Kyle Teschendorf created two engineering projects: a tabletop hockey set and an egg cracker. For the hockey set, he iteratively designed and 3D printed goalie figurines with increasingly complex and realistic motion over four versions using CAD software. His egg cracker prototype included a spinning colander mechanism activated by a lever that efficiently cracks eggs for small bakeries. He conducted design testing to optimize variables like colander weight and spindle angle. Both projects demonstrate his skills in CAD modeling, prototyping, and designing for user experience and manufacturability.

1. Project Portfolio
KYLE TESCHENDORF

2. Index
 Tabletop Hockey Set 2 - 9
 EggStream Egg Cracker 10 – 18
1

3. Tabletop Hockey Set
(October 2014-Present)
2

4. Purpose/Need
 To become acclimated with PTC Creo and rapid
prototyping beyond the classroom experience
 To effectively combine two personal interests (engineering
and hockey)
 To create, with the user in mind, an entertaining game that
requires skill and strategy
 Game Description: One or two players with toy hockey sticks
attempt to score a small puck past a human-controlled
goalie figurine
3

5. Iterations
Goalie
Each version is more aesthetically pleasing and
functional than the last. Common improvements
included easier assembly (slide 7), tolerance/fit
adjustments, and new concepts (moving limbs).
Early designs only included leg control. This was
eventually expanded to all four limbs.
Net
V.2 of net uses detachable clips to secure
netting instead of glue; more user friendly
4
Stick
More realistic design provides better shot control
and less clumsiness relative to early renditions
Concept V.1 V.2 V.4
*V.3 not
included
V.1
V.2
Concept V.1 V.2 V.3

6. CAD Timeline
5
V.1: Concept came alive
V.2: Simplified and improved V.1 assembly
V.3: Added glove control with second trigger
V.4: Added blocker arm control and
reverted to single trigger for simplicity

7. Overview of Goalie Control
 Goalie control is based around a single, tension-activated trigger.
 A rubber band keeps limbs in “ready” position, fishing line is attached to the trigger.
 Each stance leaves different holes open for shooters; strategic choice for goalie
Trigger not pulled: legs
are split, arms remain up
Trigger pulled: legs
together, arms dropped
6
One rubber band runs between
four limbs to keep them in place.
When the trigger is pulled, the
fishing line repositions the limbs.

8. Assembly Improvements
• Overall goal is to move away from glue in
favor of snap fits and other faster and easier
assembly methods
Press fit plugs replaced with easier (and
removable) snap fit plugs
Goalie assembly became progressively simpler, even after the implementation of rubber bands.
Early designs required multiple strands of fishing line, multiple rubber bands, and multiple knots.
V.4 requires one of each due to the use of “hooks” on each limb. 7

9. Assembly Highlights
8
Net snap-fits into back board for security
Slot fit for boards
Post clips keep net firmly attached
but removable
Threaded handle: Provides for easy
grip and simple assembly

10. Creative & Detail-Oriented Decisions
Goalie mask makes the goalie look more
authentic
Comb-toothed net attachment was created
for more realistic play. With this attachment,
when the goalie falls down to block a shot, its
side-to-side movement is inhibited.
Plastic pucks were deemed too light and
bouncy. A puck mold was created to make
clay pucks, which are much easier to track
Saran wrap “glass” is sturdy, light, and keeps
the puck in play
9

11. EggStream Egg Cracker
August 2015 – December 2015
Groupmates: Jen Alinger, Eric Horning, Jerome Sacherer, James Schackmuth
10

12. Purpose/Need
 Project was assigned for ME 270 (Design for Manufacturability). The
assignment was to conceptualize, design, and build an original
product.
 After brainstorming, my group decided to create a small, automatic
egg cracker.
 Single egg crackers and large industrial egg crackers are on the
market, but there is no current solution for small bakeries (10-12 eggs
at a time)
11

13. Initial Drafting
 We balanced two possible designs: a centrifugal egg cracker and a
spring-loaded “egg stapler”
Drawing credit: Jerome Sacherer 12

14. Initial Design CAD
• Eggs are dropped into the colander where they are
broken by the impact. The liquids are spun out.
• Cons: Too bulky, too much to wash, not original enough
13
• Spinning mechanism: four-legged engager digs into grooves in the lid as spiral is
pushed down, but disengages when pressing is relieved. Linear -> Rotational motion

15. First Prototype
• Colander is suspended from spinning
“lid”
• Can be placed in bowl or over frying
pan
• Only colander needs to be cleaned
Cons:
• Too much friction to spin quickly
• Colander “wobbles” due to off-
axis torque
• Difficult to detach colander
from lid
• Impossible to drop eggs in while
assembled 14

16. Final Prototype
• Ball bearing greatly reduces friction
• Detachable “deflectors” on colander
redirect egg downward for frying pans
• Holes in lids allow for eggs to be dropped
directly into colander
15

17. Notable Improvements for Final
Prototype
Snap cover: Snap fits to the
top of the assembly, covering
the ball bearing and spinning
mechanism
Spinning lid was originally planned
to snap fit onto colander. Instead,
three pegs were added on the rim
of the colander to slide into the
grooves shown. Easy attachment
and removal
Fins added to the bottom of
the colander; crack the
eggs when they strike.
16

18. Cost Analysis
Part Name Material: Process Total Fully Burdened Cost Manufacturing Country
Engager Aluminum - 6061: Sheet Metal $0.25 CHINA
Deflector Polyethylene: Injection Molding $1.24 CHINA
Snap Ring Polyethylene: Injection Molding $0.81 CHINA
Shaft Polyethylene: Injection Molding $1.20 CHINA
Lid Polyethylene: Injection Molding $1.34 CHINA
Plastic Bearing NA $12.08 USA
Colander Polyethylene: Injection Molding $4.32 CHINA
Outer Lid Polyethylene: Injection Molding $3.06 CHINA
Button Polyethylene: Injection Molding $1.41 CHINA
Spiral Aluminum - 6061: Bar & Tube Fab $1.64 CHINA
Self-Threading
Screws
NA $0.26 USA
Total Cost: $27.61
Cost analysis performed using
APriori
• Polyethylene Terephthalate -
dishwasher safe
• Aluminum 6061 - mechanically
sound
17

19. Design of Experiments
Variables:
• Weight of colander (x1): light vs. heavy
• Degrees of twist on spindle (x2): 720 vs. 900
• Deflectors (x3): on vs. off
Optimal settings: light colander, 900
degree spindle, deflectors on
Characteristic Equation:
y = 76.8657 + 1.91(x1) + 3.58(x2) -
4.99(x1*x2*x3)
Maximum percentage of egg weight
lost: 83.53%
18

20. For videos, additional pictures, or any other information on these
projects or others, please feel free to contact me.
Email: teschen2@Illinois.edu
Mobile number: (618) 560-8754