Brain Teaser Puzzle
OBJECTIVES
 Discover properties of different materials & ways in which
materials can be manipulated.
 Practice using precise measuring techniques.
 Learn and demonstrate safe and proper use of tools and
equipment.
A special thanks to Daniel Western of SUNY Oswego,
Oswego, NY, for sharing his Brain Teaser Puzzle on the
IdeaGarden. We have put our own twist to his original ideas.
Design Brief
Brain Teaser Puzzle
Situation/Challenge
Brain Teaser Puzzles have been used for centuries by people across the world for
entertainment. You may have seen them in restaurants as a way to keep people
occupied as they wait for your order to be delivered. They come in a lot of different
sizes and styles, but they all have one thing in common...THEY MAKE YOU THINK!
Your challenge is to read the design briefs of the different parts, study the working
drawings, make each part within 1/32" tolerance and assemble the BTP in the correct
manner.
Criteria & Constraints
- Final assembly will look like the Brain Teaser Puzzle picture.
Tools & Materials
- Listed in each part design brief.
Procedure
1.
2.
Open your Engineering Notebook and make a new entry for today.
Restate your challenge in your own words.
You do not have a specific order in which you need to complete the
different pieces of the Brain Teaser Puzzle. It is your choice which piece
to work on. ALL pieces must be completed before you begin the
assembly.
Design Brief
Brain Teaser Puzzle - Square Part
Situation/Challenge
Plastic is used in A LOT of items, from your backpacks to milk cartons. Your challenge
is to measure, cut, and drill your square parts for your Puzzle.
Criteria & Constraints
- All layouts must be done at your workstation within a 1/32” tolerance.
- You MUST follow the procedure exactly as written.
Tools, Materials & Equipment
- Safety Glasses
- Working Drawing
- Ruler
- Square
- Miter Box and saw
- Drill press with 1/4” bit
- Plastic acrylic material
Procedure
SAFETY:
SAFETY:
SAFETY:
SAFETY:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
safety glasses must be worn during this procedure
you must hold down square part in miter box with hands - keep
fingers away from saw
on drill make sure bit is tight in chuck before drilling
secure square part in safety jig or drill press vice before drilling
Study the working drawing below.
On the plastic material, layout the measurements on the paper covering
the plastic.
Turn your call light on and have a teacher check your layout markings.
Locate the miter box & back saw - take back to your workstation.
Cut out both square parts using the miter box and saw.
Return miter box and back saw.
Secure piece in the drill press safety jig designated for the square part.
Drill the holes in both square parts. Drill slowly so you don't break or crack
the plastic.
File and sand edges flat and smooth and round the corners on your
square parts.
Remove the paper from both sides of the plastic.
Square Part
3/4”
1 ½”
1/8”
3/4
1 ½”
3/4
1/4" Diameter
Note:
 Need 2 typical square parts
 This piece is made from
colored acrylic plastic
Design Brief
Brain Teaser Puzzle - Body Part
Situation/Challenge
Masonite is a hardboard material that was developed in 1924 by a man named William
H. Mason. Masonite is a composite material that is made by breaking down wood into
its two basic parts: wood fibers and lignin. Lignin is the natural binding agent that is
found in trees to hold the wood fibers together. The wood fibers are then rearranged
and bound together with lignin under high pressure. The surface is sometimes treated
with a chemical to make the exterior surface hard. The end result is a strong flexible
material that is sometime cut into flat sheets or molded into shapes and textures.
Masonite is often used in cabinetry, interior doors, ping pong table tops, and skateboard
ramps. Its durability, strength and low cost make it a popular choice for many
applications in the construction industry. Your challenge is to measure, cut, and drill the
body part for your BTP using the masonite.
Criteria & Constraints
- All layouts must done at your workstation within a 1/32” tolerance.
- You MUST follow the procedure exactly as written.
Tools, Materials, & Equipment
- Safety Glasses
- Working Drawing
- Scroll Saw
- Drill Press (the one specific for the Body Part) with 1" forstner bit
- Flat file
- Sandpaper
- Masonite material
Procedure
SAFETY:
SAFETY:
SAFETY:
SAFETY:
1.
2.
3.
4.
5.
6.
safety glasses must be worn during this procedure
on drill make sure bit is tight in check before drilling
secure masonite in the drill press safety jig securely - keep fingers
away from bit
secure scroll saw foot to firmly hold down masonite - keep fingers
to the side of the blade
Study the working drawing below.
Layout measurements on the smooth side of the masonite.
Turn your call light on and have a teacher check your layout markings.
You can choose to cut or drill your piece first. Use the scroll saw to cut
the piece. Secure piece in the drill press safety jig - drill piece.
Math terms like chamfer are often used when developing products. What
does the term chamfer mean? Write your answer in your Engineering
Notebook.
File and sand a chamfer on pieces. Be sure to remove loose wood pieces
and sharp edges.
Body Part
1”
1”
1 1/2"
3/16”
1”
diameter
15o
4”
2 3/4"
1 1/2"
3”
Note:
 This is made from masonite
 All edges to be chamfered
using sandpaper
Design Brief
Brain Teaser Puzzle - Dowel Part
Situation/Challenge
A dowel can be used for many purposes. It can be hidden from you to hold a product
together. It can be used for a support or have a function. It can also be used as a
decoration. Your challenge is to measure, cut, and drill dowel pieces for your Puzzle.
Criteria & Constraints
- All layouts must done at your workstation within a 1/32” tolerance.
- You MUST follow the procedure exactly as written.
