The Badge Archive

Egg Safe Vehicle Build

Fulfills Steps 3, 4, and 5 of GSUSA Brownie Automotive Engineering badge requirements.

Items Needed

  • Paper towel roll halves (vehicle body)
  • Hardboiled egg (for crash test)
  • 4 wheels (plastic lids, bottle caps, or foam circles)
  • 2 axles (wooden skewers, dowels, or plastic straws)
  • Short straws (optional, for smoother axle movement)
  • Modeling clay, rubber bands, sponges, or hot glue to attach wheels
  • Duct tape, glue, markers, scissors
  • Extra materials for safety features (foam padding, cotton balls, bubble wrap)
  • Slope for testing crashes (ramp or inclined surface)
  • Paper and pencils for recording results

Instructions (Estimated Total Time: 45–50 minutes):

  1. Step 1: Build the Basic Vehicle (10 minutes)
    • Cut an opening in the center of the paper towel roll for the egg to sit inside.
    • Cut slits at the front and back of the roll for axles.
    • Slide the axles through the slits and attach wheels securely.
    • Test if the vehicle rolls smoothly. Adjust axle slots if needed for movement.
    • Optional: Insert short straws into axle slots before adding axles for smoother rolling.
  2. Step 2: Add Safety Features (10 minutes)
    • Scouts modify their vehicle to protect the egg in a crash.
    • Use materials like foam, cotton, or bubble wrap to cushion the egg.
    • Reinforce the body to absorb impact using extra cardboard or padding.
  3. Step 3: Test & Record Results (15 minutes)
    • Place the vehicle at the top of a ramp and release it to crash into a wall.
    • Check the egg for cracks after impact.
    • Scouts record results (Did the egg survive? What worked or failed?).
  4. Step 4: Improve & Retest (10 minutes)
    • Based on results, adjust safety features (stronger padding, reinforced structure).
    • Retest vehicles and compare improvements.
  5. Wrap-Up Discussion (5 minutes)
    • Scouts share what worked and what could be improved.
    • Discuss how real engineers test and refine safety designs in vehicles.

How Engineers Test Vehicle Safety

  • Crash Testing – Engineers run controlled crashes to see how a vehicle protects passengers.
  • Impact Absorption – Materials like airbags, foam, and crumple zones help absorb force.
  • Seat Belt Effectiveness – Engineers check if seat belts hold passengers securely during impact.
  • Real-World Simulations – Tests include water, snow, and uneven terrain to prepare for different road conditions.

How Engineers Improve Designs

  • Strengthen Weak Areas – If a vehicle crumples too much, engineers reinforce the frame.
  • Modify Safety Features – Adjust seat belts, airbags, or padding based on test results.
  • Improve Stability & Control – Make changes to tires, traction, and body shape for better handling.
  • Repeat Testing – Engineers test over and over to make each version safer.

Discussion Questions for Scouts

  • How did your vehicle perform in crash tests?
  • What changes could make your design safer?
  • What real-life safety features do cars use to protect people?

References

Alternative Builds

Tia Kennard