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Holy Grail Project - Re-Usable Collapsible Cup from Sustainable Materials

intro
 

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.
Holy Grail Project - Re-Usable Collapsible Cup from Sustainable Materials
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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 -…


30 comments
Aug 4, 2008. 3:06 PMkillerkorn says:
and what if it breaks youd get soaked

...just saying

but i like it

Aug 22, 2009. 12:36 AMDavidnipp says:
that's what she said...
Aug 21, 2009. 11:45 PMeuntrepreneurintraining says:
recycle #5 polypropylene is not a foodsafe material. Better than PET? Yes. Good for you? No. Try this link for more information;
http://www.hpakids.org/holistic-health/articles/108/1/Plastic-Water-Bottles

That said, I am really impressed with your design. Good work!

Aug 1, 2009. 5:37 PMlynnekz says:
So where can I buy one? I'm not very handy/crafty/mechanically inclined and would never be able to make this myself but it is such a neat idea and I have been looking for a collapsible cup to carry in my purse.
Apr 24, 2009. 7:20 PMnaweedshams says:
Great product daniel. We thought of this idea too not long ago. But havent thought of which material to use to prevent heat burning the hands. I think you deserve the appreciation for your inventions. We're planning to start manufacture within the coming months, we would be happy to share the royalties if you contribute further ideas to the product.
You may contact me directly at naweedshams@hotmail.co.uk
All the best
Naweed.
Jun 16, 2009. 4:21 AMjoshuagiles1 says:
Hi Daniel,

Great design i was wondering if you had progressed any further on this project. I would like to have a chat with you in regards to sampling a few of these re-usable collapsible cups and also discuss my background and why im intersted in this particular project. contact me at: businessbistro@yahoo.co.uk.

many thanks
Josh
Jan 23, 2009. 4:31 PMtsgreenwood says:
This looks like a great idea. Do you have any ideas for a simple way to personalize it with a logo or something, such that it would not affect the structure or the integrity of the cup?
Jan 23, 2009. 4:34 PMtsgreenwood says:
http://www2.eng.cam.ac.uk/~sdg/dstruct/cylinders.html is no longer a viable link. Could you provide a fresh one by any chance? Thanks!

Nov 9, 2008. 9:54 PMPReDiToR says:
If you never cut towards yourself, you'll never cut yourself.

An age old adage.
Sep 23, 2008. 2:29 AMcorey_caffeine says:
looks like an emergency tankard for Germany but then we need an emergency pipe for holland
Jun 8, 2008. 11:24 PMgoobyalus says:
First of all, that is AWESOME!
I've got a few questions though-How durable are the creases, especially the ones you welded? Will they withstand repeated bending and temperature changes? And how hard is it to clean?
If I can find an old folder I'll try to make one, but I think I'll make one out of paper either way just cause it looks cool.
Jun 25, 2008. 8:59 AMgoobyalus says:
I can't find a PP folder anywhere so I guess I'll have to go buy one. So much for recycling. Anyway, a paper thing I made inspired by this is here: http://jaslab.deviantart.com/art/Not-so-Cylinder-89730228
Thanks for the awesome instructable!

Jun 9, 2008. 10:33 AMDarkStar851 says:
Why not simply use one of those sack things they have for baby bottles? they collapse as their used. But instead of using the "nipple tip," you could attach a straw :D
Jun 17, 2008. 8:27 AMDarkStar851 says:
Yeah, they collapse as the milk, or other fluid, leaves the bottle. So the baby's don't have to suck too hard to get it out.
Jun 17, 2008. 4:32 AMkillarowa says:
sack thingie for baby bottles?
Jun 13, 2008. 3:00 PMiamthemargerineman says:
well done.
Jun 12, 2008. 2:30 PMlittlegandhi1199 says:
this is a great idea and would work well when camping
Jun 9, 2008. 11:18 AMEscVelocity57 says:
yeah my worry is spills. ugh I would love to see this is a variety of colors, clear white just gives me chills. I love it! wonderful idea, and I love how it is shape into a hexagon.
Jun 9, 2008. 3:14 PMDarkStar851 says:
O_O seems a lot of things give you chills :p

Your right about the spills though, I cant imagine this is very sturdy... :P
Jun 9, 2008. 8:44 AMcowscankill says:
sweet. sweet. sweet. gotta make this XD
Jun 6, 2008. 12:05 PMfungus amungus says:
Cool beginning, but where's the rest of it?
Jun 9, 2008. 7:49 AMfungus amungus says:
Ah, cool, there it is. Great job!
Jun 6, 2008. 8:03 PMrimar2000 says:
Awesome!
Jun 6, 2008. 1:28 PMpyroelectro says:
i was gona ask the same as fungus

looks like a cool concept, and i see where your going but a plan of where to bend is needed

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