2021 Aluminum Extrusion Design Competition Winning Entries Displayed at ET
Nearly 110 designs by students from 40 universities, colleges, design schools and high schools, hailing from some 15 countries around the world were received for the 2021 International Aluminum Extrusion Design Competition. Four judges reviewed and evaluated the entries, including Todd Boyer, Director of Sales and Marketing for Mid-States Aluminum in Fond du Lac, Wisconsin; Joe Jackman, President of Almag Aluminum in Brampton, Ontario, Canada; Brook Massey, President of MI Metals in Oldsmar, Florida; and Craig Werner, President of Werner Extrusion Solutions in Lake Forest, Illinois.
Congratulations to the winners of the 2021 International Aluminum Extrusion Design Competition! The ET Foundation and the Aluminum Extruders Council thanks all of the participants - students and schools alike - that took part in this year's competition. Special thanks to those faculty advisors that advance aluminum extrusion education in the classroom by using the Aluminum Extrusion Design Competition as a teaching tool.
First Place - $5,000 Scholarship
"Electric Rail" Computer and Drawing Desk
Predrag Porobic, Megatrend University
Igalo, Herceg Novi Montenegro
Predrag Porobic, a senior studying design at Megatrend University in New Belgrade, Serbia, won First Place in the 2021 International Aluminum Extrusion Design Competition, earning a $5,000 scholarship. His winning design, "Electric Rail" Desk, is a completely new desk concept for industrial, graphic and interior designers, architects and other design and engineering professionals. The desk uses linear motion to quickly and easily maneuver monitors and lighting accessories and a specially designed extruded aluminum chase system to stow cables and cords out of the way. "The aluminum profile, aluminum bracket and metal tube with plastic articular rotators make the user's work easier" so that the height and angles can be adjusted according to the user's own ergonomic requirements, according to the student.
The desk can be configured with any number of monitors and lights to illuminate the work surface according to the user's preferences. Several aluminum extruded brackets fit inside the profile to connect and attach the accessories. The main aluminum profile is screwed along the entire structure of the desk and follows the length of the worktop. The profile contains rails on which the wheels of the brackets move and a bearing for a plastic extruded element that serves an insulating role. The electric rail desk mode of operation is based on the use of electrographite brushes as a current conductor between the monitors/lamp and the case.
The 15-cm-long aluminum extruded bracket's role is to slide inside the aluminum profile along the recesses intended for its wheels. The bracket has three tube holes that run through its body all the way to the base where there are two holes for the electrographite brushes.
The desk structure, rail and accessory connection brackets are made of aluminum extrusions. The structure profiles are welded together and screwed to the computer worktop and wooden boards on the sides of the desk. The desk includes a drawing board that can be inclined at various angles according to the user's preference. "The characteristic feature of this desk is that the computer and drawing surfaces are connected from one part, which is why the desk structure contains welded parts under the drawing surface."
Through market research, surveys and brainstorming, Porobic realized there was a need for his desk system. "For easier visibility of project work, designers often use two monitors, and sometimes even three. More monitors mean more cables, more cables mean more mess. When users buy this type of desk, they not only get a worktop, drawers and storage for accessories, but they also get a completely new concept of a work platform," Porobic explained. "Since this product is based on linear motion, aluminum profiles play a key role within the product. Two different profiles were used: one larger that follows the length of the desk and one smaller inside the large profile. The smaller profile is present in three copies: two for monitors and one for the lamp. Market potential, innovation, creativity and practicality are synonyms for this product."
Porobic continued: "By merging the profile with the worktop, thanks to the fluid and round surfaces, one gets the impression that the work top and the aluminum profile form one element, although they are two different elements and two different materials, which completely meets the aesthetic role of the aluminum profile in this product."
"This entry capitalized on many of the design advantages of aluminum extrusions, including the ability to put metal where needed, ease of finishing options such as anodizing, aluminum extrusion's strength for mounting purposes, and the ability to incorporate functional parts into a single extrusion," commented Craig Werner. "Of particular interest were the interactions of the wheels allowing the inner extrusion to be easily repositioned throughout the length of the outer extrusion – both of which were beautiful in form. By utilizing aluminum extrusions, Predrag was able to incorporate ease of adjustability and functionality, with the possibility of limiting electrical cords for a cleaner, organized workspace. This unit could be used as part of a total desk design or sold modularly for retrofit to any desk," he continued.
Joe Jackman of Almag, Inc. noted, "The extrusion design is well thought out. By incorporating screw bosses and guide details within the extrusion, some secondary fabrication steps are eliminated, which also reduces the number of parts needed to manufacture the desk, resulting in reduced manufacturing costs."
Second Place - $4,000 Scholarship
HORAE Temporary Wall Screen
Valeriia Shveikina, Jan Evangelista Purkyně University in Ústí nad Labem
Prague, Czech Republic
HORAE is a temporary wall/screen with an integrated mounting system for plants that, "like the goddesses of Greek mythology, creates a balance between humans and nature," according to the student. The screen wall system is made up of extruded aluminum profiles fixed between the floor and ceiling and plant holder profiles that allow for mounting plants to bring some greenery inside.
