>> ♪ We've got two days to get this straight ♪ We got a challenge just won't wait our eyes are on the prize ♪ Two engineers just set the date ♪ We got this client can't be late oh, no, it's go time ♪ Build it, test, fix it debug now and kick it ♪ Got to get it off the ground yeah ♪ Stick around and you'll see what teamwork's supposed to mean ♪ It's so key Design Squad Design Squad!

♪ >> I'm Gerthy Lahens, and I was born and raised in Port-au- Prince, Haiti, and I can show you a tape on Haiti.

So let's roll.

I don't know if you've heard of Haiti.

It's a small country in the Caribbean just 600 miles off the coast of Florida.

Unfortunately, years of political unrest and environmental damage have made Haiti one of the poorest countries of the world.

Work is very hard to find.

The one-third of our population that are working makes about ten U.S. dollars a week.

Haitians can make more money if they can grow their own food, processes it, and sell it as a product.

Peanuts are a very important crop for Haiti because they are good for the soil.

Peanut butter is a great source of protein.

We love it.

We call it mamba.

It's so popular because it's cheap and nutritious.

What Haitians need is to find a cheaper and easier way to process food.

Here's where you can help, Design Squads.

I want you to build a prototype of a peanut butter maker.

It must be made with low-cost materials, and most importantly, it must be human powered.

The winning peanut butter maker will be used by a woman's cooperative in Haiti.

>> What did you mean by prototype?

>> A prototype is an early model of a design.

The squads will make an alpha prototype, which is the first model that's fully functional.

But before the alpha prototype can be used, the design, materials, or fabrication will need to be upgraded.

So a second generation or beta prototype will be built.

>> Do we get to shop this week?

>> This week is special.

Deanne and I will do any of the shopping that you guys need.

And as usual, the winning team this weeks gets 100 points.

And for your brainstorming, we've provided all kinds of tools in your workspaces that you can use to explore how to make peanut butter out of these peanuts.

>> Good luck, Design Squads.

Start brainstorming.

>> Hey.

>> Whoa.

>> Look at this.

>> What the... >> We got to turn this stuff into peanut butter.

>> That's pretty good.

>> What do we need to make peanut butter besides peanuts?

Have you guys made it before?

>> The only way I've ever tried to make peanut butter, it's like snack time at school, you just chew them up, and then you go, "Ah, peanut butter."

>> Well, I guess then it's like a crushing motion that makes peanut butter.

>> All right, you know what?

I'm going to go online and see.

Peanuts are ground twice, pulverized to small bits first-- that's the grinding-- then ground with salts.

>> Guys, we have a lot of tools on our table.

Should we try an experiment to see if we can make peanut butter?

>> It's, like, peanut powder.

In order to get, like, the oils out to make it actually buttery, it has to be crushed, I guess.

>> Let's put the peanuts in there.

>> Literally just mush them?

>> Yeah, mash it like that.

>> Yeah.

>> The crushing made the best peanut butter, I mean, because the food processor just kind of chopped it up and made peanut powder.

>> Tom's idea is a disc mill, and here's how it works.

Pressure from the weight of the top stone crushes the peanut.

A spinning motion grinds the nut and releases its oil, creating peanut butter.

>> When you saw Kim, like, moving it back and forth like that, if we were able to just move it once, two big strokes, and then have the squeegee, we'd make tons of peanut butter in one, like, simple stroke.

>> Look at, like, the peanut butter that I've made right now.

It's basically exactly what we want to make, and what we did is we ground it up really finely, then used those fine pieces and compressed them and made, you know, this creamy peanut butter.

So I think we should try and do that.

>> This is our mortar.

This is the cup shape that we drive the pestle into.

Then we have a giant screw that goes down in here with an inclined plane wrapped around.

We put the peanuts in the bottom.

We start spinning it, right?

And I'm not sure-- I haven't really tested this yet-- but I think that as it grinds, it will spin up to the top of this screw.

>> Yeah, it can go up.

We can make it go down, depending on which way the thread is on the screw.

>> We definitely could.

>> All right, so we need to find a really big screw.

>> We're going to have to make it.

>> It's going to be a three-step process, right, you guys?

>> The first step is, like, grind it fine.

The second step is compress.

