Form 4 Pupils Gain Design Insights at Morgan Motor Company
Towards the end of last term, 30 Form 4 GCSE Design and Technology pupils visited Morgan Motor Company in Malvern, to gain an insight into the production process of their classic cars.
Morgan, who have been producing cars since 1909 and have been located at their current site since 1914, use traditional coach building techniques to create their cars. Pupils saw some of the latest models up close, alongside learning about Morgan’s past, present and future before starting their tour of the production facilities. This aspect of the day helped pupils understand the brand’s heritage and their continued popularity.
During their visit, pupils saw how master craftspeople use traditional techniques to produce these iconic cars. Pupils saw first hand the use of jigs and templates in the production of these vehicles, along with the traditional tooling still used today, despite the modern update in manufacturing now being used elsewhere. Pupils learned how the combination of an ash frame and aluminium body work, teamed with a BMW engine, to create a sports car which has stood the test of time.
The first stop on the tour was to witness how the engine and electronics are fitted into the chassis and how a customer’s bespoke requirements are built into this process. The pupils then went back a stage to see how ash wood from Lincolnshire is hand crafted into the frame for the body using specialist jigs to create the iconic body shape, followed by seeing the car ‘come to life’ as the aluminium body was attached. Pupils also saw how despite traditional skills still being used, the ‘production line’ had been adapted with new technology to allow for more comfortable and easier working positions for the members of staff.
Once the group had seen the car take shape, they proceeded to see the finishing touches being added, including the leather upholstery. Pupils saw how customers could not only choose the colour of their interior but also add their own personalised monogram. Pupils also got to see the range of timbers and finishes which could be used for the dashboard and the process of lamination and ‘bag pressing’ which allows for the timber to be formed into the shape of the dashboard.
Following this, the young designers viewed the final stages of quality control, which was carried out in a futuristic looking workshop, where the cars were placed under UV lights to make sure there were no problems or damage to the paint work. The contrast between this area and the main factory was amazing to see and demonstrated to the pupils how technology can be used side by side with traditional techniques.
The final stop was the museum, where pupils not only got a chance to see some of Morgan’s past and present vehicles but also got to have a go at designing their very own vehicle!
The day passed in a blink of an eye but pupils left with not only a vast array of knowledge of the automotive industry but also about techniques, processes, and technology they can use in both their practical and theoretical work.
