jenny cerullo

  • Aqua Aura

    2024
    Project: University Project
    Timeline: 2 months
    My Role: Research synthesis, user testing, designing and fabricating
    Materials and P: SolidWorks, Keyshot, 3D printing

    The Problem

    Backpackers need a way to lighten their load and keep their hands free on long trips, as they currently carry too many separate, essential items.

    The Goal

    Make hikers lives easier by helping them have less items on hand while still ensuring they have everything they need at their fingertips.

    Context

    You should drink one litre for every two hours you hike.

    Opportunity Analysis

    The classic camping trick of placing a light under a bottle.
    Light without water bottle:
    Saturated at the bottom, not well dispersed, hard to look at.
    Light with water bottle:
    Smoother comforting light, easy on the eyes, brighter.

    Competitive Product Analysis

    Existing water bottle lanterns are poorly designed. The light source is at the top, causing it to lose its reflective power as the water level drops, and the handles are thin and thus, uncomfortable to use when the bottle is full and heavy, making them awkward to carry.

    Ideation Sketching

    The best option should have a combination of a comfortable handle for lantern purposes, a lid that is attached to the bottle to prevent getting lost, a plain shape to reflect light without patterns and a cylindrical shape for a comfortable grip.

    Ergonomic Prototyping and Testing

    Final Product Design

    Slides seamlessly into your backpack.
    Easily snap the light to the bottom of the bottle. The bottle can be used with and without the light. The foggy bottle reflects the perfect smooth glow and the water illuminates the light for a perfect diffused look.
    Use the puck light as an on-the-go compact flashlight for your camping adventures.
    Sip or chug from the narrowed spout without worrying about spills. The lid is attached by a rubber strap so you can refresh without worrying about misplacing the lid.
    With its lift-off drinking spout, this water bottle offers a wide opening for effortless ice cube insertion or hassle-free cleaning.
    Convenient carabiner built in to the handle to clip onto your tent, backpack, or secure your camping gear.
    The packaging is made of molded pulp from recycled paper, cardboard offcuts, and natural fibers. This is a sustainable alternative as it is biodegradable, cost-effective, and offers a high level of protection.

  • Espresso People

    2024
    Project: Espresso organizer
    Timeline: 6 weeks
    Team: Created in collaboration with Spencer Kirkhope
    My Role: Ideation, design, metal fabrication
    Materials and Processes: SolidWorks, plasma cutting, mild steel, concrete, wood

    Your morning espresso one-stop shop.

    The Problem

    Espresso machines rely on numerous tools and accessories, often turning the art of espresso into a cluttered and time-consuming process.

    The Goal

    Design a shelf that organizes espresso tools and looks good on a kitchen counter.

    The Build

    I helped come up with the design, and was responsible for all the metal work.

  • Cora

    2025
    Project: Industrial Design Capstone
    Timeline: 6 months
    My Role: Research synthesis, user testing, designing and fabricating
    Materials and Processes: SolidWorks, Keyshot, mild steel, welding, plasma cutting
    Click here for my full process book and technical drawings

    The Problem

    Women in Tanzania have to walk long hours to distant milling facilities. The machines in these facilities cause a loss of maize during grinding, are expensive to use, and often have unreliable access to electricity.

    The Goal

    Improve daily food processing in rural Tanzanian communities by introducing a hand-powered corn grinder that is portable, electricity-free, and made entirely from locally available materials.

    Context

    In many rural Tanzanian communities, women grind maize to make their country’s national dish, Ugali, a staple corn pudding. This is a time-consuming, labour-intensive task primarily done by women. On average, women in Tanzania spend four times more hours on unpaid domestic work than men. Maasai women often walk long distances to village-based milling facilities, which are costly, unreliable due to frequent power outages, and lead to 2kg of maize loss per grind.

    50%

    of daily calories in Tanzanian households come from Ugali.

    65%

    of Tanzania’s population lives in rural areas with limited access to grinding facilities.

    62%

    of Tanzania has no electric grid or no connection to an electric grid.

    92%

    of the rural areas of Tanzania do not have a reliable electricity supply.

    Opportunity

    Improve daily food processing in rural Tanzanian communities by introducing a corn grinder that is portable, electricity-free, and made entirely from local materials. Reducing travel time to distant milling facilities and minimizing maize waste can empower women, enhance food security, and create opportunities for small-scale corn-grinding businesses.

    Affordability

    Using inexpensive and widely available materials and local manufacturing.

    Variability

    Using size adjustable mechanisms to fit all users and removeable components for cleaning and portability.

    Durability

    Using weather-resistant materials and replaceable parts to ensure durability and ease of maintenance over time.

    Currently

    In Tanzania, electric corn grinding facilities are often only available in the larger towns. These facilities typically feature two electric corn grinders designed to process maize quickly.

    Mechanism Exploration

    Typical hand-crank grinders are made using expensive manufacturing methods that cannot be recreated in rural Tanzania.
    Flat burrs
    Course grind, adjustable plate distance, hard to grind, weak table grip, bits of metal chipped into the grinds, and unable to be produced in Tanzania.
    Conical burrs
    Finer grind, hard to grind, adjustable plate distance, and unable to be produced in Tanzania.
    Conical and flat burrs
    Course grind, easy to grind, adjustable grind plate distance, does not require advanced manufacturing methods, and is possible to recreate in Tanzania.

    On-site Research

    Through calls with Tanzanian locals, I explored ways my machine could best work for them. By talking directly with Maasai women, I was able to understand their daily routines, preferences, and priorities when it comes to maize processing.

    My Findings

    – Women would store the grinder in a dedicated corn grinding boma.
    – They want to use it while standing, with the handle turning clockwise.
    – Corn would be ground directly into a bag or bucket.
    – They typically grind enough for one family meal at a time.
    – The grinder would be used exclusively by women.
    – The flour must be very fine to be suitable for Ugali.
    – They hope to use the grinder to create a small grinding business.
    – While not moved often, they would want it to be portable.
    – The grinder should be easy to take apart for cleaning and maintenance.

    Prototyping in Tanzania

    I worked with local welders and translators to bring my prototype to life.
    I used anthropometric data to determine key design dimensions, ensuring the grinder fits comfortably within the range of a 50th percentile woman. Measurements such as elbow height, arm reach, and grip diameter guided the positioning of the crank, the overall height of the grinder, and the handle size, making the device ergonomic and efficient.
    Weight considerations:
    – Safe lifting capacity: 10–15 kg
    – Design Implication: Break into parts under 8 kg, each no longer than 90 cm for ease of carrying and setup.

    Presenting in Tanzania

    I presented the prototype I had developed in Tanzania to a group of 30 Maasai community members and local manufacturing business owners. The response was highly encouraging, proving clear interest and confirmation that the product filled a real need in the region.
    The primary concern raised was that the grinder must produce a fine flour, as the current version only produced a coarser grind, which was not suitable for preparing Ugali.

    Concept Actualization

    Since the corn needed to be ground finer than I had originally thought, the grind plates had to have a tighter tolerance. This meant I needed a rotating auger to push corn through the plates. I designed a new type of grind plate that could work with an auger, while also being easy to produce locally.
    Classic grind plate
    Cora grind plate
    – Made using expensive iron casting or metal CNC cutting.
    – Time consuming to angle grind and requires a plasma cutter that can etch to recreate something similar.
    – The plates are usually concave to allow the coarse original item to funnel into the center. This curve is extremely challenging to recreate using local manufacturing methods.
    – Can be made using an angle grinder as it allows for large tolerances.
    – Can be made using plasma cutting, an inexpensive method that can easily be mass produced, and does not require an etching tool.
    – Large ridge in the center allows unground corn to funnel into the middle, and the star ends guide the corn towards the edges.
    – Achieves the same result with fewer cuts.
    The corn hopper holds enough corn to feed up to five people. This is an ideal size for a Maasai family in Tanzania, which typically consists of five to eight people.
    Most corn grinders use a cast iron auger, which isn’t practical to produce with simple tools or local materials. Instead, I used standard steel washers or split lock washers, which are widely available and easy to work with. The threaded rod allowed the grinding plates and handle to be screwed on securely, creating a functional, low-tech auger that could be easily fabricated with basic tools.
    The bent metal tube handle provides a natural turning motion for the user. The final handle length balances torque and ease of rotation, while remaining simple to produce and repair locally. The grip features a wider diameter and an extended length for a two handed grip, specifically tailored to fit the hand breadth of a 50th percentile woman.
    I designed bean-shaped feet. This shape provides a platform that the user can step on to add downward force if the machine is on uneven ground. Additionally, Users can place rocks on the feet for extra weight or insert a wooden peg through the hole to secure the grinder in place, ensuring it remains steady.

    The Final Outcome

    This resulted in a hand-powered corn grinder that can grind corn into a fine powder, come apart into pieces, and adjust in height.