Design Your Own Nano-Polymer Smartphone Case - Maker Challenge - TeachEngineering 6/02/23, 12:03 AM

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MAKER CHALLENGE
Design Your Own Nano-Polymer Smartphone Case !
Quick Look
Grade Level: High school; also scalable for middle school
Time Required: 1 hours 30 minutes (wild guess!)
(over two days)
Subject Areas: Computer Science, Physical Science, Physics, Problem Solving, Science and Technology

A near-finished example of a student’s nano-polymer smartphone case.

Maker Challenge Recap

Students work through the engineering design process to design and create their own nano-polymer smartphone
or tablet case. Students choose their design, mix their nano-polymer (based in silicone) with starch and add
coloring of their choice. While thinking critically about their design, students embed strings in the nano-polymer
to optimize both case strength and flexibility. Students may apply strings in a variety of ways in order to maximize
their individual design’s potential. Determining the best mixing ratio is also key for success in this challenge.

Maker Materials & Supplies

silicone (construction silicone will work)
silicone gun
silicone pigmenting (liquid coloring works well)
corn starch or potato starch
gloves
braided fishing string, or a similar type of robust string
scissors
scalpel
table cover
plastic wrap
aluminum foil
construction paper (for embossing; the thicker, the better)
sandpaper (used for smoothing the cases)
several objects that are the approximate size of a smartphone for students who do not want to model their
cases off their actual phones (optional)

Worksheets and Attachments

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Design Your Own Nano-Polymer Smartphone Case - Maker Challenge - TeachEngineering 6/02/23, 12:03 AM

Polymer Challenge Visual Guidebook (docx)

Polymer Challenge Visual Guidebook (pdf)
Engineering Design Process Notebook (docx)
Engineering Design Process Notebook (pdf)

Visit [www.teachengineering.org/makerchallenges/view/rice-2136-design-nano-polymer-smartphone-case-maker-
challenge] to print or download.

Kickoff
Does anyone know what a compound is? (Listen to students answers). A compound is a pure substance
composed of two or more different atoms chemically bonded to one another. That means that it can not be
separated into its constituents by mechanical or physical means and only can be destroyed by chemical means. A
compound is a homogeneous substance. That is, it is same throughout in properties and composition. Compounds
also have fixed melting and boiling points.

Nano-polymers, also known as silicones, are any type of synthetic compound made up of a chain of silicon atoms
and oxygen atoms and combined with carbon, hydrogen, and other elements. Nano-polymers are widely used in
our daily lives. (Question for the class: ask students to give one example of when they may have used silicone
in the past.) Because silicones are flexible and durable, one way to use them is to create molds for specific
objects. Silicone is also relatively easy to work with as far as adding design elements. Based on what you know
about silicone, today’s challenge will be to design an object that projects one of our most valuable pieces of
technology: our smartphones!

Using silicone, you will mold flexible structures into smartphone case prototypes and embed fishing string either
inside the prototypes or on the surface of the case to increase durability of the model. Think critically about the
placement of the strings and brainstorm about how they affect the structure’s durability.

Some key concepts while constructing your models are:

Tension – the pulling force transmitted by each end of an object

Compression – the application of pushing forces at different points of a material
Torsion – twisting of an object due to an applied torque
Shear – when force is applied to a parallel of a material while the other parallel is held in place
Bending – the behavior of a slender structural element subjected to an external force; also known as
flexure

Resources
Refer to the Engineering Design Process hub on TeachEngineering to guide your students through the
challenge.
As needed, utilize the Engineering Design Process Notebook for engineering process documentation.
How It's Made - Industrial Wire Ropes - https://www.youtube.com/watch?v=eDVf71xd2cQ
Concrete screed rail system - Acra Screed - https://www.youtube.com/watch?v=ar03sj-gfyY
Mold Making & Casting Tutorial - https://www.youtube.com/watch?v=Zs9SBpday84
Examples to use as guidance are located in the NanoPolymer Maker Challenge album. More examples are
located within the Polymer Challenge Visual Guidebook.

