Document Type

Journal Article

Publication Date

2025

Keywords

Additive manufacturing, 3D printing, Eggshell PLA polymer, Design innovation

Abstract

I present an innovative project-based learning (PBL) module implemented with third-year product design students, focusing on sustainable product development and commercialization. Sponsored by Ka Shui Ltd., the module challenged students to design products primarily using eco-sand 3D printing technology, incorporating functionality, sustainability, and a distinctive aesthetic to appeal to modern consumer preferences. The initiative offered students practical experience in sustainable design, technical material applications, and market commercialization, supported by prizes and free 3D printing for their prototypes. Eco-sand 3D printing, a cutting-edge technology that uses 95% natural sand as its primary material, was central to the project. This sustainable process creates products with a unique black, rough, sandy texture and requires minimal post-processing. Students explored the technical capabilities of eco-sand printing while building on prior knowledge of other sustainable materials, such as eggshell-PLA composites. The project brief tasked students with designing innovative products that leveraged eco-sand’s properties while addressing market demands. Outcomes included a diverse range of prototypes, such as lighting fixtures, vases, wine racks, candle holders, self-watering plant pots, and automated plantariums combining misting and watering functions. The educational framework incorporated master lectures on eco-sand material properties, processing requirements, and design considerations. Students conducted market analyses to develop compelling value propositions for their designs, gaining insights into consumer behaviour and sustainability-driven product development. Despite the challenging and seemingly narrow scope of the brief, tailored support and guidance enabled students to craft innovative concepts that exemplified the potential of sustainable manufacturing processes. A class competition culminated in professional evaluations of the students’ designs, with top-scoring projects receiving prizes and the opportunity to be commercialized through Ka Shui Ltd.’s online store. This provided students with invaluable real-world experience, allowing them to test their value propositions in the marketplace and receive actionable feedback on both their designs and marketing strategies. This module demonstrates the effectiveness of project-based learning in product design education, offering students a holistic experience that integrates technical skill development, sustainable innovation, market analysis, and commercialization. It provides a compelling model for equipping future designers with the tools to address real-world challenges while fostering creativity, technical expertise, and entrepreneurial thinking.

Source Publication

6th International Symposium on Education, Economics, Psychology and Social Sciences. July 23 - 25, 2025

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