Pupils Explore Car Manufacturing at Morgan Motor Company

Last Friday, Year Ten Design Technology Resistant Materials pupils travelled to Malvern for a behind-the-scenes tour of the Morgan Motor Company, learning more about one of Britain’s most distinctive car manufacturers.

For pupils studying GCSE Resistant Materials, Morgan provides an opportunity to see traditional craftsmanship alongside modern engineering. Unlike many contemporary car manufacturers that rely heavily on automated production lines, Morgan continues to build its vehicles using a largely hand-crafted process, preserving techniques that have been part of the company’s heritage for more than a century.

During the visit, pupils explored the factory floor and observed the different stages involved in constructing a Morgan car. One of the highlights was seeing the famous Morgan chassis taking shape and learning how different materials are selected for their unique properties.

Pupils saw how laminated ash wood is used to create the body frame, valued for its strength, flexibility and vibration-dampening qualities. They also watched technicians hand-form lightweight aluminium panels over wooden formers, demonstrating the material’s malleability and the skill required to shape each panel.

The tour also included a visit to the trim shop, where pupils observed how the structural frame is combined with high-quality leather finishes as part of the vehicle’s final construction.

The visit provided pupils with real-world insight into design and manufacturing principles, helping to connect classroom learning with practical engineering processes.

Mr G Batchelder, Head of Design & Technology