>> The third is the pushing.

>> The problem we have now is trying to get these three steps into human-powered processes that can be done on a co-op in Haiti.

>> You guys want to give me the rundown on your design?

>> What we're thinking of is having a giant screw and then having a type of funnel here that will screw the peanuts up, and as it screws up, it's going to grind them into peanut butter.

>> Making the screw, have you thought about how you're going to it?

>> Yeah, out of, like, concrete.

>> It's not going to cure for basically the rest of the week.

Incidentally, that design I think will work better if you are grinding it down.

>> That was Giselle's idea.

>> Oh, one more thing about the force, too, is not only is the screw itself going to be taking that force, but you're going to be putting an equal amount of force into the cone itself, and so you're going to... >> The cone could possibly break-- is that what you're saying?

>> It's very likely that the cone will break unless it's build really, really strong.

>> Steel, man.

>> Right now we should try and figure out how to make this out of parts in the garage, because we know that people aren't going to be able to afford to buy this.

Remember those drill bits we used for the bridge that Marcus gave us, those huge ones, the auger bits?

>> Oh, yeah, yeah.

>> Remember how bit those were?

>> Yeah.

>> Wouldn't that work perfectly for this application?

Do you guys want to try to explore that, see if they can buy us a bunch of auger bits that we can play with?

>> Also, the auger bit, isn't it sharp at the end?

>> Yeah.

>> We could use that to our advantage by putting up a screen or something with holes in it, and all the threads will push the peanut to force it through.

>> I just wanted to go through, like, the whole piston idea with you guys just to see if you guys want to use it.

>> Okay, that's cool.

>> Whoa.

We've got peanut patty.

>> There's no grinding motion with that.

It's all just crushing.

>> Guys, I feel that we're missing something, like we overlooked something.

>> Normally about this time... >> We've be, like, designing it.

>> ...we have a design and we're already getting to work on it.

>> What are the things that we've thrown out?

>> We've thrown out the piston.

We've thrown out the rock.

We've thrown out the cone.

This is actually a challenge where I feel bad if I... >> ...if we fail.

>> ...if we fail, exactly-- if we don't even have a design period.

>> It's not about the 100 points anymore.

>> Yeah.

>> It's about the peanut butter.

>> No, it's not even funny.

>> It's about the people.

>> What about this?

We lift it up, and we just drop it somehow-- like, mechanically, we drop it on peanuts.

>> What about if we used a rolling pin?

>> Last night, I was baking a cheesecake, and I had to crush up graham crackers, and the way I did it, I put it on a table, and I just took a rolling pin, and I rolled over them several times.

Then I got this really fine powder.

>> You guys, what about, like, a mill?

We have a hopper of, like, peanuts, and then they fall down in, like, a middle... it's like a big rock or, like, whatever it is you can find.

This one spins this way, and the other one spins the opposite direction, and they kind of squish them together?

It's modeled after an ancient Roman flour grinder.

They just had, like, the cone idea, and they basically just walked around in a circle, and the grain went in up here, and it came out flour on the bottom.

The reason it worked so well is because it's stone and it has, like, an uneven texture.

>> If you want such a large surface area, where are you going to get the large stone?

>> We can't get a stone that big, but what we can do is get terra-cotta.

>> Is that what they make flower pots out of?

>> That's what they make flower pots out of.

>> Nice.

>> Two flower pots tossed in, one big flower pot, smaller flower pot.

This is absolutely brilliant.

>> Would flower pots break though?

>> Yes-- that's the short answer.

No is the long answer.

>> Here's kind of the general design we have.

We have a plywood box with our pot set inside of it, and this is the view from the side.

You can see we have this other pot set in concrete inside the box.

And then the top pot kind of sits in there, and it comes out of the bottom, so we can have a bucket down there to collect the peanut butter.

>> That's a really good drawing.

>> And it's set on cinder blocks.

>> All right, you guys, for our materials list, we should really get Nate and Deanne a list.

>> Well, I'm just going to ask for strong flower pots.

>> Auger bits and PVC pipes that fit with the auger bits.

>> That's pretty much all we need.

>> Yeah, that's all we need.

>> A lot of flower pots.

>> Hey, guys, got your list?

>> Yeah.