Three aluminum extrusions are needed, including one profile for the wall system, one for the flowerpot holder and one angled profile for the mounting system. "Thanks to [aluminum extrusion technology] it is possible to produce a long profile with grooves inside on which the holders with flowerpots can be moved freely," explained Shveikina. The potholder is designed to form two halves, which can be attached to the wall separately. "In this way, it is possible to use flowerpots of different sizes," with variable heights, lengths and distances between the planters.
The student suggested the system can be used in homes and in businesses where it is "necessary to subdivide the space elegantly and without much intervention. It is a subtle wall that will make your interior more interesting and stylish and bring you closer to nature," she noted.
Competition judge Todd Boyer of Mid-States Aluminum noted of the student's design: "The ability to configure an extruded aluminum wall screen for use in multiple commercial and residential environments was both functional and attractive. However, adding the green space on the one side made an "ordinary" wall screen something very special. The unit also provides portability for people flow so often needed in commercial offices, restaurants, and homes."
"What drew me to this design was the modularity of the concept, allowing single units to be used or multiple uprights combined into linear, curved or other creative forms," commented Werner. Valeriia created interlocking parts using just a few extruded profiles. The ability to incorporate these into office, home or commercial environments to bring plant into the architectural realm of interior space was very appealing. The modularity and ability to provide the product in various anodized or painted finishes, or even mill finish, would enable space designers to utilize these to enhance interior spaces. I could even see selling small "kitted" units to homeowners to incorporate herb, vegetable or other plants into interior spaces."
Third Place - $3,000 Scholarship
BAKS Chair
Pierre-Olivier Santerre, Dawson College
Delson, QC Canada
Pierre-Olivier Santerre explained in his design entry that there are not a lot of chairs on the market that use aluminum extrusion to its advantage, and most hide the process and material behind a thick coat of paint. "Moreover, aluminum extrusion is not often used for indoor furniture, and when those chairs use aluminum it is often for small parts and they are hidden."
So, Santerre set out to design a chair that highlighted aluminum and the extrusion process, was easy to assemble, long lasting, and comfortable. The chair features a simple, mid-century modern design aesthetic made of ash wood and aluminum. The aluminum profiles include a back, front and top spar, and legs. The leg extrusions utilize bending, and the spar profiles include screw bosses, taking advantage of the ability of the extrusion process to build in features that eliminate additional fabrication steps.
Extruded aluminum was used to make 90 percent of the parts, making the chair lightweight and easy to move, easy to manufacture, and sustainable. Aluminum was chosen for its attractive natural color and multiple finish possibilities.
"I think the design is attractive and could see this being used in reception areas and doctors' offices," commented competition judge Brook Massey of MI Metals.
"By mixing in wood with the aluminum extrusion, Pierre-Olivier has come up with a beautiful, modern, sturdy and lightweight chair," said Jackman. "The bent legs show how versatile and ductile aluminum extrusion is, and the incorporated screw bosses allow for minimal fabrication and ease in assembly."
Sustainable Design HM - $500 Scholarship
Agricultural Robot
Sanat Seitov, Lomonosov Moscow State University
Moscow, Russia
Sanat Seitov, a senior studying agricultural economics at Lomonosov Moscow State University in Moscow was recognized for his design entry of an agricultural robot for detecting and combating plant diseases. The robot collects information about the health of the plants in the fields of agricultural farms with subsequent treatment of plants with protective agents.
"Thanks to aluminum, the robot has less weight and has less pushing effect on the ground," explained Seitov. "The fully assembled robot weighs 600–800 kilograms (1,323 – 1,763 pounds), and the support area of all wheels is equal to 400 cm2, therefore, the specific ground pressure is 1.5–2.0 kg/cm2. Such low ground pressure saves the soil structure. The pressure is less than that of tractors of the same class, since the mass is lower due to material from which the robot is made – aluminum."
The robot is modular and made from aluminum, so it is easy to assemble, repair and upgrade. These solutions reduce manufacturing complexity, repair costs and the ultimate cost of robots. For rapid development, aluminum extrusion was used, according to the student.
The robot was aimed at solving four problems:
- Increasing the efficiency of land resources use, expressed in an increase in yield achieved through the early tracking of plant diseases by a robot;
- Reducing the overspending resources volume (fungicides, medicinal and chemical preparations for the treatment of plant diseases);
- The maximum possible decrease in the role of the human factor in crop production, reduction of labor costs in field work;
- Ensuring environmentally friendly crop production through robots that do not lead to shear deformations of the soil cover, do not push the upper soil layers, do not change the water and air regime of the soil. That is why the living conditions of beneficial microorganisms do not deteriorate, i.e., favorable factors of soil fertility are preserved in full.
