The objective of the project was to design and develop a new range of cooking accessories for an upscale market segment; using coconut shell, bamboo, wood and metal. Also to develop a protocol for production by standardizing the design details and processes for the purpose of training the craftsmen.

The set of products includes Serving spoon, Ladle, Spaghetti fork, Serving spork, Draining spoon and saute spoon.

Various ideas for Material usage, joint details, formal language and aesthetics were sketched out.

The ideations were then conceptualized through a set of quick study models. The models were made using Styrofoam and aluminium sheet to understand the overall product form and feel.

The initial sets of prototypes were more focused on the design and details of the handle, but the main problem area of those prototypes were the joint between the coconut shell and the handle. In order to make the design work, a seamless joint was required at the junction. A new detail for the joint is then worked out and tested. The design of the handle was also developed further, and explored various combinations of metal and bamboo reaper to finalize the design. A second design for the handle using round sections were also explored.

Various types of explorations were done throughout the design process to understand the possibilities and to add value to the product.

Laser etching was one of the explorations; which adds a lot of value to the product by engraving patterns or designs on to the product. This extend out the possibility of product customization. Custom designs or texts can be engraved for a special user requirement. 

Another exploration was to try out the possibilities of various methods for joining the round handle to the wooden neck piece (the wooden piece where the coconut shell is attached) for the second design option.

An explorations was done in order to understand the possible range of product forms and formal language in coconut shell. The possibility of varying the angle of the joint was also explored through this.

Exposing the metal in front of the handle in the final design was a conscious choice made to add richness to the design and also to extend the scope for value addition, customization and design options. Various hammering and punching techniques were explored in sheets of copper and brass. 

Various forms for the round handles were explored through some initial sketching and then in lathe. Type of wood, size of the handle, and shape of the handle were explored. In order to add value to the products, various types and combinations of groves were also explored. Possibility of filling the groves with silicon for a better grip was also attempted.

The second part of the project was the production. The standardization of the geometry and the process is very important for maintaining and monitoring the quality of the product while production.

In order to make a standardized manual for production, the entire process of manufacturing was documented.

Requirements for new tools and jigs were identified while making. A sanding bit was developed for sanding the inside of the coconut shell.