A group of academic scholars and DT students visited the Morgan car factory with Dr Jones, Head of Library & Enrichment, Mrs Rolfe, Head of Design Technology and Mrs Dege-Edy, Design Technology technician.

Below are some of the insights from the students who went on the trip:

The guided tour was a fascinating experience that allowed the group to venture inside the historic workshops and see the unique processes that go into building a bespoke Morgan car. We had a very knowledgeable guide who gave us insights into Morgan’s heritage and craftsmanship.

Today we learned about how Morgan cars are manufactured. I found it very interesting that the cars are partly made of ash wood. I learned that every tree they use to build Morgan cars they plant six new ones. They use ash wood because it is light weight so will make the car more aerodynamic.

I found out that every morgan car is different. They are tailored to its buyer with different choices of interiors, paint and detailing. They are handcrafted so they take time and lots of effort to build just one car. Around 800 Morgan cars are sold every year making them rare and highly sought for. The wings on the Morgan car symbol mark speed and agility.

Henry Frederick Stanley Morgan founded the Morgan Motor Company in 1910 in Malvern. The first Morgan car was a three-wheeler, a lightweight vehicle powered by a motorcycle engine. – Lucy 

I enjoyed the trip very much as it was a very good insight into the inner workings of the Morgan Factory.

I learnt a lot, including how the company go through the process of making their cars, how the company was founded and all the different people who contributed to it and why the brand of car is so iconic. I especially enjoyed seeing the people constructing the cars and seeing the different stages of manufacturing as well as the different things everyone had to do to complete the car. I also liked learning about how you can start as an apprentice and work your way up the company. – Clem Year 7

The Scholar’s Malvern Factory trip was extremely valuable and beneficial to us. The most intriguing aspect was being able to view the bespoke creations. Each car had a specification dedicated to their customers, allowing each vehicle to be unique. To further Morgan’s individuality, their process of production was immaculate and entirely hard crafted, using specialists and apprentices. Their use handcrafted methods and machines, which are more than 100 years old, add incredible charm to each car. However, combined with modern, cutting-edge technology, an impeccable process and history was formed. I have witnessed the beautiful production of such delicate craftmanship and have learned an important lesson. Sometimes the most recent methods are efficient, but older process have the same, or even more value. Overall, this Trip was very educational and fascinating, where I learnt the importance of handcrafted work. – Stephanie

Visiting the Morgan factory was a fascinating experience that gave me a deeper understanding of how these iconic cars are made. Unlike many modern car manufacturers that rely heavily on machines, Morgan still uses traditional craftsmanship. I learned that ash wood is used to build the frames, which surprised me because I had always assumed cars were made entirely from metal. Seeing how heritage and innovation are combined in the factory helped me appreciate the unique element of the company’s approach.

Walking through the different stages of production was like following the journey of a car from start to finish. I saw raw materials being shaped, leather interiors being stitched, and engines being fitted with precision. Each step revealed the care and attention to detail that goes into building a Morgan car. It was clear that every vehicle is treated as a one-of-a-kind creation rather than just another product on a production line.

What I enjoyed most was watching the skilled workers at their craft. Their expertise and patience were inspiring, and it felt special to witness the artistry behind something as complex as a car. I also loved the atmosphere of the factory—the mix of wood, leather, and metal gave it a character unlike anywhere else. Seeing the classic designs lined up, especially the vintage-style models, was a highlight of the visit.

Overall, the trip taught me how much tradition and pride are woven into Morgan’s cars. I enjoyed not only learning about the process but also experiencing the passion that goes into each vehicle. The visit left me with a new appreciation for craftsmanship and showed me how history and modern technology can work together to create something truly remarkable. –Iona

I found the scholars’ trip to the Morgan factory very insightful, as it helped me to see the care, detail and effort taken to manufacture these unique cars. We were given a tour of the factory, which showed us the majority of the processes needed to design and build the cars, as well as live work on them. During this tour, I learnt how aluminium and ash wood are used to create a strong infrastructure, as the techniques for creating the base of the car are also used in aircraft manufacture, and that the majority of Morgans manufactured in the UK are exported to countries such as the USA, Germany and Indonesia. – Saira

