Grade 5 · Low-Tech Builds · Lesson 30

Cardboard Furniture Challenge

Turn flat sheets into a strong, useful seat for a stuffed-animal client.

Time2–3 × 60 minutesTeamsTeams of 3–4EquipmentNo powered equipment required

Project inspiration · 3 images

See, build, and test

Use these images to understand the kind of making, details, and testing involved. They are inspiration—not designs students must copy.

Finished student example for Cardboard Furniture Challenge
01Finished project
Close construction and materials view for Cardboard Furniture Challenge
02Construction detail
Students testing and recording results for Cardboard Furniture Challenge
03Student testing

Student directions · Grade 5

What will you make and do?

You will make a miniature cardboard chair that holds the teacher’s test weights. It is a model chair—students must not sit or stand on it.

Teacher overview: Students will plan the specific object described below, make and test a first version, then use their results to improve it. Read one step together, demonstrate the unfamiliar action, and let students complete that step before moving on.

  1. 1Plan your project

    Choose a pretend client and sketch two chair shapes. Mark the seat, legs or supports, and the places likely to bend.

  2. 2Make the first parts

    Try folded tubes, ribs or layered cardboard beneath a small seat. Compare how the corrugation direction affects a sample before choosing it.

  3. 3Put it together

    Join the seat and supports on a flat surface. Add a back or visual details only after the model stands without rocking.

  4. 4Test it fairly

    Place the same small weights in the same seat position. Record the supported load, tilt and bending; keep hands clear if it collapses.

  5. 5Improve one part

    Change one support shape or joint and repeat the load test. Keep the chair’s size and loading method unchanged.

  6. 6Show and turn in

    Display the model with its client description, support sketch and before-and-after load results.

How will you know it works?

  • Supports the target load
  • Remains stable from different directions
  • Shape and surface fit the chosen client

Before you move on

Explain which measurement, input or design choice you are testing. Predict the result and record what stays the same so your comparison is fair.

Machine cutting, printer setup and electrical power-on require adult approval. A basic-materials model is a valid way to demonstrate the design when equipment is unavailable.

Keep your plan, test notes and before-and-after evidence with the printable design brief below. Use the detailed teacher plan and any coding guide for tool instructions. These steps continue across the lesson’s meetings, not all in one sitting.

For teachers

Engineering standards

This shows how the lesson connects to the national NGSS engineering standards and what student work you can collect.

Assessed

3-5-ETS1-1

Teams define the user or purpose, success criteria, and limits before building.

What students show: Problem statement with measurable criteria and material constraints.
Practiced

3-5-ETS1-2

Students sketch and compare at least two solutions before choosing or combining features.

What students show: Two labeled ideas and an evidence-based design choice.
Assessed

3-5-ETS1-3

Teams use a repeatable low-tech test—place the same client and added masses in the same position for 30 seconds—then revise one feature.

What students show: Test notes, before-and-after design, and explanation of improvement.

Materials

  • Corrugated cardboard sheets and offcuts
  • Paper tubes and index cards
  • One standard stuffed animal and test masses
  • Rulers, pencils, markers, and planning paper
  • Masking tape, glue dots, paper fasteners, clips, and rubber bands
  • Scissors and other teacher-approved hand tools
  • Reused and student-proposed materials approved before use

Teacher preparation

  1. Set out a broad materials buffet instead of identical kits.
  2. Build one small test rig, not a finished example students may copy.
  3. Mark size, time, and material limits visibly.
  4. Prepare a team planning page and shared test-data table.
  5. Create a safe holding area for drying or unfinished builds.

Step by step

How to teach it

Day 1 · 0–20

Explore the challenge

  1. Introduce the mission: Build a cardboard chair that supports the same stuffed-animal client for 30 seconds without collapsing.
  2. Identify the user or audience and what success should look like.
  3. Explore how sample materials bend, fold, join, compress, slide, or balance.
Day 1 · 20–60

Imagine and prototype

  1. Each student sketches a different possibility.
  2. Teams compare ideas against criteria and constraints.
  3. Build a quick model using only part of the material budget.
Day 2 · 0–35

Build and test

  1. Complete the first working version.
  2. Use the same procedure each time: place the same client and added masses in the same position for 30 seconds.
  3. Record what worked, what failed, and where it happened.
Day 2 · 35–60

Improve with evidence

  1. Change one important feature rather than rebuilding randomly.
  2. Repeat the same test and compare results.
  3. Add color, surface, form, or story details that strengthen the purpose.
Optional Day 3

Gallery and challenge round

  1. Display designs with a one-sentence mission and test result.
  2. Let visitors try the project using the same rules.
  3. Teams explain one tradeoff and one idea they would try next.

Assessment

  • Problem statement includes a purpose, criteria, and constraints.
  • Sketches show meaningfully different ideas.
  • Material choices are explained using properties.
  • Test is repeatable and produces recorded evidence.
  • Revision responds to a specific result or failure point.

Supports & extensions

  • Offer picture directions and sample joining techniques.
  • Provide pre-cut pieces, adaptive scissors, or larger materials.
  • Allow students to explain through drawing, speaking, or demonstration.
  • Assign flexible roles: designer, builder, tester, recorder, and artist.
  • Extension: reduce material use while maintaining performance.

Safety & responsible use

  • Use only clean, teacher-approved reused materials.
  • Carry scissors and tools safely; cut away from hands and bodies.
  • Cover sharp cardboard corners, wire ends, skewers, or fasteners.
  • Use a defined test zone and keep faces away from moving or falling parts.
  • Teacher handles hot glue, craft knives, and any tool not approved for students.

No-machine alternative

The entire project is already designed for common classroom materials. Substitute paper folds, tabs, slots, string, tape, or found objects while keeping the same criteria and fair-test cycle.

Printable student design brief

The challenge

Build a cardboard chair that supports the same stuffed-animal client for 30 seconds without collapsing.

Success criteria

  • Supports the target load
  • Remains stable from different directions
  • Shape and surface fit the chosen client

Constraints

  • Cardboard is the main structural material
  • No hot glue in student construction
  • Fits inside the assigned volume

Engineer’s notes

Our design should…
We chose this material because…
Our first test showed…
The failure point was…
We changed… because…
Next time we would…
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