Allowing students to sketch out their designs helps with the design process!

Maker Time

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Design Your Own Nano-Polymer Smartphone Case - Maker Challenge - TeachEngineering 6/02/23, 12:03 AM

Use the following steps as well as the Polymer Challenge Visual Guidebook to guide students through the
design process. These steps are intended to help the teacher move the students through building their cases and
provide background or pointers in case the students are stuck.

Step 1: Set a thick, protective cover on the design table; aluminum foil also works well.
Step 2: Have students to design their structure on paper. Have them partner up or discuss the designs in
groups.
Step 3: Tell students to design a symbol or initials by cutting out a piece of construction paper (thicker paper
works better for embossing the mold.) This design will be pressed on to the back of the mold to personalize
their product.
Step 4: Have students wear gloves and determine if they will use their cell phone (or another object) for the
molding. Instruct them to estimate the amount of silicone and starch mixture they will need by calculating
the volume of the object.
Step 5: Wrap the smartphones with one layer of plastic wrap (if the students choose to use their own
electronic devices).
Step 6: Mix the estimated amount of silicone and starch. At this point students can add silicone dye. Add
more starch if the mixture is too watery; add more silicone if the mixture is too viscous.
Step 7: Roll the silicone mixture out into a 1-3 mm thick layer using a cylindrical object like the silicone tube.
Sprinkle starch on the silicone mixture to prevent it from sticking.
Step 8: Place the strings either inside or outside the silicone mixture and then embed them by applying
pressure. Ensure sure the strings do not overlap the front edge of the phone as it is a struggle to cut off
excess after the molds have cured.
Step 9: Place the device in the silicone mixture and bend the edges over the sides and front. Using a ruler or
flat object to help bend the mixture over the edges will ensure an even surface.
Step 10: Place the cardboard logo or initial design on the table and press the phone on top of the design to
embed it.
Step 11: Leave it to cure for a minimum of four hours (and up to 12 hours). Preparing the cover in one day
and allowing it to cure overnight will produce the best rests. Students can then trim and sand the excessive
silicone on the next day.
Step 12: Cut off the excess pieces and any other pieces that hinder the smartphone buttons.
Step 13: Use sandpaper to smooth the surface of the now-cured silicone case, if desired. Remove the device
carefully and remove the plastic wrap then place the device back in the case, and you’re done! Your
personalized smartphone case is ready!
Instruct students to clean up their areas, properly dispose of unnecessary items, and return tools.

Wrap Up
Have students share their final product and their designs. Analyze a few different styles.
Ask them to describe at least three different occasions that they would use this methodology.
Have students research more about nano-polymers and their bonding chemistry; follow-up with a class
discussion.

Tips
Instructors should do the activity on their own beforehand in order to better guide students during the challenge.

Check the freshness of the silicone; do not rely on old stacks in the lab.

For an extended activity, the teacher may want to consider testing the key concepts (torsion, compression,
tension, shear, bending) on a test case. This is a great way to include a qualitative analysis in the maker
challenge.

Copyright
© 2019 by Regents of the University of Colorado; original © 2018 Rice University

Contributors
Fatih Gozuacik

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Design Your Own Nano-Polymer Smartphone Case - Maker Challenge - TeachEngineering 6/02/23, 12:03 AM

Supporting Program
Nanotechnology RET, Department of Earth Science, School Science and Technology, Rice University

Acknowledgements
This material was developed in collaboration with the Rice University Office of STEM Engagement, based upon
work supported by the National Science Foundation under grant no. EEC 1406885—the Nanotechnology
Research Experience for Teachers at the Rice University School Science and Technology in Houston, TX. Any
opinions, findings and conclusions or recommendations expressed in this material are those of the authors and do
not necessarily reflect the views of the National Science Foundation or Rice University.

Last modified: December 17, 2021

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