"Now, the field will be under the reliable protection of our robot – 16 hours a day without recharging. Increased profits, reduced risks of crop failure are achieved by analyzing the condition of plants – using an automatic device that protects the health of cultivated plants," the student explained. "The economic effect is possible as follows: one farmer will be able to control several robots and give them tasks, thus cultivating several large fields. That is, robots will be engaged in physically hard and painstaking work, which will improve the attitude towards employment in agriculture. A farmer can give commands to the robot remotely. This will allow a farmer to control agriculture using a computer from home (he/she can hire pilots who live in the village, which will lead to lower costs when hiring qualified personnel)."
Werner commented, "Sanat utilized aluminum extrusions for a strong, stable, corrosion - free framework upon which this fascinating design is based. The ability to meld technologies such as vision systems, artificial intelligence and GPS to further modernize farming is fascinating. The use of minute, targeted pesticide use versus broadcast spraying certainly would provide immense environmental and health benefits."
"The design was very well thought out," said Massey. "The reduction of chemical usage could be huge for our environment and a great cost savings for the farmers."
Sustainable Design HM - $500 Scholarship
ShowFold Shower Chair
Kevin Zhao, Rochester Institute of Technology, School of Design
Rochester, NY USA
Kevin Zhao, a senior studying Industrial Design at Rochester Institute of Technology, designed a shower chair assistive device to be installed on a bathtub. The ShowFold is a new, innovative shower seat that was designed to help with balance in the shower. The easy, two-step installation provides independence for those that need assistance while bathing. "The aluminum extruded seat and legs allow the chair to be lightweight and non-corrosive. Also, with simple aluminum extrusions, this product can be easily mass produced and assembled to lower cost and time in production," noted the student.
"The aluminum also makes the chair extremely weight bearing, making it accessible to people of all sizes. On top of the aluminum, the grab bar is made of wood (teak or oak is suitable for the wet environment of the bathroom) which, in combination with the aluminum, adds a modern and simple look to anyone's' bathroom. For safety purposes, the seat is set at an angle to prevent the suction-cupped legs from moving in the bathtub for a non-slip and worry-free experience. The legs also have a 90-degree locking mechanism that ensures optimal stability," Zhao explained.
"I really like the way the frame doubles as a handrail to assist with entry and exit of the tub," said Massey.
"Kevin was able to use the beauty and functionality of aluminum extrusions, coupled with other materials, to design a functional retrofit safety and comfort system for aging adults or others needing stability assistance to bathe safely," said Werner. "The "screw-on-the-tub design" allows the unit, utilizing the strength and light weight of aluminum extrusions, to be easily removed should a resident or guest in a home or other environment need assistance for a limited time period."
Sustainable Design HM - $500 Scholarship
Extrusion-based Erosion Control System (EBEC)
Will Asproth, University of Minnesota, College of Science and Engineering
Chaska, MN USA
Will Asproth, a high school Senior who plans to study aerospace engineering at the University of Minnesota in Minneapolis in the fall, designed an erosion control system that aims to alleviate water- and gravity-based soil erosion. The student noted that the design is a two-part system that consists of one part that "should slow down and redirect surface water, and the other part should prevent sections of the earth from separating. The proposed design uses submerged plates to prevent surface erosion and long rods to prevent mass-movement erosion. These plates and rods are interconnected to form a matrix that protects the shape of the earth. While the plates can be made from a multitude of materials, the best material for the rod part of the matrix was found to be aluminum."

Aluminum extrusions were chosen for the design because they can be formed into the correct shapes to connect the plates, which makes the system highly customizable and adaptable to any potential erosion environment. After consulting the AEC Aluminum Extrusion Manual, Asproth decided "6063 aluminum alloy was best suited for this application because of its favorable characteristics in extrusion, its relative abundance in recycling, and its high strength."
Six different plates were designed for various environments and erosion prevention, including high-slope areas, and where water pass-through is preferable. Together, the extruded aluminum stakes in varying lengths and the plates are the building blocks of the EBEC System. "An engineer would use these tools to create custom matrices for whatever environmental conditions where erosion needs to be prevented," explained the student.
Asproth used the tools and resources available to him on the AEC website to design his erosion control system, which helped him to optimize his profile design. The resources included consulting the Aluminum Extrusion Manual and the "Key Considerations" page in the Extrusion Design section of the AEC website.
"I was in southern California last year, spending time walking and biking along the coastal shoreline," said Werner. "I saw many examples of extensive construction work attempting to limit or correct the effects of bluff erosion. With climate change comes alternating periods of drought and sometimes intense rain. Without the ability of longer or deeper root vegetation to help stabilize bluffs or hillsides, the drier soil is easily washed away during rainy periods. Will's system may be one of the solutions to help stabilize the soil to allow vegetation to "take root" more securely or to otherwise help to control and direct the flow of water, reducing the devastation caused by erosion."

Thank you to the 2021 Student Aluminum Extrusion Design Competition Sponsors: