Design and Technology Pupils Experience Morgan’s Tradition of Hand Built Manufacturing

“I had the pleasure of taking the Sixth Form Design and Technology pupils to visit the Morgan Motor Company in Malvern. Morgan is a name long associated with British craftsmanship and traditional automotive engineering, and the visit offered our pupils a rare opportunity to see firsthand the skill, precision and heritage that define Morgan’s distinctive hand-built cars.

“Morgan car have been produced on this historic site since 1914, and it was striking to see how much of the manufacturing process has remained largely unchanged for more than a century. While most modern car manufacturers rely on robotics and highly automated facilities, Morgan continues to prioritise human expertise and artisanal methods. Last year, the company produced just over 650 cars, a figure that reflects both the complexity of the work involved and its commitment to quality over volume.

“During the tour, the pupils and I were guided step by step through the entire manufacturing journey, following a Morgan from its bare chassis to the finished vehicle ready for delivery. The chassis is the first component to be assembled. It contains the engine, gearbox, electrical systems and other essential mechanical elements. Even at this stage, it was clear how much precision is required to ensure each car performs with reliability.

“We were then introduced to one of Morgan’s most iconic features: the handcrafted ash frame. Highly skilled craftspeople shape lightweight ash timber to create the structural skeleton onto which the aluminium body panels and interior trim are later fitted. Watching this traditional woodworking technique in action was genuinely fascinating. It is a craft that has been handed down through generations and is now rarely seen in modern automotive manufacturing.

“The pupils were particularly intrigued to learn that each ash frame, and likewise each complete set of body panels, is produced by a single individual. This approach ensures exceptional quality control and also gives each craftsperson a strong sense of ownership and pride in the vehicle they build. It reinforced the message that a Morgan is not simply a product but a reflection of human skill, patience and creativity.

“We then moved on to the paint booths, where each car is spray-painted with remarkable care to achieve a flawless finish. Even with technological support, it is still the trained eye and steady hand of the painter that ensures each surface is perfect.

“Our next stop was the trim shop, the workshop responsible for the interior of the car. Here, technicians cut, stitch and assemble the leather upholstery, working with high-quality hides available in an impressive range of colours. We also observed the Mohair hoods being crafted and individually fitted to each car. This was yet another example of Morgan’s dedication to customisation and attention to detail. The pupils were able to see how ash wood, polished aluminium and premium leather combine to create the aesthetic that makes Morgan vehicles so iconic.

“Overall, the tour was extremely impressive and thoroughly enjoyed by all the pupils. Although there was an assembly line of sorts, what stood out most was the minimal use of automation. Instead, Morgan relies on a team of highly skilled craftspeople whose specialist expertise is central to producing vehicles that are as much works of art as they are machines. The visit not only showcased traditional manufacturing techniques but also highlighted the enduring value of craftsmanship within modern industry, a lesson I believe is invaluable for any aspiring designer or engineer.”

• Jason Grindle, Head of Design and Technology