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Engineering activity

Design the Device: Hardware Prototype

Design the actual DEVICE — the hardware! Where does the speaker go? The buttons? The camera? Cut a phone-shaped piece of cardboard and stick on the parts. NO screen content today — just the case.

Hands OnAbout 25 minutesScreen-freeParent help expected

Materials and setup

How this changes by age

Pre-K (ages 3–4)

Design the actual DEVICE — the hardware! Where does the speaker go? The buttons? The camera? Cut a phone-shaped piece of cardboard and stick on the parts. NO screen content today — just the case.

Difficulty 1 of 3

Steps

  1. Cut a phone-sized rectangle from cardboard or thick paper. This is the OUTSIDE of your device.
  2. Decide where physical things go: speaker (top? bottom?), buttons (sides? front?), camera (back? front?), charging port (bottom?), volume buttons (side?).
  3. Stick on circles of foil for the camera lens, foam dots for buttons, a slot for the charging port. Decorate the case (color, pattern).
  4. Hold it in your hand. Is it comfy? Are buttons in easy spots? Move parts around if not.
  5. Show a parent and explain WHY each part is where it is. NO screen drawings — the screen is OFF in this activity.
  6. Tell a grown-up one thing that surprised you.

Learning objectives

  • Think about the physical placement of hardware components
  • Consider ergonomics: how a device feels in the hand
  • Distinguish hardware (the device) from software (the screen content)

Kindergarten (ages 5–6)

Build a 3D cardboard prototype of an electronic device of your choice (gaming handheld, smart watch, voice speaker). Place the components and label each one.

Difficulty 2 of 3

Steps

  1. Pick a device to design: gaming handheld, smart watch, smart speaker, drone controller, e-reader.
  2. List the components your device needs: speaker, microphone, screen (placeholder only), buttons, charging port, antenna, camera.
  3. Build the case from cardboard, tape, and foil. Make it 3D (box-shaped) if you can.
  4. Place each component on the case with labels. Consider: which side has the buttons? Where does sound come out?
  5. Hold and 'use' the prototype. Adjust component positions until it feels right in your hands.
  6. Tell a grown-up one thing that surprised you.

Learning objectives

  • Design a 3D physical case for an electronic device
  • Place common hardware components: speaker, mic, ports, buttons
  • Test ergonomics by holding and using the prototype

Early elementary (ages 6–8)

Design the hardware layout for a device: size, buttons, ports, and major parts. Build a to-scale cardboard model and test how it feels to hold.

Difficulty 2 of 3

Steps

  1. Pick a device. Write a simple hardware spec: target dimensions, case material, and the main jobs the device needs to do well.
  2. List the major hardware parts: screen, speaker, mic, battery placeholder, buttons, ports, and any sensors you want to include.
  3. Build a to-scale cardboard model. Use the dimensions you specified. Mark every component with its position and a label.
  4. Test: hold it and pretend to use it. Are the buttons reachable? Does it feel balanced? Would you move anything?
  5. Iterate: adjust at least 2 component placements based on the hand test. Document the change and why.
  6. In one sentence, tell a parent or sibling what surprised you today.

Learning objectives

  • Write a hardware specification with measurable targets
  • Lay out all components on a to-scale physical model
  • Iterate hardware placement based on ergonomic testing

Upper elementary (ages 8–10)

Industrial design challenge: design the device with a few real constraints like size, material, and comfort. Explain the tradeoffs you made.

Difficulty 3 of 3

Steps

  1. Research a real device category and find the actual dimensions, weight, and materials of a popular product. Use that as your benchmark.
  2. Set design constraints: a max size, a target material, and one comfort goal such as 'easy to hold with one hand.'
  3. Sketch and build a cardboard model. Lay out the main internal areas: screen, battery placeholder, speaker, buttons, ports, and any vents or sensors you think matter.
  4. Identify tradeoffs: bigger battery means more weight, a thinner device leaves less room for ports, larger speakers take up space. Document at least 3 tradeoffs you faced and which side you chose.
  5. Think about assembly at a simple level: what parts would need to go in first, and what part might be hardest to repair?
  6. Write a 1-page industrial design brief: constraints, layout decisions, tradeoffs, and one repair or usability consideration.
  7. In one sentence, tell a parent or sibling what surprised you today.

Learning objectives

  • Design under real engineering constraints (weight, size, material)
  • Account for layout and simple assembly considerations
  • Document and defend hardware design tradeoffs

Safety and evidence note

Read the full activity before beginning. An adult should supervise tools, heat, food, outdoor work, movement, and experiments as appropriate. Completion records that the activity was done; the child’s explanation, work sample, photo, or demonstration is stronger evidence of learning than a completion check alone.

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