Making a Coffee Carrier out of Recycled Plastic

We designed and made this flat-pack coffee cup holder with a carry handle for those coffee lovers who always seem to be carrying a million things at once.

This was made with 550g of collected recycled plastic waste HDPE from bottle lids and milk bottles. Once the plastic was all nice and melted and pressed into a sheet, we chose the scroll saw to cut this out. This is because it has a super thin blade so the waste produced is a lot less. We also collected all of the waste that came off all the tools and used this again in another project.

We went on to use this as a prototype for a product that we sold for over a year. Sadly we have discontinued our two and four-cup coffee caddies, as they were still fairly tricky to make, even when injection moulded, as they came in three parts. So we just need to come up with some clever design tweaks to make it a more viable product.

If you have any suggestions, we're all ears! ☕