The CREATE Education Project would like to thank Lloyd Griffiths, Design Technology Teacher at Newport High School for sharing this lesson and resources.

During the lesson, learners will be taught about thermoset and thermoplastics. What the two categories of plastic are used for and why.

Learners will also be taught about the injection moulding process, using a 3D printed model of simplified injection moulding machine. Normally a difficult process to understand, the model aids learners understanding of both the process and the materials used.

The teacher will be required to 3D print and assemble the Injection Moulding Model prior to the lesson; they should also use the PowerPoint resource and differentiated worksheets.

Newport High School Logo, Wales, UK

To accompany this project, there are 3 supporting resources:

  • Injection Moulding and Thermoplastics Lesson Plan: This includes an overview of the lesson, details of each lesson stage, activity and student tasks and WJEC Design and Technology Specification links/references.
  • Injection Moulding Lesson Presentation: PPT Visual aid that structures the lesson.
  • Injection Moulding Student Worksheets: Learner worksheets, double sided and differentiated into “Bronze, Silver and Gold” tasks.
  • Injection Moulding Model STL files: A set of STL files for printing the injection-moulding machine model.

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In The Classroom

The project was developed for the WJEC Design and Technology 2017 GCSE Specification, but it would be suitable for any of the KS4 GCSE or Scottish Higher Design Technology qualifications. This project could also be used for relevant FE courses.

This lesson will look at the injection moulding and the use of thermoplastic. The categorisations of plastics and their uses, and the use of injection moulding in manufacturing. This covers the following elements of the GCSE Specification:

2.1.1 In-depth knowledge and understanding

Engineering Design & Product Design Strands

(b) Thermoforming and thermosetting polymers

(g) The way in which the selection of materials or components is influenced by a range of factors such as functional, aesthetic, environmental, availability, cost, social, cultural and ethical

(h) Stock forms, types and sizes in order to calculate and determine the quantity of materials or components required

(i) Alternative processes that can be used to manufacture products to different scales of production

(j) Specialist techniques and processes that can be used to shape, fabricate, construct and assemble a high-quality prototype