Holy Grail Project - Re-Usable Collapsible Cup from Sustainable Materials
introHoly Grail Project - Re-Usable Collapsible Cup from Sustainable Materials
In brief... A 'Re-Design' project - How to make your own fold-down,
re-usable cup that collapses from 16cm high down to 2cm, can fit in a
pocket or clip onto a belt, holds hot beverages without burning your
hand and is made almost entirely from sustainable, used materials.
I'm a third year year industrial design/mech eng student studying in Australia (fun :-) ), and for a recent assignment, we familiarised ourselves with the movement known as redesign - a collaboration of product designers who endeavor to take used components/materials, and make new products from them in a sustainable way (http://www.redesigndesign.org/ is a main website if you're interested).
My personal project, therefore, was to prevent the purchase of plastic P.E.T water bottles by devising a cup that was convenient and portable to carry around and use every day (after all, in many places, the health standards are higher for tapwater than bottled). Moreover, it had to be long lasting, easy to clean, recyclable, and able to hold the hot uni-cafe coffee I inevitably need, after staying awake all night working on things like, well, this.
The result is a cup that can hold more than a can of soft-drink when full, yet is about 2cm thick when flattened, and fits easily in a pocket (it can also be looped securely onto a belt). The shape does not transmit heat to the hand easily, and best of all; it's made mostly from the polypropylene covers of used folders where the spine had broken. I write this instructable in the hopes that others may also manufacture one, and I intend, with time, to refine this project further.
I'm a third year year industrial design/mech eng student studying in Australia (fun :-) ), and for a recent assignment, we familiarised ourselves with the movement known as redesign - a collaboration of product designers who endeavor to take used components/materials, and make new products from them in a sustainable way (http://www.redesigndesign.org/ is a main website if you're interested).
My personal project, therefore, was to prevent the purchase of plastic P.E.T water bottles by devising a cup that was convenient and portable to carry around and use every day (after all, in many places, the health standards are higher for tapwater than bottled). Moreover, it had to be long lasting, easy to clean, recyclable, and able to hold the hot uni-cafe coffee I inevitably need, after staying awake all night working on things like, well, this.
The result is a cup that can hold more than a can of soft-drink when full, yet is about 2cm thick when flattened, and fits easily in a pocket (it can also be looped securely onto a belt). The shape does not transmit heat to the hand easily, and best of all; it's made mostly from the polypropylene covers of used folders where the spine had broken. I write this instructable in the hopes that others may also manufacture one, and I intend, with time, to refine this project further.
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step 1Materials
You will require:- Polypropylene plastic sheet, approximately 0.5mm thick. If you wish to adhere to redesign principles, I got mine from a marbig folder that had split alon…

step 2Tools
You will need: - a scalpel or stanley knife - a metal ruler - a thick, dark pen or marker - double-sided tape - a soldering iron, preferably with a 4mm wide chisel tip…

step 3Template for fold lines
In order to achieve the fold pattern of the cup around the cylindrical section, a template must first be made. I have supplied an image below that can be scaled to create a…

step 4Obtaining the Plastic Sheet
Assuming you are using a folder for your source of plastic, you'll probably want to get one flat sheet out of it. Just grab that scalpel and split the folder along its seam…

step 5Applying the Template to Plastic
Take the printed template, and double-sided tape it firmly onto the back of your polypropylene sheet. The idea behind using a translucent colour is that you can see the tem…

step 6The Folding Commences
Getting the plastic sheet into a cylindrical shape is where the project begins to get a little tricky. As you know, the horizontal lines, and the lines at 60 degrees, are m…

step 7The Seam
I'll be frank with you, this part of the project took a long time to get right and it's pretty frustrating, so if you're trying to do this at home, you may have to persever…

step 8Bottom, Top, and Strap for the Cap
Now that you have the collapsible part made, it'll probably need a top and bottom. The bottom is simply a hexagonal peice, but the top obviously has to have a hole for the …

step 9The Cap
The last piece of the cup is the cap that allows it to seal, whether flat, or extended and filled. Having access to a cost-price objet rapid prototyper machine at uni, and …

step 10Using the Cup
If you put the cap through the hole on the end of the strap, you're done! I hope that my instructions have been comprehensive enough to achieve this - if not, let me know -…
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