21/07/2024
House of Science create a variety of science kits to send to schools around New Zealand, enabling hands on learning of specific topics from outer space to electricity and everything in between.
They approached us with an issue they were having with a 3D puzzle they have of the earth and its tectonic plates. This clever little puzzle, originally designed by Rebecca Haisman from the University of Canterbury, enables the different tectonic plates to clip in and out of the earth, but still allows the plates to move and wiggle a little when clipped in, teaching students about how earthquakes are created.
Unfortunately, the puzzle pieces were getting broken easily. They were originally 3D printed from white resin and then painted. As the paint wore away, the tolerance loosened on the clips and the pieces would fall out too easily. The resin was too delicate for rough school kid hands, and the clips would often break off from the puzzle pieces.
So we thought, we can fix this! We redesigned the push-fit clips, beefing them up to be both wider and deeper, with a larger radius at the join of where clip meets puzzle piece. We added an o-ring to the clip with o-ring groove inside the holes in the globe. This little o-ring enabled a smooth push-fit clip in design yet also provided grip of the pieces in the puzzle. The o-rings would take the brunt of the wear of being clipped in and out away from the puzzle pieces themselves, yet were cheap and easily replaceable. We 3D printed the puzzle pieces from blue and red ABS. This is a tough and durable plastic, and much cheaper than the original delicate resin. 3D printing the pieces in the required colours eliminated tolerance wear from paint rubbing off, and ensured consistent push-fits from all the puzzle pieces into the globes.
The puzzles have been well received by both teachers and students, with the pieces being easy to clip in and out. The House of Science branch managers who check and maintain the puzzles have had no issues with the new o-ring design and only minimal damage to the puzzle pieces from students. It's been positive feedback all round!
It just shows how much design can make an impact for the smallest little components.