Introduction: Slotted Construction Sea Otter Stage Costume

This costume is the product of a project for my technology class. With a need to learn how to design and create final products using only slotted construction and the ever-present push to “live green,” my teacher gave us the task of making a line of marine-themed costumes. This sea otter is one of five in a line of marine mammal themed stage costumes.

Design Brief

Design and create a costume for the marine mammals themed costume line. Design costume to be worn on a stage by middle school students. Create costume out of recycled cardboard and slotted construction. The costume needs to be made in flat pack product design form for easing transport and storing. These costumes are designed so that an adult can assemble them. The costumes are designed to be worn inside or outside. Costumes shall be created following the mentioned requirements with the consumer (middle school students) in mind.

Specifications

The costumes must:

• Only use single-ply, double-ply, and/or tri-wall cardboard

• Be flat pack construction

• Use slotted construction

• Have a marine theme

• Be safe for the specific age range we are working with (middle school students)

Limits

• Only use cardboard obtained through recycling

• Pieces designed for slotted construction

• Pieces designed using flat pack design.

Materials

Item            Material Description         Quantity       Remarks-part

S1           Single-ply cardboard panel      2           Top (front and back) (P1)
S2           Single-ply cardboard panel      1           Top (side) (P2)
S3           Single-ply cardboard panel      2           Bottom (front and back) (P3 and P4)
S4           Single-ply cardboard panel      1           Bottom (side) (P5)
S5           Single-ply cardboard panel      1           Arm with hand (P6)
S6           Single-ply cardboard panel      1           Feet (P7)

Tools/Equiptment

Item           Tool                                                                                        Use

T1         CUTTING MAT (or thick cardboard)       Cut cardboard on this mat, use with UTILITY 
                                                                                    KNIFE (T2)
T2         UTILITY KNIFE                                           Cut cardboard
T3         RULER                                                        Measure lengths on cardboard
T4         PENCIL                                                       Outline pieces of costume on cardboard
T5         MARKER                                                     Outline pencil marks on cardboard

Step 1: Parts Production

Part List

Item      Quantity             Part Name

P1.              2                   Top (front or back)
P2.              2                   Top (side)
P3.              1                   Bottom (front)
P4.              1                   Bottom (back)
P5.              2                   Bottom (side)
P6.              2                   Arm with hand (left and right)
P7.              2                   Foot

The following steps will tell you how to produce the parts above.

Step 2: Top (front or Back) (P1)

1. Using scale on orthographic drawing, ruler (T3), and pencil (T4), draw top front (P1) onto cardboard panel (S1)

2. Using ruler (T3), utility knife (T2), and cutting mat (T6) cut out front (P1)

3. Using cut out front as template, trace back (P1) using pencil (T4) onto cardboard panel (S1)

4. Repeat step 2 for back (P1)

Step 3: Top (side) (P2)

1. Using scale on orthographic drawing, ruler (T3), and pencil (T4), draw top (side) (P2), onto cardboard panel (S2)

2. Using ruler (T3), utility knife (T2), and cutting board (T6) cut out side (P2)

3. Using cut out side (P2) as template, trace other side (P2) using pencil (T4) onto cardboard panel (S2)

4. Repeat step 2 for other side (P2)

5. On both side pieces (P2) locate and measure in for slots using ruler (T3) than draw slots with pencil (T3)

6. Using ruler (T3), utility knife (T2), and cutting mat (T6) cut out along line of slots

Step 4: Bottom (front) (P3)

1. Using scale on orthographic drawing, ruler (T3), and pencil (T4), draw (P3) onto cardboard panel (S3)

2. Using ruler (T3), utility knife (T2), and cutting board (T6) cut out front (P3)

3. Measure in for slots using ruler (T3) than draw slots with pencil (T3)

4. Using ruler (T3), utility knife (T2), and cutting mat (T6) cut out along line of slots

Step 5: Bottom (back) (P4)

1. Using cut out front (P3) as template and pencil (T4), trace back (P4) onto cardboard panel (S3)

2. Using ruler (T3), utility knife (T2), and cutting board (T6) cut out front (P4)

3. Measure in for slots using ruler (T3) than draw slots with pencil (T3)

4. Using ruler (T3), utility knife (T2), and cutting mat (T6) cut out along line of slots

Step 6: Bottom (side) (P5)

1. Using scale on orthographic drawing, ruler (T3), and pencil (T4), draw (P5) onto cardboard panel (S4)

2. Using ruler (T3), utility knife (T2), and cutting mat (T6) cut out side (P5)

3. Using cut out side (P5) as template, trace other side (P5) using pencil (T4) onto cardboard panel (S4)

4. Repeat step 2 for other side (P5)

Step 7: Arm With Hand (P6)

1. Using scale on orthographic drawing, ruler (T3), and pencil (T4), draw (P6) onto cardboard panel (S5)

2. Draw fingers of hand under arm using marker (T5), can be done to whatever size desired (not drawn to scale)

3. Using ruler (T3), utility knife (T2), and cutting mat (T6) cut out arm with hand attached (P6)

4. Using cut out arm with hand (P6) as template, trace other arm with hand (P6) using pencil (T4) onto cardboard panel (S5)

5. Draw fingers of hand under arm using marker (T5), can be done to whatever size desired (not drawn to scale)

6. Repeat step 3 for other arm with hand (P6)

Step 8: Foot (P7)

1. Using scale on orthographic drawing, ruler (T3), and pencil (T4), draw (P7) onto cardboard panel (S6)

2. Draw toes of paw using marker (T5), can be done to whatever size desired (not drawn to scale)

3. Using ruler (T3), utility knife (T2), and cutting board (T6) cut out foot (P7)

4. Using cut out foot (P7) as template, trace other foot (P7) using pencil (T4) onto cardboard panel (S6)

5. Draw toes of paw using marker (T5), can be done to whatever size desired (not drawn to scale)

6. Repeat step 3 for other foot (P7)

Step 9: Assemble the Costume

1. Insert tabs of top (front) (P1) into corresponding slots of one side (P2). Fold tabs over.

2. Insert tabs of top (back) (P1) into corresponding slots of same side (P2) used in step one. Fold tabs over.

3. Insert tabs of top (front and back) (P1) into corresponding slots on last side (P2) Fold tabs over.

4. Insert tabs of right arm with hand (P6) into corresponding slot on right side of top (P2). Fold tabs over.

5. Insert tabs of left arm with hand (P6) into corresponding slot on left side of top (P2). Fold tabs over.

6. Insert tabs of bottom (front) (P3) into corresponding slots of one side (P5). Fold tabs over.

7. Insert tabs of bottom (back) (P4) into corresponding slots of same side (P5) used in step one. Fold tabs over.

8. Insert tabs of bottom (front) (P3) and bottom (back) (P4) into corresponding slots on last side (P5) Fold tabs over.

9. Insert tab of right foot (P7) into corresponding slot on right side of bottom (front) (P3). Fold tab over

10. Insert tab of left foot (P7) into corresponding slot on left side of bottom (front) (P3). Fold tab over

11. Don costume and break a leg.
 

Step 10: Plan of Procedures

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