Project 141Puzzle Design Challenge

By Jeffrey Walker,2014-06-17 21:55
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Project 141Puzzle Design Challenge


    Have you ever looked at a product that has been well-designed? Do you find

    yourself asking questions, such as, “How did the designer think of that idea?” or

    “What is involved in the creation of that product?” The more you study and learn about design and how designers create items, you begin to learn certain skills and

    knowledge that you can only acquire through experience. Design challenges provide

    opportunities to apply skills and knowledge in unique and creative ways.

Taking an idea you have and transferring it from a concept to a sketch, to working

    drawings, to models, and then to a working prototype is exciting and fun. It also

    entails several steps. When you are a one-person design and build team, the task of

    effective communication is rather simple. However, what happens when you must

    communicate your ideas to others, or the responsibility for building a team’s solution

    falls on someone else’s shoulders? This increases the level of responsibility significantly and requires the development of a complete set of design

    documentation in order to communicate effectively.


    ? Engineer’s notebook

    ? Number 2 Pencil

    ? 27 ? in. hardwood cubes

    ? Scotch or masking tape

    ? 27 interlocking plastic centimeter cubes(optional)

    ? Digital camera

    ? Paper towels

    ? Isometric grid paper

    ? Markers and Colored pencils

    ? Wood glue

    ? Sandwich size Ziploc? bag for storage

    ? 220 abrasive paper

    ? Computer with 3D CAD solid modeling software


    This project will provide you the opportunity to exercise your creativity and develop

    your sketching and modeling skills, as well as your ability to use the computer as an

    efficient communication tool.

    Project Lead The Way, Inc.

    Copyright 2007

    IED Unit 1 Lesson 1.4 Project 1.4.1 - Puzzle Design Challenge Page 1

    What you have learned throughout Unit 1 Design Process will be applied to this project. The activities that you have completed throughout the lessons of Unit One

    will provide you with the information, components, and requirements needed to

    complete this project.


1. Study the Puzzle Cube Design Brief located on the following page.

    2. Brainstorm and sketch on isometric grid paper possible puzzle part combinations

    for your cube using Activity 1.4.2 Brainstorming Possible Combinations.

    3. Neatly sketch and color code your five parts used in the cube solution and show

    how they fit in the isometric view of the cube on isometric grid paper. See your

    teacher for an example. You will need a total of two solutions with ten different


    4. Choose your best option from the two solutions.

    5. Create the five parts to your cube using 3-D modeling software. Color the parts

    the same color combination used in the sketching phase of your project.

    6. Create multiview drawings for each of the five parts using 3-D modeling software

    and print out using a drawing sheet.

    7. Fabricate your five parts using the 27 cubes and glue. Color using markers or

    colored pencils and assemble your cube.

    8. Assemble your cube using 3-D modeling software and print out the completed

    cube on a drawing sheet.

    Project Lead The Way, Inc.

    Copyright 2007

    IED Unit 1 Lesson 1.4 Project 1.4.1 - Puzzle Design Challenge Page 2

    Client: Fine Office Furniture, Inc.

    Target Consumer: Ages 3+

Designer: _____________________________________

Problem Statement:

    A local office furniture manufacturing company throws away tens of thousands of

    scrap ?” hardwood cubes that result from its furniture construction processes. The

    material is expensive, and the scrap represents a sizeable loss of profit.

Design Statement:

    Fine Office Furniture, Inc. would like to return value to its waste product by using it

    as the raw material for desktop novelty items that will be sold on the showroom floor.

    Design, build, test, document, and present a three-dimensional puzzle system that is

    made from the scrap hardwood cubes. The puzzle system must provide an

    appropriate degree of challenge to a person who is three years of age or older.


    1. The puzzle must be fabricated from 27, ?” hardwood cubes.

    2. The puzzle system must contain exactly five puzzle pieces.

    3. Each individual puzzle piece must consist of at least three, but no more than six

    hardwood cubes that are permanently attached to each other.

    4. No two puzzle pieces can be the same.

    5. The five puzzle pieces must assemble to form a 2 ?” cube.

    6. Some puzzle parts should interlock.


    1. Why is it important to model an idea before making a final prototype?

    Project Lead The Way, Inc.

    Copyright 2007

    IED Unit 1 Lesson 1.4 Project 1.4.1 - Puzzle Design Challenge Page 3

2. Based on your experiences during the completion of the Puzzle Design

    Challenge, what is meant when someone says, “I used a design process to solve

    the problem at hand”? Explain your answer, using examples from the work you


3. What else could the furniture company do or make with the scrap used to make

    your puzzle cube?

4. If your design were going to be mass-produced, would hardwood cubes be the

    best material from which to construct the puzzle pieces? Explain your answer.

5. What forms of technical communication did you utilize during your work on the

    Puzzle Design Challenge?

    Project Lead The Way, Inc.

    Copyright 2007

    IED Unit 1 Lesson 1.4 Project 1.4.1 - Puzzle Design Challenge Page 4

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