Our first assignment was to learn to use the water jet by designing snowflakes. The snowflakes were to measure two inches on a side and mimic patterns found in nature as closely as possible.

Here is a picture of the finished product:

With the water jet mastered, our next challenge was to design a coffeecup holder for the coffeehouse at the Learning Center. One of the main problems with the way their coffeeshop is run is the cup holders. Due to cost the most viable option for them is to use cardboard cupholders from Dunkin Donuts, which are flimsy, disposable and hard to hold. We came up with our own design, which allows for a few improvments. Here are some pictures of the work in progress:

-Matt cutting holes for the coffee cups

-Ken evaluaing our first deisgn

-Greg testing the ease of cup removal from our first design

-Testing removability in our second design

-Sketching the final design in OMAX

-The finished products!

The first prototype is the design on the left. It allowed for six cups to be held with a handle in the center. Placing the holder on a table top caused the cups to lift out of the holder, allowing them to be easily removed. However, there were a few flaws with this design. First of all, the handle hole is quite small, suitable only for small children. Second, spilling coffee is an issue when using any cupholder, and this design did not lend itself to easy cleaning. This design was more for proof of concept than anything else.

The second design (middle) had a few noted improvments. First of all the handle is an open design, allowing for any sized hand to hold it. The cupholder itself is made out of lexan, making it easier to clean, cut cleanly on the waterjet, and making it easy to bend feet out of the material as shown. Finally any sharp edges were eliminated, making it safer for the students of the Learning Center to use. However, it was noted than in addition to carrying coffee the students must also carry envelopes of change for the customers. This led to the rubber bands on the handle as shown in the picture.

Our final deisgn (right) includes a more ergonomic handle, a clear slot for change envelopes as well as a gap for easy cleaning and removal of spilled change. The cups in the middle are further spaced from the handle to allow for more radial symmetry, so it is easier to carry with some cups removed. This design is on stie undergoeing its first field tests!

Next we decided to tackle the problem of their cafeteria trays. The trays are quite slippery, leading to numerous spills when students accidentally tilt the tray or bump into each other. After a few iterations we decided on a design that clips on to the tray with tabs:

The tabs allow for easy clip-on and removal from the cafeteria trays, so the staff can attach/detach them with ease depending on the student. They are made out of lexan for easy cleaning, and they were also cut on the water jet.

Many tab designs were considered before we chose one. The device both must clip onto the tray shown and have space to hold a bowl and two cups, while leaving room on the tray for plates, silverware and other items:

-Our project near comlpetion!

Our next project will be to design a device for students to hold a hand drum comfortably. See our Plans page for more info!