3D Printed Repair to Connect Four

 

Challenge: To repair a game part to ensure that the game can be played successfully.

Background: This classroom game was unable to be used as the sliding bar at the base of the game was no longer functioning.   It was the students themselves who came up with the solution to this which was to print a replacement version for the piece allowing the game to be played.

This task was completed by students who are eight years old working independently who have used Tinkercad and the Tinkercad App (which is essentially the same program) since the start of this year as they are part of the cohort one group of students in the classroom.   The task was split into two parts.   The first part involved the printing of a basic bar.   This bar was 250mm long 20mm high and 5mm wide.  This bar when placed in the location that it was required (as shown in the photograph above) could not remain in its location independently, as it fitted relatively well but the students had to use tape to stick it into place.  They also decided that rather than replacing the tape every game it was easier when the game was completed to tip the game upside down so that the counters slid outside.

The original design used 44g of PLA to complete the print at a cost of $1.10.   The print took two hours to complete on the regular default settings.

Once a project is completed we tend to assess it with the students and think about how it might be improved or what potential there is for improving or challenging their engineering skills (for instance the recent repairs to the 'barn' toy are a good example where the focus shifts from a basic shape (the door frame) to a more complex engineering challenge (which in this case was the hinge allowing the door to swing open and then close again)

To further complicate this matter in regards to this hinge or swing point the entire design needs to be able to fit inside the legs of the device when it it is closed.  This proved to be a more complex challenge than anticipated.

Level of Difficulty: Original design (low) secondary and improved design medium.   Hinge and swing points are a concept our students are still getting to grips with and involving some trial and error for the students.

Size: The secondary print involved more PLA as the students attempted to create a hinge.   The variation in size was not significant in length, remaining at 250mm but the ends created were 60mm high.   There was a degree of rafting running the length of the design, although we are more comfortable with this now as we are collected it for recycling.

Cost/Price: As noted the original cost $1.10 to produce the revised version shown left was 47g of PLA and had a price cost of $1.46.   The difference between the two prices was reflected in the increase due to the additional features of the design.

Timeframe - the original took two hours, the revised version, including the side supports was two hours and forty minutes.

What we would do differently/Next step for the students: The revised version works but the locking mechanism of the stand onto the frame restricts the access points for the students design.  They cannot both work in conjunction with each other so while students have completed the brief they will need to revise the design again to take this into account.   It also has significantly challenged their engineering principal skills, which is a very positive thing.

Bird Blockers: Engineering 2026 Solutions

 

Challenge: To using iPads, Tinkercad App and 3D Printer to engineer a solution to a 'bird blocking' problem.

Background: As can be seen in the photograph shown left the birds nesting in seating areas of our school is again producing an issue, as the nesting birds are 'fouling' one of the seating areas where our students eat their lunches.   Our main school block is significantly older than a lot of schools and as a result on the decking outside our school there are various locations where the house sparrows in the area have forced their way into the spaces creating by the building and the decking.

Last year we completed an extensive project on this, which is detailed in-depth on this post from November 2025.

Since that point the sparrows have not nested again in the areas that we secured last year, however they have now created additional nesting spaces.   While we don't particularly look to repeat the same process as last year in this instance the process, the results and the outcomes were the same, however it was a different cohort of students involved.

For this instance the students iPads and the measure app was vitally important.  The location where the 3D Print would ultimate need to be fixed into place was several metres above the ground.   It would not have been safe or possible for the students to measure accurately the space and distance involved in this task.  Using the app allowed the students to accurately measure the distances that they were dealing with.

By using the Tinkercad App the students were able to project their potential designs into the location where the nest entrance was - again the practicality was that this wouldn't have been possible without the app allowing the students to 'project' their ideas to ensure that the entrance would be covered.

As a brief update from last year the November set of printings have lasted the distance without any signs of damage or wear.   The school has been repainted since they were put in place meaning that the prints that were put in place are now indistinguishable from the actual decking itself.

The wedges shown left are a result of last years projects, and we have maintained a group of them depending on what needs to addressed at different locations throughout the school (although it has not been an issue we have potentially thought this could solve any rodent issues if they arose or access points that needed to be sealed for other reasons).

Level of Difficulty: Low - this was completed by a pair of Y4 students who are eight year olds easily within a few minutes, the geometric shapes involved are very simple and the design aspect of it was taken care of by the measure app.  The students simply met with the Principal of the school to address the problem, then spent a short time organising the solution which was then printed.

Size:  The prints to solve this issue were 140mm across were between 40mm and 60mm wide and 20mm thick.  There was a slight 'L' shaped developed so the print could be fixed hard against a join where the nest is located.

Cost/Price: To complete this print the it took 40g of regular PLA filament.  This has a price guide as suggested by Bambu Lab Studios of $0.99 to produce.

Timeframe: Forty minutes to complete the print on the regular settings.  The house sparrow while being an invasive nesting bird is relatively small, hence its ability to get into small gaps and in this instance this suits with the printing because a relatively small hole needs to be covered.   

What we would do differently/Next Steps for the students: Nil - this task is successfully.   We hav shown over time that PLA printing has proven to be effective and works long term.   We have ample evidence that long term exposure to the elements does not weaken the PLA such as this post from last year which is an eight year update on a set of numbers used by our school for evacuation.