2024 Aluminum Extrusion Design Competition Winning Entries Displayed at ET
A total of 75 entries were received in the 2024 International Aluminum Extrusion Design Competition from students and professionals from 13 countries across the globe. The entries were evaluated by Brook Massey, President of MI Metals, Inc.; Mark Butterfield, President of Manufacturing for Pennex/Metal Exchange Corporation; and Craig Werner, President of Werner Extrusion Solutions LLC. Many thanks to Almag Aluminum Inc., MI Metals, Inc., and Pennex Aluminum Company LLC for sponsoring the Student Design Competition again this year.
The winning entries for both the Student and Professional Classes of the competition were displayed at the Extrusion Showcase during ET ’24, April 30 through May 2, in Orlando, Florida. Six students received awards, including two Honorable Mentions, and three professionals received awards, including the Grand Prize.
First Place - $5,000 Scholarship
Illumina Highway Guardrail
Alexander Ho
Purdue University
West Lafayette, IN
Alexander Ho, a sophomore studying Industrial Design at Purdue University in West Lafayette, IN, won the First Place Student Award with a $5,000 scholarship for his design of the “Illumina” Highway Guardrail.
The guardrail was designed as a “revolutionary advancement” in highway safety, according to the student, combining LED technology with aluminum guardrails. He chose aluminum extrusions for his design because it “ensures reliability, ease of maintenance, recyclability, and longevity of the guardrail to work in all conditions.”
Illumina features an aluminum extruded rod construction, engineered for durability and longevity. The integration of LED light strips within the guardrails ensures optimal visibility during low-light conditions, adverse weather, and nighttime driving, noted the student in his entry.
By leveraging energy-efficient LED technology, Illumina minimizes energy consumption and carbon emissions, contributing to environmental sustainability, and aluminum is 100 percent recyclable at end of life contributing to its sustainability attributes.
Ho noted in his entry, “The LED lighting system also allows for color switching lighting, which can be color coded to signal unsafe conditions to drive or caution zones. This feeds drivers more information as they are commuting along the freeway and adapt accordingly to the situation.”
The main module consists of two parts, the extruded aluminum railing and the base post, which holds the rail mounts on top of the concrete Jersey Barrier.
Second Place - $4,000 Scholarship
HORTUS
Defne Çinuçev
Yaşar University, Bornova, Turkey
Second Place, with a $4,000 scholarship was awarded to Defne Çinuçev of Yaşar University in Bornova, Turkey, for HORTUS, a vertical gardening modular pot design. It is a hydroponic system with an automatic led lighting and irrigation system that can be programmed with a timer.
The student, a senior studying industrial design, specified 6061 aluminum alloy for its good strength-to-weight ratio and corrosion resistance, which is important for ensuring the stability of the pot. The pots are mounted on aluminum frames arranged in a shelf configuration to allow different levels. For the drip system, a T-shape and perforated pipe will be used, and a channel for the LED lights is incorporated into the extruded profile.
Third Place - $3,000 Scholarship
Retrax Truck Cap
Maxwell Shepard
Purdue University, West Lafayette, IN
Max Shepard, a Sophomore studying Industrial Design at Purdue University in West Lafayette, IN, won Third Place for his design of “Retrax” retractable truck cap. The Retrax truck cap transforms functionality, seamlessly shifting between covered and open configurations. The foldable design uses extruded aluminum ribs and a track that allows the ribs to travel along the truck bed to open and close.
Aluminum was selected as the material of choice for the construction of Retrax due to its exceptional strength-to-weight ratio and its inherent suitability for crafting a modular design. The decision to utilize 6061 Aluminum was based on its notable corrosion resistance.
The modular design allows for the need of only two extrusions. The base rail that extends along the truck bed. The ribs consist of one extrusion cut to three lengths. The ribs feature standard T-Nut sliders allowing for interior storage customizability.
Sustainable Design Challenge Award - $3,500
Strataponix Hydroponic Farming System
Soren Bruehler
Purdue University, West Lafayette, IN
Soren Bruehler, a sophomore studying Industrial Design at Purdue University, noted in his entry materials, “Strataponix takes the process of aluminum extrusion and applies it in a practical and novel way. It takes old methods of hydropinic farming and makes it easier to grow large quantities of food all year round.”
Soren Bruehler, a sophomore studying Industrial Design at Purdue University, noted in his entry materials, “Strataponix takes the process of aluminum extrusion and applies it in a practical and novel way. It takes old methods of hydropinic farming and makes it easier to grow large quantities of food all year round.”
Specifying aluminum alloy 6063 for its extrudability and corrosion resistance, the design employs four extruded aluminum profiles for the planter, which connect to two vertical and one horizontal support beams.
Honorable Mention
Vinteca Modular Temperature-Controlled Wine Rack
Ella Blatnik
Purdue University, West Lafayette, IN
“This design is practical because it is compatible with typical size extrusion presses, ensuring feasibility and scalability in production. It’s cost effective, sustainable, and easily fabricated, making it ideal for mass production. Vinteca leverages the flexibility of aluminum extrusion by using a complex shaped extrusion profile with integrated locking and temperature control that is specific to this product and would be difficult and more costly to make with other manufacturing processes. The product also demonstrates close tolerances in order to maximize functionality,” the student explained in her entry materials.
Ella believes that her design shows huge market impact potential because there is nothing like it on the market today and because of its wide variety of user applications and blend of style and functionality.
Assembled by simply sliding the components into their designed spots, Vinteca’s extruded aluminum design incorporates heatsink fins for a thermoelectric cooler unit. “The fins dissipate heat by increasing the surface area available for airflow, facilitating the transfer of heat from the refrigerant to the surrounding air,” explained Blatnik. “Piezoelectric units provide temperature control through using electric currents across semiconductor junctions to transfer heat from one side to another,” she noted. Daisy chain cabling allows the modules to be interlocked through USB-C jumper cables so the rack only requires one outlet.
“The ability to adjust temperature per bottle within a modular display is a creative feature that caters to wine enthusiasts who value precise temperature control for different types of wine. The modular and stackable nature of the display allows for versatility in usage and scalability based on the size of the wine collection and available space. It can cater to both residential and commercial settings, enhancing its market appeal,” Blatnik reasoned.
Honorable Mention
The Ecoglide Composter
Thomas Gingrich
Portland Community College, Portland, OR
The Ecoglide tumbling composter was designed by Thomas Gingrich, a student studying Computer-Aided Design and Drafting at Portland Community College.
The Ecoglide tumbling composter was designed by Thomas Gingrich, a student studying Computer-Aided Design and Drafting at Portland Community College.
The modular design, made with 9 separate extruded profile sections, bolts together seamlessly to form a 60-gallon drum or cylinder complete with a crank handle to turn the compost and a standard T-Slots® extruded aluminum stand. According to the student, minimal post-machining is needed. The Ecoglide features extruded sliding doors to access the composting chamber, insulated extruded aluminum panels and dual chamber system. Gingrich specified AA6063 for the design due to its excellent extrudability, strength-to-weight ratio and high corrosion resistance. With lightweight aluminum, the composter would be easier to ship, handle, and install while maintaining the necessary strength and durability compared to other materials like steel. The hollow cavities of the extrusion are filled with expanding polystyrene or polyurethane insulating foam. The insulation helps regulate the internal temperatures, which optimizes the composting process by accelerating decomposition.
Gingrich also envisions that with a few design changes, including a watertight liner, the composter can transform into an ice bath.
Thank you to the 2024 Student Aluminum Extrusion Design Competition Sponsors:
