Can You Design A Functional AAA Battery Holder?

Objective

Design a durable and functional AAA battery holder that securely attaches to cardboard and can position the battery in multiple orientations (horizontal, vertical, upside-down). Utilize 3DuxDesign materials for prototyping and TinkerCAD with Boxlight 3D printing technology to finalize your design.  This activity encourages creativity, problem-solving, and technical skills, all while integrating STEAM tools in an engaging and practical way.

Materials

• 2 AAA batteries (for testing)
• Corrugated cardboard (single-ply, 3-4 mm thickness)
• 3DuxDesign connectors (optional - you could use glue or tape instead)
• Scissors or a craft knife (for cardboard cutting)
• TinkerCAD software (free online CAD tool)
• Access to a Boxlight 3D printer (optional - any 3D printer will work)
• Ruler or measuring tape
• Optional: Decorative materials for aesthetics
• Student Reflection Worksheet

Introduction

In this challenge, you’ll address a common engineering problem: creating a safe and secure battery holder for classroom projects. AAA batteries are a safer alternative to lithium batteries, but they require innovative solutions to integrate with hands-on models. Your task is to design a holder that is easy to use, fits securely, and works seamlessly with cardboard-based projects.

Design Process

1. Explore and Brainstorm
• Review the dimensions of an AAA battery (10.5 mm diameter, 44.5 mm length) and the thickness of corrugated cardboard (3-4 mm).
• Consider different ways to attach the holder to the cardboard: over the edge, piercing through, or adhering flat.
• Sketch potential designs, keeping durability, functionality, and flexibility in mind.
2. Prototype
• Use 3DuxDesign connectors and cardboard to create a basic prototype of your holder.
• Test how well the battery stays in place in different orientations and under movement.
3. Model in TinkerCAD
• Follow the provided TinkerCAD tutorial to create a digital 3D model of your refined design.
• Ensure precise measurements and incorporate features like grooves or clips for a snug fit.
4. 3D Print Your Design
• Prepare your STL file and print your design using a 3D printer.
• Test the printed model with a real AAA battery and cardboard to confirm its functionality.

Presentation and Reflection

• Presentation:
• Create a short video or photo series explaining your design process, challenges, and final solution.  The video should be 2 minutes or less.
• Include details on how the holder can attach to cardboard in multiple orientations.
• Reflection:
• Complete the student worksheet to reflect on the project.
• Write or discuss what you learned from this challenge.
• Consider how you might improve or adapt your design for other uses.

Optional Extension Activities

1. Advanced CAD: Experiment with adding features like a built-in switch or cable holders to your design.
2. Decorative Design: Customize your holder’s appearance to align with specific project themes.
3. Functional Testing: Integrate your holder into a moving or vibrating project to test its durability further.  (The small 3DuxDesign motors make a great tool for testing.)