Hedge Structures Inc. is seeking an innovative design for a precision plastic molding that connects modular greenhouse window panels vertically while supporting high energy efficiency.

The primary challenge is to engineer a molding profile that minimizes heat transfer, enables hermetic edge sealing, and ensures a consistent 1 mm spacing between dual window panes. The design must also incorporate a discreet port feature to enable inter-panel connectivity or access for sealing components, while remaining optimized for scalable, cost-effective manufacturing — making this a true design-for-manufacturing challenge.

Learners will explore materials, structural forms, and sealing strategies to address these combined thermal, mechanical, and manufacturing requirements. Activities will include:

• Researching existing framing and sealing methods for insulated glazing systems
• Evaluating material options for thermal resistance, UV stability, and long-term durability
• Brainstorming molding shapes that maintain a uniform 1 mm internal gap
• Designing port features for panel integration or functional access
• Developing 2D/3D CAD models of the proposed design
• Justifying design choices with respect to energy performance and manufacturability

Deliverables will include a detailed design concept (sketches or CAD), material selection rationale, port design, manufacturing considerations, and a brief report summarizing the design process and potential improvements. This design will directly support Hedge Structures Inc.’s development of next-generation greenhouse systems that address global energy and food security challenges.

The project deliverables include a detailed design report and a prototype model of the plastic molding connector. The report should outline the design process, material selection, and manufacturing considerations. Additionally, it should include a cost analysis for scalable production.

The prototype should demonstrate the molding’s ability to minimize heat transfer, maintain a 1 mm pane spacing, and support hermetic sealing using appropriate methods such as adhesives, compression seals, or other sealing techniques.