>> Sounds good.

I'll be back as soon as I can.

>> Drilled in here are going to be, I guess, eye hooks or something, and there can be a pulley or just a wire that's going to lift this stone up and then drop it repeated on this piece of wood, and the peanuts under there are going to get crushed.

>> I think that works pretty well grinding up those peanuts.

>> Are we having both the roller and that?

>> And if the roller doesn't work, we've got a very good backup plan.

>> Here's the last of your pots.

>> Kim and Joey, you guys want to get started on the box?

You probably won't finish it tonight, but we can finish it tomorrow.

I'm going to start making sure that that actually grinds peanuts into peanut butter.

And then we don't have that much time left, so we'll just pick it up tomorrow.

>> All right, this is the last of it.

>> Now that we have our materials, what are we going to do?

>> Why don't we start working on the grinder itself?

>> Okay.

>> Wow, that's a really nice fit.

>> Yeah.

>> Try to work on the feeding mechanism to try to, you know, transfer the crushed peanuts into this.

>> Put your tools down, Design Squads.

That's it for day one.

>> Right now I don't care who wins as long as we have a product to send to them.

>> All of us realize the importance of this prototype, have realized that we need to probably put our best work into it, because we know that it's going to really affect people in another country and how they earn their money.

>> Let's hear it for day two.

>> Yeah!

>> I don't want to break this pot, because we only have two of them, so instead of holding this up and jamming this one down in it, we don't have our concrete around it, so I'm just going to put the peanuts in the space between the two and then move the bottom pot to grind them, and hopefully it won't break.

>> Oh, wow.

>> All right, let's see what's in the bucket.

And that's not peanut butter.

>> Looks like wood shavings.

>> We got some peanut butter on here, with terra-cotta.

>> Terra-cotta flavored peanut butter.

>> I think that's going to be a big hit.

>> Twist, Giselle, twist.

Ah-- uh-oh, I head a crack.

>> I did too.

Lift it up.

>> Hold it... don't let the bottom thing... >> Uh-oh.

>> It's cracked.

It's cracked.

Do you want to see if we made anything close to peanut butter?

>> I don't think we did.

>> Well, let's just see.

>> Yeah, we made terra butter.

>> Careful, because it's... >> Actually... no.

Poor pot.

All right, guys, what now?

>> This is the feeding tube for the peanuts.

This will be turning like this.

It'll force the peanuts down-- the blade's right here-- cut the peanuts, and it forms them into peanut butter.

Oh, we have peanut butter.

Check it out.

Check it out.

Guys, this is going to be our design.

Look at what this made.

Oh, hot, hot, hot peanut butter.

>> We just used a drill on high.

How are we going to get a person to do that?

>> The people in Haiti won't be using drills, but they'll be using a hand crank.

>> This is for the crank that's going to grind up the peanuts into peanut butter.

>> We need to attach this to this somehow.

>> Life's tough right now.

Things that didn't work.

We can't use the pots.

Pots are not, in my opinion, a good thing.

Let's take a step back.

Millstones we know will work.

>> Wow, look at that.

That's nice.

>> Yeah, that's peanut butter.

It's got a few chunks, but we can spin it some more.

What have you got for me?

>> We can have a hopper of peanuts up there.

>> Right.

Okay, Giselle, you're working on the handle.

>> You want me to make a handle for that?

>> I want two holes through the middle of both.

Use an impact drill with a masonry bit.

It's honestly not that hard.

Joey, you want to work on the hopper?

Kim and I will start cutting groves into the stones.

So what we're doing is cutting groves into the bottom stone, and hopefully that will lead the peanuts to freedom after they turn into peanut butter.

But if it doesn't, I'm not going to be too worried about it, because we can always lift the stone up and just scrape it off.

We'll have to make a scraper, but, I mean, this is just a test-- is what I'm trying to say.

>> This is the handle that's going to turn the stone.

I took out the old handlebar that was in here, and then I found a new bar, and I'm putting it in through here so that one person can be on each side, and that's going to be turning the stone.

>> If was had circular stones, we could have a casing around it so nothing can get out the sides.

We don't have two pieces together right now.

We have two stones, I think a bucket that's being cut... >> Handlebars.

>> ...and handlebars.

