Upcycled STEAM Maker Kit: Turning Waste Into Hands-On Learning for Kids

The problem

An educational product company wanted to create eco-friendly STEAM kits for children but faced three major challenges:

• Converting sawdust waste into a safe, usable material. 
• Designing hands-on projects that were fun, educational, and child-safe. 
• Ensuring all components were precise, consistent, and easy to assemble.

They needed a low-waste, scalable way to produce physical kits from recycled material, without compromising safety, usability, or learning value.

Our goal

Design and prototype a durable, engaging DIY kit using upcycled sawdust boards, with laser-cut components suitable for young learners.

The design approach

We approached this project with the utmost understanding of the impact it will have in the real-world, and thus, the need to design and develop with sustainability first.

Key design principles:

• Repurpose sawdust into sturdy sheet material.
• Design STEAM kits that encourage creativity and problem-solving.
• Ensure parts are safe, child-friendly, and easy to handle.
• Use digital fabrication for accuracy and repeatability.

What we built

Our prototype included:

• • • Recycled boards made from compressed sawdust.
    • Multiple child-friendly STEAM projects designed in-house.
    • Laser-cut components for precision and easy assembly.
    • Instructions tailored for kids and educators.
    • Built and tested over a 3-month period, from raw material R&D to kit production.

Tools and techniques used:

• • • Fusion 360 for CAD design.
    • Laser cutting and 3D printing for prototyping.
    • Material testing to ensure durability and safety.
    • Small-scale production for pilot classroom testing.

Outcome

The project proved that waste material can fuel hands-on learning.
The kits were well-received in early tests.