Project Status: 🤝 Group Challenge | Focus: Structural Engineering & Impact Physics
This week marked our first Group Challenge. The objective was deceptively simple: design a 3D-printed enclosure capable of protecting a raw egg dropped from a height of 3 meters.
Constraint: The egg must not crack.
Strategy: Maximize impact absorption, minimize air resistance, and secure the payload.
We started with two competing theories on how to survive the fall.
Concept A: The "Exoskeleton" (Partner's Design)
Structure: A pyramid-style frame structure.
The Innovation: The logic was to create a custom "seat" that matches the egg's geometry, ensuring it settles securely rather than rattling around.
See Figure 1 (upper).
Concept B: The "Capsule" (My Design)
Structure: A smooth, cylindrical body with a domed top.
The Innovation: A focus on external aerodynamics and avoiding sharp corners to deflect impact energy.
See Figure 2 (lower).
Figure 1
Figure 2
We couldn't decide on vibes alone, so we turned to physics. We compared the two shapes to see which would actually survive the drop.
The Verdict:
We decided to proceed with the Cylindrical Capsule for its structural integrity but integrated the "secure seating" philosophy from my design using internal foam padding.
Physics Rule of Thumb:
To save the egg, we need to increase the Time of Impact (Delta t).
According to the Impulse-Momentum theorem (F*Delta t = m*Delta v), extending the time of the collision (using foam/padding) reduces the Peak Force transferred to the egg.
Once we chose the shape, we hit a roadblock: How big is an egg?
I didn't exactly have the blueprints for a chicken egg.
My thought process: "Am I supposed to open the fridge, grab a raw egg, and interview it with a ruler?" 🥚📏
The Reality: Yes, basically. (But I used ChatGPT to be safe).
The Data Sheet: After some "highly technical" research, we established the tolerances:
Length: ~5.5 cm to 6.0 cm
Diameter: ~4.0 cm to 4.5 cm
We designed the enclosure using the mean average of these ranges to ensure a snug fit for any standard egg.
Download the Survival Capsule: Want to test gravity yourself? The STL files for the final enclosure are available below.
