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Our design and problem solving class was tasked with designing and creating marine-themed halloween costumes.  The costumes had to be made out of recycled cardboard and be made for middle school children.  The class was spilt up into groups of 4-6 people.  My group decided to do benthos, or animals that live on the sea floor.  My costume was a mussel.

Design Brief: Design and create a mussel costume that is made out of recycled cardboard.  The costume must use slotted construction so it is easy to contruct and be made for middle school aged children.

Specifications-
The costume must:
• Fit middle school children
• Must be made using slotted construction
• Be a flat pack, meaning it can be taken apart into flat pieces.

Limitations-
• (Materials/Supplies) Cardboard
• (Time) Designing time, Production time
• (Tools and Equipment) Utility Knife, Cutting Mat, Pencil, Ruler

Materials List -
• (S1) 2 56" x 48" Single Ply Cardboard Pieces
• (S2) 4 18" x 6" Sing Ply Cardboard Pieces

Tools and Equipment-
• (T1) Cutting Mat
• (T2) Utility Knife
• (T3) Ruler
• (T4) Pencil
• (T5) Circle Template or Compass

Parts List-
• 4 (P1) Connectors
• 1 (P2) Front Side
• 1 (P3) Backside

 

Step 1: Part 1: Connectors

1. Use the Ruler (T3) to measure 11" by 4" rectangles on the cardboard (S2) 
2. Mark lines on the cardboard (S2) with the pencil (T4).
3. Place a Cutting Mat (T1) under the cardboard (S2).
4. Cut the cardboard (S2) using the Utility Knife (T2).
5. Use the Ruler (T3) to measure 1" by 2" slits 1.5" from each side of the (P1) connector.
6. Mark lines on the cardboard (S2) with the pencil (T4).
7. Place a Cutting Mat (T1) under the cardboard (S2).
8. Cut the cardboard (S2) using the Utility Knife (T2).
9. Repeat steps 1-8 four times.

Step 2: Part 2: Front Side

1. Use the Ruler (T3) to measure 8/10 of the occupant's height by double the occupant's width on the cardboard (S1).
2. Mark lines on the cardboard (S1) in an oval shape connecting the top, bottom, and sides of the rectangle measured in step 1 with the pencil (T4). Reverse the oval at the bottom (See Picture).
3. Use the Ruler (T3) to measure 7" by 5" rectangles half way down the oval for arm space.
4. Use the Pencil (T4) to mark the arm spaces.
5. Use the Circle Template or Compass (T5) to draw the head space on the cardboard (S1) a little more than 1/5 down from the top of the oval.
6. Use the Ruler (T3) to measure four 2" by 1/2" slits.  Two slits belong right under the head space, over the shoulders.  The other two are at the bottom.
7. Use the Pencil (T4) to mark the slits.
8. Place a Cutting Mat (T1) under the cardboard (S1).
9. Cut the cardboard (S1) using the Utility Knife (T2).


Step 3: Part 3: Back Side

1. Use the Pencil (T4) to trace the Front Side (P2) on the cardboard (S1). Do not trace the head space.
2. Mark the four slits in the same places as the slits were placed in the Front Side (P2) using the Pencil (T4).
3. Place a Cutting Mat (T1) under the cardboard (S1).
4. Cut the cardboard (S1) using the Utility Knife (T2).



Step 4: Assembly

1. Insert 1 Connector (P1) into each slit on the Back Side (P3).  The slots on the connectors (P1) face up.
2. Place the Front Side (P2) over the Connectors (P1) and insert the Connectors (P1) into the Front Side (P2).
Nice instructable! I love it!

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