Students learn how roadways are designed and constructed, and discuss the advantages and limitations of the current roadway construction process. They look at current practices of roadway monitoring, discuss the limitations, and consider ways to further road monitoring research. To conclude, student groups compete to design smooth, cost-efficient and sound model road bases using gravel, sand, water and rubber (representing asphalt). This lesson prepares students for the associated activity in which they act as civil engineers hired by USDOT to research through their own model experimentation how to best use piezoelectric materials to detect road damage by showing how piezoelectric transducers can indicate road damage.

The goal of this maker challenge is to demystify sensors, in particular the ambient light sensor, and to map its readings visually. In today’s world, we make sense of the environment around us by filling it with sensors, and we use output devices to display real-time data in a meaningful way. Take any smartphone as an example. Aside from the embedded camera and microphone, a number of other sensors collect a wide range of data. Depending upon the model, these sensors may collect data on proximity, motion, ambient light, moisture, compass, and touch. Some of these data are directly visualized through an app, while many operate internally and without a user interface, just below the surface of the screen. In order to become more familiar with the technology that we use (and often take for granted) on a daily basis, your challenge is to assemble a light sensor circuit, observe its readings using the Arduino Serial Monitor, and then create your own unique visualization by interfacing with the Processing software. Students learn how to use calibration and smoothing to capture a better picture of the data. Afterwards, they share their visualizations with the entire class. The time required for this challenge depends on students’ prior knowledge of Arduino and Processing software. Background resources for beginners help students get up to speed on microcontroller hardware and offer additional challenges for intermediate and advanced users.

Students apply high school-level differential calculus and physics to the design of two-dimensional roller coasters in which the friction force is considered, as explained in the associated lesson. In a challenge the mirrors real-world engineering, the designed roller coaster paths must be made from at least five differentiable functions that are put together such that the resulting piecewise curving path is differentiable at all points. Once designed mathematically, teams build and test small-sized prototype models of the exact designs using foam pipe wrap insulation as the roller coaster track channel with marbles as the ride carts.

Students learn the metric units engineers use to measure mass, distance (or length) and volume. They make estimations using these units and compare their guesses with actual values. To introduce the concepts, the teacher needs access to a meter stick, a one-liter bottle, a glass container that measures milliliters and a gram scale.

Students learn about the statistical analysis of measurements and error propagation, reviewing concepts of precision, accuracy and error types. This is done through calculations related to the concept of density. Students work in teams to each measure the dimensions and mass of five identical cubes, compile the measurements into small data sets, calculate statistics including the mean and standard deviation of these measurements, and use the mean values of the measurements to calculate density of the cubes. Then they use this calculated density to determine the mass of a new object made of the same material. This is done by measuring the appropriate dimensions of the new object, calculating its volume, and then calculating its mass using the density value. Next, the mass of the new object is measured by each student group and the standard deviation of the measurements is calculated. Finally, students determine the accuracy of the calculated mass by comparing it to the measured mass, determining whether the difference in the measurements is more or less than the standard deviation.

After watching a short online video that recaps the enormous scale of accumulating plastic waste in our oceans, student teams are challenged to devise a method to remove the most plastic microbeads from a provided commercial personal care product—such as a facial cleanser or body wash. They brainstorm filtering methods ideas and design their own specific procedures that use teacher-provided supplies (coffee filters, funnels, plastic syringes, vinyl tubing, water, plastic bags) to extract the microplastics as efficiently as possible. The research and development student teams compare the final masses of their extracted microbeads to see which filter solutions worked best. Students suggest possible future improvements to their filter designs. A student worksheet is provided.

Students learn the physical properties of sound, how it travels and how noise impacts human health—including the quality of student learning. They learn different techniques that engineers use in industry to monitor noise level exposure and then put their knowledge to work by using a smart phone noise meter app to measure the noise level at an area of interest, such as busy roadways near the school. They devise an experimental procedure to measure sound levels in their classroom, at the source of loud noise (such as a busy road or construction site), and in between. Teams collect data using smart phones/tablets, microphones and noise apps. They calculate wave properties, including frequency, wavelength and amplitude. A PowerPoint® presentation, three worksheets and a quiz are provided.

Students work in teams to design a tabletop supply organizer inspired by the natural home of an insect species. Their prototype stores the group’s classroom supplies (scissors, crayon boxes, pencils, and glue sticks). In addition to following measurement constraints that apply to their prototype, students must design their supply organizer with the idea that supplies must be easily retrievable and the organizer must be sturdy enough to withstand everyday classroom wear and tear. Students test their prototype in the classroom for a period of 5 days and evaluate its effectiveness.

Student teams are challenged to design and build architecturally inspired cardboard furniture, guided by the steps of the engineering design process. They cultivate their industrial engineering and design skills to design furnishings that meet functional, aesthetic and financial requirements. Given constraints that include limited building materials and tools, groups research architectural styles and period furnishings. The teams brainstorm ideas, make small-scale quick prototypes, then make detailed plans and create full-scale prototypes of their best solutions. The full-size prototypes are evaluated by peer critique for aesthetic alignment to the targeted architectural style and tested for functionality. After final refinements, teams present their concepts and display their final prototype furnishings in an exhibition.

