2023 Aluminum Extrusion Design Competition Winning Entries Displayed at ET
More than 75 entries for the 2023 Student Aluminum Extrusion Design Competition were submitted by students from 16 countries around the world. High school and college students submitted entries for the opportunity to receive a cash scholarship. Thank you to Almag Aluminum, MI Metals, and Pennex Aluminum for sponsoring the cash prizes totaling $15,500.
The following students are the winners of the 2023 Student Aluminum Extrusion Design Competition.
First Place - $5,000 Scholarship
TRIadd Modular Aluminum Extruded Traffic Light
Drew Klopfenstein, Purdue University
West Lafayette, IN
Drew Klopfenstein, a sophomore studying Industrial Design at Purdue University in West Lafayette, Indiana, was awarded First Place for his design of a modular traffic light made from extruded aluminum components. Each light module slides on and off from the main base plate. His design of the TRIadd traffic light uses extruded aluminum for a number of reasons. "This product is a unique and practical use of aluminum extrusion," noted Klopfenstein. "It uses sliding functionality of extruded parts to allow for easy traffic light repair. Each light module slides off from the main light base plate." Aluminum was specified for the design due to its durability, weather resistance, light weight and it will not shatter on impact if it falls during a storm, he commented. He created the modular design to improve on existing traffic light designs that are constructed as one complete piece to make it easier, faster, convenient, and practical for repairs.
The student chose aluminum alloy 6063 for its favorable strength-to-weight ratio. The back plate can be used to attach to already existing poles. The extrusion process provides a series of holes on the back plate to be attached at various points to the pole for a truly customized design.
"This design is practical and improves on existing designs. With aluminum's durability, light weight and structural strength, the student has designed a very clever improvement to an existing product that has great market potential," commented competition judge Brook Massey, President of MI Metals and AEC Chairman.
Second Place - $4,000 Scholarship
ATLAS Electric Motorcyle
Brady Hawks, Purdue University
West Lafayette, Indiana
Brady Hawks of Laingsburg, Michigan, studying Industrial Design at Purdue University, won Second Place earning a $4,000 scholarship prize for his design of ATLAS, an electric motorcycle made of extruded aluminum. The student chose AA6061 aluminum for his design due to its light weight, strength, corrosion resistance, workability, and cost-effectiveness. "Using 6061 will overall improve the performance, handling and efficiency of the motorcycle," the student explained. "The custom frame build from extruded aluminum makes the ATLAS special. Rails are built into the design of the frame, allowing for easy installation and removal of various accessories, making the ATLAS incredibly modular and customizable," Hawks continued.
The motorcycle is designed to be used in urban environments. His design was born out of an examination of existing electric motorcycles that "lack the fusion of functionality and agility in their designs." He created this design to adapt to the user's needs with a modular design that "maximizes functionality without compromising on agility," noted the student.
The competition judges liked Hawks' design, calling it sleek and modern looking, and the simple yet attractive modular design with the drivetrain and battery housed inside the extruded aluminum frame makes it even more attractive.
"This electric motorcycle is like nothing I've seen anywhere else," commented Joe Jackman, President of Almag Aluminum. "Creating a system that allows for easy installation of accessories like a side storage bay and jump seat is a great idea that makes it extra versatile."
Third Place - $3,000 Scholarship
Oasis Retail Shelving
Sarah Fatouros, Dawson College
Montreal, Canada
Sarah Fatouros, a Senior studying Industrial Design at Dawson College in Montreal, Quebec, was awarded the $3000 scholarship prize for her Oasis Retail Shelving design. Explaining her product design, she noted, "my design was originally meant to be a much simpler version of what it is, one simple vertical element with [three] shelves that went on a wall. Over much development it transformed into a more unique design, a functional piece of art. The configuration of my design is unlike any other shelving found in retail stores, and the flexibility/modularity of the design adds a lot as well. I used the materials in a way to highlight their raw beauty."
Sarah continued her explanation, noting, "The linear design makes using aluminum extrusion for the main body an obvious choice, as well as for the LED light insert part. No post process work needs to be done to the extrusions other than curving the LED insert extrusion, anodizing and de-burring throughout. Every part of my design offers several features, such as the cut out for the lights in the shelves, or the height adjustability in the main extrusion."
Multiple configurations can be made from this design giving retailers flexibility in the way the shelves are used. A built-in accent lighting feature, rarely found in one product as the student noted in her design materials, and the adjustable shelving heights made this attractive design a winner in the eyes of the judges.
"This design really shows off aluminum extrusion's attributes. Not only the attractive metal aesthetic by anodizing, but the modular, adjustable, and practical design realized by her use of the extrusion process," explained Craig Werner, President and CEO of Werner Extruded Solutions and Chairman of the AEC Business Excellence Steering Committee. "The rail system integrated into the extrusion, the linear design and her choice of 6063-T6 aluminum alloy for its good surface finish and high corrosion resistance really shows off aluminum extrusion's benefits."
Sustainable Design Challenge Award - $3,500
Urban Bus Stop
Bhushan Deshmukh, Royal College of Art
London, U.K.
Bhushan Deshmukh of Manchester, U.K., studying Intelligent Mobility at the Royal College of Art in Battersea, London, U.K., won the Sustainable Design Challenge awards, earning him a $3,500 scholarship for his design of a multipurpose low-cost bus stand. The versatile covered bus stand provides an area for seating, a built-in bicycle stand, integrated solar panels, and even a garden wall feature.
"One of the standout features of the extrusion profile is its versatility. The aluminum frame's slots allow for the vertical garden to be integrated, adding an element of greenery and eco-friendliness to eh bus stand," note the student.
"The unique extrusion profile of the aluminum frame allows for quick and effortless assembly, making it the perfect choice for busy transportation hubs," explained the student in his competition entry.
The judges liked the modern look and flexibility of the design. "Aluminum extrusion gives the bus stop design versatility, ease of installation and built-in features; a good use of aluminum extrusions," said Joe Jackman.
Honorable Mention
Aluminum Extrusion Ceiling Storage
Tiffney Ancil, Purdue University
West Lafayette, Indiana
Tiffney Ancil, of Oxford, Indiana, a sophomore studying Industrial Design at Purdue University, won an Honorable Mention for her design of a ceiling storage system made of aluminum extrusions for garages and sheds. The versatile system provides for bin storage by sliding the bins into place between two extruded aluminum profiles. The multifunctional framing pieces also allow for hooks to slide onto the base as inserts to hang items from the framing system, like bikes, garden tools, etc.
Although similar products exist on the market now, the judges appreciated her attention to detail, making the product easier to fabricate and more user friendly by adding hooks for extra storage. The simple "standard size" extrusion is used, saving money, time and manpower, according to Tiffney.
"I would buy this today," said Craig Werner. "It's so handy, and the hooks are a great addition!"
Thank you to the 2023 Student Aluminum Extrusion Design Competition Sponsors: