MaterialCycle - Prototype Archive

MaterialCycle: Archive of Failures

Welcome to our Archive of Failures — a curated collection of prototype experiments, curious mishaps, and “well, that didn’t work” moments. Each stepping stone represents a lesson learned, nudging our designs forward, occasionally tripping us up, and sometimes giving us a good laugh.

This archive celebrates the journey of experimentation, showing that every setback is a step toward better solutions. From cracked buckets to bent risers and broken mini solar panels, each failure has shaped the evolution of MaterialCycle towers — proving that even missteps can tell a story worth sharing.

Failure Date: 2019-08-03

Failure Name: Solar Still Bucket Tower

Failure Description:

Tower built on a 25 L base bucket with 20 mm PVC conduit risers, ~1.8 m tall. At the top, a 5 L brine feed bucket contained electronic float switches to automatically top up the brine. This top bucket drip-fed three lower solar still buckets, each made from halved 5 L buckets with a transparent distillation film stretched over the lid rim. The film allowed light in and collected condensation, which was drained into glass jars. Electronics—including the solar controller, water pump, and float switches—were housed in a separate 5 L bucket on top of the base. Undistilled brine returned to the base in a closed loop.

What Went Wrong:

The weight of the top brine bucket made the tower unstable. There was no dedicated solar panel for the pump and float switches. Collecting condensate from the individual still buckets was cumbersome and inefficient.

Lesson Learned:

Avoid placing brine storage at the top; instead, implement a drip-feed without a top reservoir. Integrate a lightweight solar panel at the top to power electronics, making the system more compact. Redesign the solar still buckets for easier condensate collection.

Failure Date: 2020-08-23

Failure Name: Tubular Vertical Film Solar Still

Failure Description:
Tower built on a 25 L base bucket with 20 mm PVC risers, ~1.8 m tall. A 1 L top brine reservoir fed a tubular vertical solar still made from thin transparent distillation film suspended between the top brine bucket and a lower 1 L bucket that acted as both condensate catchment and structural anchor. The weight of the lower bucket kept the film in constant tension, allowing the tube to hold its shape even in wind.

Inside the tube, a central wick core was installed with black-dyed wick strips hanging downward, held in place by intermediate star-shaped Correx cut-outs. The wick strips were intended to maximize evaporative surface area while brine was drip-fed from the top.

What Went Wrong:
Condensate collection and separation from brine was difficult. Wick strips sometimes caused uneven wetting and flow paths. The internal structure was complex and time-consuming to assemble. Sealing and maintaining consistent film tension required careful setup.

Lesson Learned:
Film tension using suspended weight works well structurally. Wick strips increase evaporative surface area but require better flow distribution. Internal support structures should be simplified, and condensate collection must be integrated more carefully into the design.

Next Steps:
Simplify internal wick support structure. Improve condensate capture and drainage. Refine drip distribution for more even wetting. Continue exploring tensioned film structures for lightweight vertical still designs.

Failure Date: 2020-12-13

Failure Name: Correx Leaf Tower Still

Failure Description:

Tower built on a 25 L base bucket with 20 mm PVC risers, ~1.8 m tall. A 1 L top brine reservoir fed Correx Leaf solar stills, designed to mimic plant leaves with a central rib and vein structure. Each leaf was a lightweight ~10 mm composite of transparent distillation film, Correx sheet, and super-absorbent black wick, with a triangular top and inverted triangular base. Brine entered from a single drip point at the top and exited at a single bottom point. Electronics—including pump and float switches—were integrated into the tower; a mini solar panel at the top was planned but not yet installed.

What Went Wrong:

Drip rate was hard to balance with the wick surface area. Cutting and layering the Correx leaves was labor-intensive. Thin leaves allowed some cross-contamination of brine and condensate. Mini solar panel not yet implemented.

Lesson Learned:

Increase leaf thickness (~20 mm) to reduce contamination. Use laser cutting for precise, faster fabrication. Integrate a top-mounted solar panel for autonomous operation. Refine drip-feed and wick balance to optimize condensation.

Next Steps:

Improve leaf design and fabrication efficiency.

Install mini solar panel at the top.

Fine-tune drip rate for optimal performance.

Failure Date: 2022-07-04

Failure Name: Flat Panel Distillation Tower

Failure Description:

Tower built on a 25 L base bucket. The distillation unit was a ~15 mm thick flat panel with a 1 mm clear polycarbonate backing and a tensioned transparent distillation film on the front. Distilled water was collected using V-shaped catchment channels on both the front and back surfaces. A black-dyed super-absorbent wick was suspended in the center between the two condensation surfaces using a 1 mm polycarbonate wick plate with drilled perforations, allowing evaporation from both sides of the wick. Brine was supplied via a top drip-feed system. The flat panel design aimed to maximize vertical tower space while keeping the system thin and compact.

What Went Wrong:

Condensate did not always flow reliably into the V-shaped channels. Edge sealing of the panel was difficult. Thin panel increased risk of cross-contamination between brine and condensate.

Achieving even wetting of the wick required careful drip-rate control.

Lesson Learned:

Flat panel design is very space-efficient but requires precise internal flow and sealing. Wick suspension between two condensation surfaces works well in theory but needs better separation and drainage design.

Condensate channels must be carefully shaped for reliable water collection. Slightly thicker panels may improve separation and performance.

Next Steps:

Improve edge sealing and internal drainage paths.

Refine V-channel geometry for better condensate capture. Test thicker panel versions. Improve drip distribution for more even wetting of the wick.

Failure Date: 2022-09-16

Failure Name: Halfmoon Polycarbonate Solar Still

Failure Description:

Tower built on a 25 L base bucket. The Halfmoon still used 1 mm clear polycarbonate bent into a halfmoon, with a thin condensation film stretched across the flat front. Tension from the natural tendency of the polycarbonate to lie flat kept the distillation skin taut.

Inside, a vertical black-dyed super-absorbent wick was suspended on HDPE mesh, allowing evaporation from both sides. Brine was fed from the top via a drip. Multiple wick configurations were tested. Mini solar panels at the top powered the pump and circulated brine.

What Went Wrong:

Capturing condensate from the internal Halfmoon profile was difficult. Sealing the top and bottom wa schallenging. Drip-feed rates required constant fine-tuning.

Lesson Learned:

Halfmoon tension works well but complicates brine handling. Top and bottom seals need redesign for easier condensate collection. Drip-feed and wick placement must be carefully calibrated. Mini solar panels are effective; refine placement for efficiency.

Next Steps:

Improve Halfmoon sealing and condensate capture.

Optimize wick and drip-feed design. Continue integrating mini solar panels for autonomous operation. Experiment with curvature and film tension for better performance.

Failure Date: 2024-11-11

Failure Name: Flat Panel Distillation Tower – 20 mm Version

Failure Description:

Tower built on a 25 L base bucket. The 20 mm flat panel is fully enclosed with thin transparent condensation film tensioned like a drum skin. A black-dyed super-absorbent wick is suspended in the center on a perforated 1 mm polycarbonate plate, allowing evaporation from both sides. Distilled water is collected via horizontal channels on the front and back surfaces, with excess brine draining to the bottom of the V-shaped wick to a single point. Brine is drip-fed from the top.

This is the cleanest, most efficient version to date, maximizing vertical space with minimal complexity.

What Went Wrong:

Condensate capture along horizontal channels can be inconsistent. Sealing the top and bottom edges is challenging. Thin panel risks brine cross-contamination.

Drip-feed requires careful control for uniform wetting.

Lesson Learned:

Central wick and tensioned film work very well for evaporation. Horizontal channels and V-shaped wick collection are effective but need refinement.

Edge sealing and drip-feed control are critical.

Future 3D-printed or injection-moulded parts could simplify assembly and improve reliability.

Next Steps:

Refine channel and wick geometry for consistent condensate capture. Improve edge sealing.

Optimize drip-feed distribution. Explore production-friendly components for assembly at scale.