Tools, Materials & Equipment
- Safety Glasses
- Working Drawing
- Tape measure
- Vise
- Back saw
- Cordless drill with 1/4” twist bit
- 3/4" diameter dowel
Procedure
SAFETY:
SAFETY:
SAFETY:
1.
2.
3.
4.
5.
6.
7.
8.
glasses must be worn during this procedure
on drill make sure bit is tight in check before drilling
secure dowel in vise but not to tight or you will damage the wood
Study the working drawing below.
From the longer dowel, you will measure and cut off the total length
needed for each person.
Layout measurements on dowel.
Turn your call light on and have a teacher check your layout markings.
Secure piece in the vise - Drill pieces.
Cut pieces using the hand saw.
Math terms like chamfer are often used when developing products. What
does the term chamfer mean? Write your answer in your Engineering
Notebook.
File and sand a chamfer on pieces. Be sure to remove loose wood
pieces, sharp edges, cutting marks, and layout marks.
Dowel Part
1 1/2"
3/4" diameter
dowel
¾”
1/4” Diameter
Note:
 Need 2 typical dowel parts
 This piece is made from a birch wood dowel
 All edges to be chamfered using sandpaper
Design Brief
Brain Teaser Puzzle - Metal Part
Situation/Challenge
Metal has several properties. The appearance of metal can be achieved through
forming and shaping. Forming can be achieved by heating, extruding or molding.
Shaping can be achieved by pounding, bending or stretching. A jig is often used to help
hold something in place. Your challenge is to shape and solder a metal rod for the
Brain Teaser Puzzle.
Criteria & Constraints
- This entire process is to be done at your workstation.
- Locate what you need and bring it to your workstation and return it as soon as
you are done using.
- Metal rod must overlap and touch.
- Solder must hold metal overlap in place.
Tools, Materials & Equipment
- Safety Glasses
- Working Drawing
- Bending Jig
- Standard Pliers and Wire Cutters
- Board to solder on with Needle Nose Pliers
- Soldering Gun
- Solder
- Wire
Procedure
(See next page)
Procedure
SAFETY:
SAFETY:
SAFETY:
SAFETY:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
safety glasses must be worn at all times
wire ends are sharp, be careful - when cutting rod always point
the piece you are cutting off toward the floor
avoid breathing fumes
soldering uses a very high heat - it can burn - keep soldering iron
tip away from body and other objects - always keep iron and
pieces on board
Study working drawing.
Locate bending jig and take it back to your workstation.
Keeping the jig flat on the workstation, begin the bend on a straight
edge. Bend the wire around the jig – if needed, use the standard pliers
to help you.
Trim the wire with the wire cutters, so it overlaps the distance on your
working drawing.
Keep working the metal until the ends touch side by side (see drawing
above).
Turn your call light on and have a teacher check your shape.
Return the bending jig and tools - get the soldering board and take it
back to your workstation.
Use needle nose pliers to help hold metal as you solder (ask partner to
help).
Solder the overlapping pieces – heat metal with iron, place solder by tip
and on metal, and melt solder so it runs smooth – let cool before
touching.
Learn more about how metal is formed by heating, extruding , molding and
shaped by pounding, bending or stretching by looking on the web.
Record all websites you visited in your Engineering Notebook – sketch
and take notes on forming and shaping methods.
Metal Part
1 ½”
½”
2 5/8”
½”
1 ½”
6 5/8”
2 5/8"
3/4"
About 1/4" to 1/2" overlap
Note:
 This piece is made from a 3/32”
mild-steel copper-coated welding
rod
 The ends are soldered together
1/8” Braided Nylon Cord
11”
Design Brief
Brain Teaser Puzzle - Assembly
Situation/Challenge
Products can be assembled in many different ways. They can be assembled using
fasteners, such as screws, bolts, or nails. Many materials are assembled and held
together using an adhesive, such as glue. Your challenge is to assemble your Brain
Teaser Puzzle to look like the picture below by following the procedure.
Criteria & Constraints
- Final assembly will look like the Brain Teaser Puzzle picture.
Tools & Materials
- Body Part (completed)
- Square Parts (completed)
- Dowel Parts (completed)
- Metal Part (completed)
- 1/8 x 11” braded nylon cord
- 2 Beads
Procedure
1.
2.
3.
4.
5.
All the parts of your Brain Teaser Puzzle must be completed. To check for
completion, go back to each design brief for the separate parts and do a
mental checklist of each procedure.
Go to the Internet and find more ways that products can be assembled. In
your Engineering Notebook, record the different methods that you found
and make a brief description of each of the methods.
In your Engineering Notebook, make an entry describing the most difficult
part of the Brain Teaser Puzzle for you.
Assemble your Brain Teaser Puzzle to look like the picture below.
You should tie knots in the end of the cording to hold it all together.
The object of the Brain Teaser Puzzle is to remove the wire ring. Try to
solve the puzzle.
Presented at the
Teaching Technology Showcase
2007 ITEA Conference
San Antonio, TX
David Shabram
Westside Middle School
8601 Arbor Street, Omaha, NE 68124
Office: (402) 390-6464
Room: (402) 408-8689
Fax: (402) 390-6454
dshabram@westside66.org
Ann Sumner, DTE
Westside Middle School
8601 Arbor Street, Omaha, NE 68124
Office: (402) 390-6464
Room: (402) 408-8689
Fax: (402) 390-6454
asumner@westside66.org
Visit our Webpage
http://www2.westside66.org/~dshabram
Original Project Idea Submitted by
Daniel Western
Manufacturing Technology Course
State University of New York, Oswego