Our trip to the Morgan factory was a really enjoyable experience, not just because of the cars but also because of the place itself. The factory had a warm and welcoming design, with neat workshops laid out in a way that let us see each stage of the car‑making process clearly. The mix of old wooden beams, polished metal tools, and bright natural light gave the whole space a calm but creative feeling. We thought it was impressive how the craftsmen worked with ash wood frames and carefully shaped the panels by hand, showing patience and skill at every step, in addition then passing those delicate skills to the next generation. What we learnt was that Morgan cars are not mass‑produced but built slowly and carefully, making each one unique and tailored to the customer’s design. The fact that they still use wood as part of the car’s structure was surprising and very interesting. Overall, the trip gave us a strong sense of tradition and artistry making the visit feel special and memorable. – Liza

Throughout this trip I gained an insight into the process of a factory, like the initial stages of forming the aluminium into the desired shape through hammering it down or the end stage of sewing seat covers with industrial sewing machines which increase the efficiency and decrease the time in which it takes to complete the final car. We also learnt that within early stages the engineers get 160 hours to create the chassis of the car and fill it with the engine and all other electrical components which shows how carefully time must be planned and the importance of sticking to a schedule.

Throughout the whole experience I learnt how the Morgan Factory innovate whilst maintaining their traditional and authentic car shapes and sizes by changing small things through iterative design. The cars are all unique to their own clients and are all hand crafted to fit exactly their clients wants and needs. They know what the customer wants exactly through a specification. The business themselves is also unique in another way as they have a variety of 40,000 paint colours to choose from and if they don’t suit your wants you can simply bring in a sample for them to paint match which shows their flexibility and willingness to suit the customer’s needs.

 From a business perspective, we can understand their finances and how their customer base is spilt internationally, including most there cars being sold to the US, (especially California) then UAE and finally Indonesia. 80% of their cars that are exported have an open roof design which appeals to a target market who live in warmer and sunnier climates.  During this trip we also heard about the different job roles they have. One I found interesting was the apprenticeship, as it would allow for me to grow my skills and learn how to collaborate in a factory whilst developing loads of new techniques. Overall, I really enjoyed this trip as it gave me the chance to see an insight to the processes of a car and how much work is needed behind the scenes, especially when it’s an everyday item that we don’t think about as much.  – Izzy

Today we visited the Morgan motor company and as being both a DT GCSE student and part of academic scholars it allowed me to have multiple insights into processes, manufacture, history of the company and how each car is different from one another.

Each car is specifically handcrafted, especially the bonnets showing the commitment towards keeping traditional cars like Morgans on the road. We specifically looked at the Super 3, Plus 4 and the SuperSport and looked at how each car was different than the others. As we went through the factory we saw the chassis making, metal work and upholstery, each showing how each step of making a car was done specifically to the needs and wants of the consumer, for example they have 40,000 different colours and they are able to paint match as well, showing how personalised you can make each morgan car. The main consumers of Morgan cars are America, UAE, Indonesia showing how morgan cars are renowned across the world. This trip has allowed me to see different processes I have learned in class and how they are used within industry. –Eleanor

The trip to the Morgan motor company factory was highly interesting to me as an A-level Product Design student. I was able to see many processes which I had learnt in class being used for actual high-end products in real time. This included timber laminating, press forming and the use of templates and jigs. I found the tour to be an intriguing in-depth look into how a Morgan car is actually made and the story behind the iconic design. – Imogen

This Wednesday academic scholars and DT students went on a very insightful and informative trip to the Morgan Factory. I found the unique design and the individuality of each car, tailored specifically for every customers’ needs, to be particularly fascinating. For instance, they had a huge range of 40,000 colours for customers to choose from when picking the colour of their Morgan, with the ability to colour match their car to the customer’s other vehicles. In terms of economics, it was great to see, in practise, the division of labour as each step of manufacturing process was divided and how this lead to specialisation of trade and therefore greater efficiency. – Claudia

As a business student I found the Morgan factory trip extremely mind opening in terms of how to take risks in the business world. I particularly enjoyed the information on the tour and the fact that that they haven’t changed the basis of their business model since 1914. Overall, I really enjoyed this trip not only from an educational perspective but also the fact we got to see amazing classic cars. – Faith

I really enjoyed the trip to the company. I thought it was very interesting and taught me a lot I didn’t know about how the company has developed over the century and how much history such a car could have. What also interested me was how so many cars can  be made ensuring that every one was individual and unique.  I wouldn’t hesitate to recommend this trip! – Mikayla