MetalCone

What it does

This sheet metal traffic cone replaces plastic cones with a durable, recyclable, and locally made alternative. It cuts plastic waste, minimizes material use through flat-pattern design, and can be produced easily without the need for expensive tooling.

Your inspiration

The idea came when I noticed a broken plastic traffic cone discarded on the roadside. It made me question the durability and sustainability of such everyday objects. I realized that while traffic cones are used everywhere, they’re often treated as disposable. This sparked the idea to redesign the cone using sheet metal—a longer-lasting, recyclable material. I wanted to create a solution that could be easily manufactured locally, reduce waste, and still serve the same purpose without relying on plastic or heavy industrial processes.

How it works

The traffic cone is made from a single sheet of metal that is cut into a precise flat pattern. This pattern includes fold lines and holes for rivets. Once cut, the sheet can be folded into a cone shape and secured using simple rivets—no welding, molds, or heavy machinery required. This makes the design ideal for local production, even in small workshops. The metal used is strong, weather-resistant, and recyclable, giving the cone a much longer life than conventional plastic ones. Despite being metal, the cone remains lightweight and easy to handle. It is also designed to be stackable, just like plastic cones, which makes it easy to store and transport. The combination of flat-pack production, local assembly, and durable material makes the cone both environmentally friendly and practical for everyday use.

Design process

The project began with a simple observation of a broken plastic traffic cone on the roadside. I started by studying how conventional cones are made, used, and disposed of. Realizing their short lifespan and environmental impact, I explored sheet metal as a sustainable alternative. I sketched flat patterns that could be cut and folded into a cone form with minimal waste. The first prototype was made from cardboard to test folding logic, followed by a thin metal version to study strength and joinery. I refined the rivet placements, angles, and locking mechanisms through multiple iterations, aiming for ease of assembly and stackability. Conversations with local fabricators helped validate the design for real-world production without relying on injection molding or complex tools. I also focused on making it compatible with existing cone applications—ensuring visibility, lightweight handling, and nesting ability. The final version is durable, fully recyclable, and suited for local manufacturing at scale. It reflects not just a change in material but a shift toward decentralized, low-waste production in public infrastructure.

How it is different

This traffic cone stands apart by replacing plastic with sheet metal, offering greater durability and full recyclability. Unlike conventional cones that require injection molding, this design uses a flat sheet cut into an optimized pattern that folds into shape and is fixed with rivets—eliminating the need for heavy tooling or molds. It can be manufactured locally in small workshops, making production more accessible and decentralized. The cone is also stackable like plastic cones, retaining ease of transport and storage. Its longer lifespan reduces replacement cycles, while the use of a single recyclable material supports circular design. This makes it both environmentally and economically smarter.

Future plans

The next step is to build working prototypes and test them in real-world traffic conditions to study durability, visibility, and usability. I’m currently exploring funding options to create multiple prototypes for testing and refinement. Once the design is resolved through iterations, I aim to approach government agencies and urban planning departments to seek support for larger-scale deployment. The goal is to introduce a sustainable, locally manufacturable alternative to plastic traffic cones in public infrastructure systems.

Awards

The design has been recognized at the International Busan Design Awards 2025, where it earned a place in a special category for sustainability-focused innovations. Although it was not among the top three winners, it was selected for its unique approach to environmentally conscious public design.