So it'll be nice if we could get some of that together really soon, but I think everybody's waiting on me.

>> You guys?

Done.

>> Really?

>> Yeah.

>> Let me see.

>> Try it.

>> I'm really happy.

>> Is it working?

>> Not as well as it was before.

>> That's because we had it hooked up to a drill.

>> There wasn't enough pressure being built up in the front of the thing to force it out.

Like, it was going... it was moving to a certain extent, and then it was just, like, stirring it up.

>> Krishana's right.

If the peanut butter sticks to the auger, the peanut butter will just spin in place.

Blue Team needs to carve grooves inside the PVC pipe to trap the peanut butter.

Then the auger can push it forward and out through the die.

>> We should be seeing peanut butter.

>> We have beautiful, warm peanut butter, smooth and creamy.

>> Right now I'm going to drill a hole for the shaft of our axle so that they can both spin on top of each other.

And I'm going to use this impact drill to cut right through the cement.

>> What Joey meant to say is concrete, not cement.

Cement is a powder made from crushed limestone, clay, and the mineral gypsum.

When it's mixed with water, cement turns into a solid.

Joey's actually drilling concrete, a conglomerate of small rocks, sand, and cement.

>> There you have your Stone Age wheels.

Now, what's going to happen is the rock's going to sit right on top of this rod, and as we pull the rod up, it's going to lift the rock itself.

They can use the handlebar that Giselle made, which looks extremely nice.

>> A little more.

Let her rip.

Almost ready to scrape, sir?

Want to do a check?

>> I want some smooth peanut butter.

I don't want any... you know, some lazy... uh-oh.

>> We bent the rod.

>> We're using the epoxy to secure the rod that's grooved inside the rock.

>> We have rollage.

>> Our team worked together so well.

We didn't argue over anything.

We were very open about testing everyone's ideas.

>> Does it come out nicely?

>> Yes, it's coming right out of the hole.

>> Good flow.

>> Very good flow.

>> So how much do you think we have?

>> Right now we probably have about a tablespoon or so.

Look at that.

Oh, yeah.

>> That's some peanut butter.

>> We don't have a whole lot of peanut butter, because it's all on the sides.

>> It is important to know that you guys have one hour left.

It is definitely crunch time.

>> The problem is when the top stone's on the bottom stone, they both spin, which is bad.

>> Make sure the surface that we're sticking that on is clean and dust-free.

Okay, I'm going to go try this out.

Get some peanuts.

>> I will feed you peanuts.

>> You have to lift it up just a little bit.

>> It could use some more grinding.

>> The sidewalk will help, because the bottom piece will grip the sidewalk.

>> Yeah, no, you're right.

>> Feeling butter.

Okay, we got peanut butter right there.

>> All right, lift it up.

>> And there's two.

>> Two in a minute.

>> I bet it's enough to fill one sandwich.

>> I'm adding strength so if it does start spinning... listen, it's not going to.

>> We don't need it.

>> Tom, don't do that.

>> Even if we don't need it, it's not going to hurt us at all.

>> No, no, no, no.

Seriously, we are five minutes over.

We have to just do this.

>> We're not five minutes over.

They're not coming out and telling us that we're five minutes over.

We should do this so we have something to stand on while we're grinding it.

>> No, you just stand on the bucket.

It's fine.

It works.

>> I don't want to stand on the bucket.

I want to stand on the ground.

>> Well, who says' you're turning it?

>> No, I'm actually standing on the ground.

>> Fine, Giselle, you turn it.

You can stand on this.

But I want to have something to stand on, all right?

It's not going to hurt you if I drill holes in that.

>> The demon within Tom emerged.

>> Tom, we're going to show you how it works so you know you don't need to do this.

>> You can show me how it works after I put that on.

>> No, Tom.

>> It's not... tell me what's hurting that I'm drilling holes in this right now.

Tell me, what are you guys losing right now?

Go ahead.

>> Stop it.

>> I mean, acting without the consent of the team is not teamwork.

>> I saw it spin once during a test, and I don't want to have it spin during our actual experiment.

>> We just did it.

You weren't even here.

>> I know, because I was setting this up because of the last test that failed.

>> Yeah, but when we did it this time it worked.

>> Right, but when we tested it right here, it didn't spin.

>> Right, on the sidewalk.

What if they make us test inside the shop?

What if it starts raining right now?

Then what?

Should I drill the holes then?

Should I ask for more time then?

Come on.

>> I understand where Kim and Giselle were coming from when they really, really thought he was being a jerk, because that behavior is just unacceptable.

>> All right, Design Squads, time's up.

We have Gerthy, and we have someone else that's very important to the process, Peter.

>> I'm from a nonprofit that trains engineers to build these types of systems for rural villages in developing countries.

>> So, Red Team, you guys ready to go?

>> Yes, we are.

>> All right, I'm going to time you.

You have one minute.

Ready, set, go.

>> Load it.

>> Is it up?

>> We didn't have, like, rods.

Use the rod, yeah.

>> Out of the bucket.

>> Wait, wait.

Wait, wait, wait.

The bottom... no, no, no.

>> Oh.

>> See, our hopper is a fruitful concept.

>> Okay.

>> While not functioning at the moment, it would be ideal if we had an elbow joint we just ran out of time to make.

>> Ten, nine, eight, seven, six, five, four, three, two, one, and time.

>> Lift it up.

>> I wish that hopper didn't get in the way.

>> It looks like about three- quarters of a table spoon.

>> You guys want to check this out?

>> Oh, I would not eat that if I were you.

>> That... it's good, very good.

>> You're really getting a great consistency of peanut butter here.

>> I am a little bit concerned about the ergonomics of the device.

It just seemed that he was working pretty hard to get the peanut butter going.

>> You guys have done a very nice job, but we still need to see your competition.

You guys ready to go check out Blue Team's?

>> We devised two plans to make pieces of peanut, and you can chose whatever one you like.

This one is a roller with sandpaper.

You put them in here.

>> The other device that we have is a little bit barbaric but a very easy design project.

>> This is the part that actually creates the peanut butter.

>> And go.

>> Is the peanut butter coming out?

>> Yeah.

>> Keep going.

>> Warp speed.

>> Yeah.

>> Six, five, four, three, two, one.

>> All right, that's it.

>> Do you want to give it a test, see the quality of the peanut butter?

>> Why don't we huddle up and make a decision?

>> Let's just get into it.

What did you guys think?

Let's start with Red Team, since we saw them first.

>> I like it because it's simpler and I think it would be easier for people to use and also the quality of the peanut butter is, to me, more important.

>> I'm a little bit worried about the mechanism they have for feeding, the actual long- term use of the device.

>> How about Blue Team's?

>> I really appreciate the two machines together and make a final product.

>> You could produce a system that could also scale up and could be used as a pedal-power system.

>> I think this is something that we can... that could be ready for us to bring down when we're going to Haiti next month.

>> So the bottom line is... >> I'd have to go with the Blue Team.

>> Which one do you go with?

I happen to go with the Blue Team.

>> I think I'm going to have to lean towards the Blue Team as well.

>> I think I have to go with blue.

( cheering ) >> 100 points goes to each member of the Blue Team.

>> I don't know if I will be able to bring the love and the passion that I've seen here to the people of Haiti, and you will be making a tremendous impact in their lives.

Really, I don't want to cry, but I'm applauding.

I'm so proud of you.

Thank you so much.

( applause ) Thank you, guys.

>> Hey.

>> Thank you so much.

>> At this point, I don't care that we didn't win, but the idea that our machine's not going to go to that country, I don't know, it's just upsetting.

That's all.

>> We had two rocks grinding together.

That's what we had at the end of two days, and that, to me, is unacceptable.

Frankly, I'm borderline glad we lost, because, I mean, the better machine's going to go, and that's the machine that's going to work the best for the Haitians, and they're the ones that need it.

Captioned by Media Access Group at WGBH access.wgbh.org >> I like it.

>> So after six challenges, Natasha is the cream of the crop with 480 points.

Joey and Noah are close behind with 430 points apiece, so the lead is still up for grabs when the teams get reshuffled next time on Design Squad.

All right, Deanne, here's a new challenge: describe the Design Squad Web site in ten seconds.

Go.

>> There are games, photos, new challenges, videos, quizzes, scoring updates.

>> Time's up.

>> Ugh!