Introduction to Metal Casting

ACP Lesson Plan 

Title: Introduction to Metal CastingAuthor: Shiv K Verma
Grade Level(s): 9 - 12Total Time: 3 (45 minutes periods)

Overview / Description:   

This lesson is to introduce students to casting and molding. The lesson will include the making of two identical candles by each group in the class. 

Learning goals/objectives

After completing this activity, students should be able to . . . 

  • Identify the basic features of casting
  • Explain the casting process i.e. melting, pouring of metal.
  • Explain the need for casting in mass production.
  • Explain green sand, mold, cope & drag. 
  • Replicate the process of casting by making a candle.

Workplace Readiness Skill: 

    Social Skills  x  Communication 
  x  Teamwork     x    Critical Thinking
   Attitude and Initiative  x  Planning and Organization
   Professionalism    Media Etiquette

Content Standards:

Wisconsin Standards for Technology and Engineering


Standard: MNF1.d.6.h: Demonstrate the interchangeability of parts increases the effectiveness of manufacturing processes.

Standard: MNF1.e.6.h: Recognize manufacturing system may be classified into types, such as customized production, batch production and continuous production.



Download: Introduction_to_Casting_CESA_8_Lesson_Plan.pptx


Learning Activities:

WHO (T=Teacher Focus Lesson; WG=Whole Group\; SM=Small Group; I=Independent)

Learning Activity Task                                                WHO is responsible
for this step?
Approximate time
for the task
Teacher will ask the class how would they make candles if the wax and wicks are given to them. After some discussion, teacher will divide the class into Small Groups and ask them to list the items they will need and the procedure (in steps) they will follow.T/WG10 minutes
Teacher will then present the Casting Powerpoint to the class. Students are encouraged to take notes on the process and the terminology during the presentations. 
35 minutes
The class will then watch the casting video, again taking notes and asking questions about the casting process
WG15 minutes
Teacher will divide the class back into their small groups. Groups will have the opportunity to revisit the procedure they wrote for casting a candle initially and make any changes based on the presentation and video that they watched. The teacher will then give each group wax and wicks, facilities to heat/melt the wax, and material to make molds for candles and ask them to make at least 2 identical candles of their chosen design.
35 minutes
Students will complete the Assessment quiz at the conclusion of their casting.
20 minutes


Summative Assessment - Introduction to Casting Assessment below:

Download: Introduction_to_Casting_Assessment.docx


Teacher could lead a discussion about the general uses of casting. Students could brainstorm other items which might be cast at a factory that does forging.

Extension Activity (for intervention or enrichment):

The class could take a tour of a forging operation.

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