Design and evaluate a cost-effective manufacturing process for a modular moss pole system that supports climbing plants and retains moisture more efficiently than traditional designs. Each unit will be a 1.5-foot plastic cylinder with a longitudinal slit, allowing aerial roots to access an internal moisture-holding substrate.

The project will explore options such as extruded pipe with secondary machining or low-cost molding techniques. Students will determine suitable materials, wall thickness, slit-cutting methods, and stackable joint designs. Considerations for aesthetics, color options, and ease of production will also be included.

This project emphasizes practical design-for-manufacture, material selection, and low-volume production strategy.

• A comparison of potential manufacturing techniques (e.g., extrusion with secondary operations, low-cost molding, hybrid approaches), including pros, cons, and feasibility for small to medium-scale production
• Estimated tooling and setup costs for each manufacturing method investigated
• Recommended plastic type(s) based on cost, durability, moisture retention, and ease of processing
• Recommended wall thickness and structural design parameters
• Test results supporting the selected material and thickness (e.g., strength, flexibility, moisture performance)
• Design features to enable secure stacking and water collection, along with optional enhancements (e.g., color variations, cap designs)
• Cost estimation per unit and per set based on selected manufacturing route
• Recommended North American suppliers for raw materials and manufacturing services
• Final recommendation report summarizing the optimal design and production method for launch