This unit provides the framework for conducting an “engineering design field day” that combines 6 hands-on engineering activities into a culminating school (or multi-school) competition. The activities are a mix of design and problem-solving projects inspired by real-world engineering challenges: kite making, sail cars, tall towers, strong towers and a ball and tools obstacle course. The assortment of events engage children who have varied interests and cover a range of disciplines such as aerospace, mechanical and civil engineering. An optional math test—for each of grades 1-6—is provided as an alternative activity to incorporate into the field day event. Of course, the 6 activities in this unit also are suitable to conduct as standalone activities that are unaffiliated with a big event.

Students learn about life-cycle assessment and how engineers use this technique to determine the environmental impact of everyday products and processes. As they examine what’s involved in making and consuming cupcakes, a snack enjoyed by millions of people every year, students learn about the production, use and disposal phases of an object’s life cycle. With the class organized into six teams, students calculate data for each phase of a cupcake’s life cycle—wet ingredients, dry ingredients, baking materials, oven baking, frosting, liner disposal—and calculate energy usage and greenhouse gases emitted from making one cupcake. They use ratios and fractions, and compare options for some of the life-cycle stages, such as different paper wrapper endings (disposal to landfills or composting) in order to make a life-cycle plan with a lower environmental impact. This activity opens students’ eyes to see the energy use in the cradle-to-grave lives of everyday products. Pre/post-quizzes, worksheets, activity cards, Excel® workbook and visual aids are provided.

Working individually or in pairs, students compete to design, create, test and redesign free-standing, weight-bearing towers using Kapla(TM) wooden blocks. The challenge is to build the tallest tower while meeting the design criteria and minimizing the amount of material used all within a time limit. Students experiment with different geometric shapes used in structural designs and determine how design choices affect the height and strength of structures, becoming comfortable with the concepts of structural members and modeling.

What makes rockets fly straight? What makes rockets fly far? Why use water to make the rocket fly? Students are challenged to design and build rockets from two-liter plastic soda bottles that travel as far and straight as possible or stay aloft as long as possible. Guided by the steps of the engineering design process, students first watch a video that shows rocket launch failures and then participate in three teacher-led mini-activities with demos to explore key rocket design concepts: center of drag, center of mass, and momentum and impulse. Then the class tests four combinations of propellants (air, water) and center of mass (weight added fore or aft) to see how these variables affect rocket distance and hang time. From what they learn, student pairs create their own rockets from plastic bottles with cardboard fins and their choices of propellant and center of mass placement, which they test and refine before a culminating engineering field day competition. Teams design for maximum distance or hang time; adding a parachute is optional. Students learn that engineering failures during design and testing are just steps along the way to success.