Students learn about the basic principles of electromicrobiology—the study of microorganisms’ electrical properties—and the potential that these microorganisms may have as a next-generation source of sustainable energy. They are introduced to one such promising source: microbial fuel cells (MFCs). Using the metabolisms of microbes to generate electrical current, MFCs can harvest bioelectricity, or energy, from the processes of photosynthesis and cellular respiration. Students learn about the basics of MFCs and how they function as well as the chemical processes of photosynthesis and cellular respiration

Acting as civil engineers hired by the U.S. Department of Transportation to research how to best use piezoelectric materials to detect road damage, student groups are challenged to independently create their own experiment procedures, working with given materials and tools. The general approach is that they set up model roads using rubber mats to simulate asphalt and piezoelectric transducers to simulate the in-ground road sensors. They drop heavy bolts at various locations on the “road,” collecting data and then analyzing the voltage changes across the piezoelectric transducers caused by the vibrations of the bolt hitting the rubber. After making notches in the rubber “road” to simulate cracks and potholes, they collect more data to see if the piezo elements detect the damage. Students write up their research and conclusions as if presenting evidence to USDOT officials about how the voltage changes across the piezo elements can be used to indicate road damage and extrapolated to determine when roads need maintenance service.

This video lesson presents a real world problem that can be solved by using the Pythagorean theorem. The problem faces a juice seller daily. He has equilateral barrels with equal heights and he always tries to empty the juice of two barrels into a third barrel that has a volume equal to the sum of the volumes of the two barrels. This juice seller wants to find a simple way to help him select the right barrel without wasting time, and without any calculations - since he is ignorant of Mathematics. The prerequisite for this lesson includes knowledge of the following: the Pythagorean theorem; calculation of a triangles area knowing the angle between its two sides; cosine rule; calculation of a circle's area; and calculation of the areas and volumes of solids with regular bases.

Students practice human-centered design by imagining, designing and prototyping a product to improve classroom accessibility for the visually impaired. To begin, they wear low-vision simulation goggles (or blindfolds) and walk with canes to navigate through a classroom in order to experience what it feels like to be visually impaired. Student teams follow the steps of the engineering design process to formulate their ideas, draw them by hand and using free, online Tinkercad software, and then 3D-print (or construct with foam core board and hot glue) a 1:20-scale model of the classroom that includes the product idea and selected furniture items. Teams use a morphological chart and an evaluation matrix to quantitatively compare and evaluate possible design solutions, narrowing their ideas into one final solution to pursue. To conclude, teams make posters that summarize their projects.

Many of today's popular sports are based around the use of balls, yet none of the balls are completely alike. In fact, they are all designed with specific characteristics in mind and are quite varied. Students investigate different balls' abilities to bounce and represent the data they collect graphically.

Students conduct an experiment to determine the relationship between the speed of a wooden toy car at the bottom of an incline and the height at which it is released. They observe how the photogate-based speedometer instrument "clocks" the average speed of an object (the train). They gather data and create graphs plotting the measured speed against start height. After the experiment, as an optional extension activity, students design brakes to moderate the speed of the cart at the bottom of the hill to within a specified speed range.

Students build scale models of objects of their choice. In class they measure the original object and pick a scale, deciding either to scale it up or scale it down. Then they create the models at home. Students give two presentations along the way, one after their calculations are done, and another after the models are completed. They learn how engineers use scale models in their designs of structures, products and systems. Two student worksheets as well as rubrics for project and presentation expectations and grading are provided.

Students learn how different characteristics of shapes—side lengths, perimeter and area—change when the shapes are scaled, either enlarged or reduced. Student pairs conduct a “scaling investigation” to measure and calculate shape dimensions (rectangle, quarter circle, triangle; lengths, perimeters, areas) from a bedroom floorplan provided at three scales. They analyze their data to notice the mathematical relationships that hold true during the scaling process. They see how this can be useful in real-world situations like when engineers design wearable or implantable biosensors. This prepares students for the associated activity in which they use this knowledge to help them reduce or enlarge their drawings as part of the process of designing their own wearables products. Pre/post-activity quizzes, a worksheet and wrap-up concepts handout are provided.

Student teams are challenged to evaluate the design of several liquid soaps to answer the question, “Which soap is the best?” Through two simple teacher class demonstrations and the activity investigation, students learn about surface tension and how it is measured, the properties of surfactants (soaps), and how surfactants change the surface properties of liquids. As they evaluate the engineering design of real-world products (different liquid dish washing soap brands), students see the range of design constraints such as cost, reliability, effectiveness and environmental impact. By investigating the critical micelle concentration of various soaps, students determine which requires less volume to be an effective cleaning agent, factors related to both the cost and environmental impact of the surfactant. By investigating the minimum surface tension of the soap, students determine which dissolves dirt and oil most effectively and thus cleans with the least effort. Students evaluate these competing criteria and make their own determination as to which of five liquid soaps make the “best” soap, giving their own evidence and scientific reasoning. They make the connection between gathered data and the real-world experience in using these liquid soaps.

As if they are engineers, students are tasked to design solar-powered model vehicles that are speedy and compact in order to make recommendations to a local car sales company. Teams familiarize themselves with the materials by building solar-panel model car prototypes, following kit instructions, which they test for speed. After making design improvements, they test again. Then they take measurements and calculate the volume of each team’s vehicle. They rank all teams’ vehicles by speed and by size. After data analyses, reflection and team discussion, students write recommendations to the car company about the vehicle they think is best for consumers. Youngsters experience key portions of the engineering design process and learn the importance of testing and collaborating in order to make better products. Pre/post-quizzes and numerous worksheets and handouts are provided.