New students learn from failure with cantilever project

Cantilever breaking during testing

In their first week at Imperial, new Mechanical Engineering undergrads competed in designing strong structures using just balsa wood and superglue.

The cantilever project is the first design, make and test task students are assigned as part of their Year 1 Design course. The newcomers, divided into 40 tutor groups of 4, received a kit of basic materials and tools, and dived straight into designing, making and then breaking their own cantilevered structures, out of just 6 pieces of wood and a tube of superglue.

Under the supervision of Graham Gosling (Design and Technical Manager in the department), Teaching Fellows Richard Silversides and Linda Stringer, and Year 3 student Andy McLean, the results were then tested to destruction with a rig that applies a direct load at one end, and simultaneously measures the force exerted. While some of the constructions crumbled almost immediately, the winning project managed to withstand a force of 25.8 Newtons before collapsing.

In past years, students were allowed only one attempt at producing the strongest structure, but as of 2016 they get to try twice. Teams must film the first experiment as it fails during testing, and learn from their mistakes to build something sturdier the second time around.

Students and projects waiting for testing

Watching things break and going wrong is a useful experience for engineers, as Graham Gosling explained: “You learn a lot when you have a failure. That’s why we investigate aircraft accidents, and why they never happen twice in the same way.”

The brief aims to show if new students understand the forces and principles behind building a reliable structure. Winners receive small cash prizes, but the main goal is for everyone to have fun competing with their classmates.  “It’s all about the student making something and enjoying the process”, said Graham Gosling.

Next year, the cantilever project is due for changes: more accurate measurement tools and better value materials will be brought in for an even tougher contest between stronger constructions. Meanwhile, a new challenge awaits Year 1 students on the Design course this term: next month, they will get a shot at building their own hovercrafts.