Alii
3D Printed Single Serving Coffee Maker
Alii represents my senior thesis: applying design thinking to the single-serving coffee maker and addressing the volume of end-use waste it generates. Designing the best solution required me to research economics, waste processing SOPs, electromechanical design, and designing for production 3D printing.
In an effort to build a functional prototype, I partnered up with Forrest Sheared, an Electrical Engineering student at RIT.

Enter Chemex: a design so proven, it hasn't changed since 1941. Glass, bamboo and leather work in sustainable harmony to brew the perfect cup, and disassemble with ease for cleaning. The filter paper is made with Oxygen Bleaching, a process free of harsh chemicals.
Experts praise Chemex, however it is far from convenient. Pour-over requires medium-course grounds, water boiled to a precise temp (92º - 96º C), a properly filled and thrice folded filter, and a pouring procedure that enables grounds to bloom and properly develop flavors.

Enter Chemex: a design so proven, it hasn't changed since 1941. Glass, bamboo and leather work in sustainable harmony to brew the perfect cup, and disassemble with ease for cleaning. The filter paper is made with Oxygen Bleaching, a process free of harsh chemicals.
Experts praise Chemex, however it is far from convenient. Pour-over requires medium-course grounds, water boiled to a precise temp (92º - 96º C), a properly filled and thrice folded filter, and a pouring procedure that enables grounds to bloom and properly develop flavors.
Enid Cardinal, a member of President Munson's immediate advisory staff, is a LEED-certified expert in socially responsible investing and environmental policy. Enid helped me develop a conceptual distribution platform that educates users of those involved in their coffee's cultivation.
Dr. Callie Babbitt is a professor at the Golisano Institute for Sustainability, specializing in life cycle assessment, environmental engineering, and sustainable product design. Dr. Babbitt helped us analyze environmental threats in competing products—details that are often neglected by even the most diligent of users.
Using data from a 100 participant survey, I assessed an average coffee drinker's behaviors—in terms of brewing methods, priorities and routines.
My second and third concepts almost completely depart from the design of my first. This is the result of our preliminary research, which involved interviewing users, disassembling machines from Keurig and Cuisinart, and evaluating traditional brew methods.
Keeping designs simple and using digital manufacturing enabled us to pursue a completely custom-built machine. While the exterior components would be Polycarbonate, we insisted that all parts contacting boiling water or the coffee grounds had to be food-safe. This meant turning to materials like ceramic, stainless steel and medical-grade silicone to provide uncompromising flavor protection.
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The first cone and drawer prototypes we tested. Our initial cone design was intended for just a 8 oz cup.
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The first prototype brewing. Initially, when using plastic prototype brew cups, we were testing for concentration of flavor by observing the color saturation. Here, we see brews from both a Chemex (left) and the first prototype (right).
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Our brewing setup in the studio that we used for testing and compairing brew results of prototypes to a Chemex.
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To avoid repeatedly printing the accompanying drawer with each new prototype, we developed a simple universal stand.
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The semi-finalized drawer, and finalized brew cup. The drawer is printed in Formlabs Grey resin, while the cup is glazzed ceramic that was cast from a 3D printed mold.
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Water tank prototypes. The Grey resin print is the finalized design, with recesses for a water level sensor and strain gauge.
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Some revisions of the brew cup drawer's rails with precision bearings set in the resin (far right).
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Several versions of our boiler. These were primarily used for testing the jet and pumping system.
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Forrest testing the level sensor's accuracy before calibrating it.
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An early human factors model we made to assess how our design fit on kitchen counters and in shared office spaces.
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CNC'd Aluminium body pieces. We originally proposed a "premium" version of Alii, featuring an Aluminium housing. While we liked the aesthetics of the idea, we abandoned it due to manufacturing costs.
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One of the first 3D printed prototyes, used for testing interfacining tolcerances. A combination of FDM, SLA and SLS—both plastic and metallic—is to be used for the final design, resulting in dozens of test builds to check for play and fitment.
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This build was used to check how well the drawer traveled along its rails and bearings. The grey parts are PLA, with the exception of the water tank in the back (printed with Grey Formlabs resin).
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The rails are printed with Formlabs' Rigid resin, and use retention brackets (FDM Nylon 6) to keep the bearings in-placce. Wings printed with Duable resin engage the drawer to the rails, allowing it to slide effortlessly.
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The first cone and drawer prototypes we tested. Our initial cone design was intended for just a 8 oz cup.
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The first prototype brewing. Initially, when using plastic prototype brew cups, we were testing for concentration of flavor by observing the color saturation. Here, we see brews from both a Chemex (left) and the first prototype (right).
-
Our brewing setup in the studio that we used for testing and compairing brew results of prototypes to a Chemex.
-
-
To avoid repeatedly printing the accompanying drawer with each new prototype, we developed a simple universal stand.
-
The semi-finalized drawer, and finalized brew cup. The drawer is printed in Formlabs Grey resin, while the cup is glazzed ceramic that was cast from a 3D printed mold.
-
Water tank prototypes. The Grey resin print is the finalized design, with recesses for a water level sensor and strain gauge.
-
Some revisions of the brew cup drawer's rails with precision bearings set in the resin (far right).
-
Several versions of our boiler. These were primarily used for testing the jet and pumping system.
-
Forrest testing the level sensor's accuracy before calibrating it.
-
An early human factors model we made to assess how our design fit on kitchen counters and in shared office spaces.
-
CNC'd Aluminium body pieces. We originally proposed a "premium" version of Alii, featuring an Aluminium housing. While we liked the aesthetics of the idea, we abandoned it due to manufacturing costs.
-
One of the first 3D printed prototyes, used for testing interfacining tolcerances. A combination of FDM, SLA and SLS—both plastic and metallic—is to be used for the final design, resulting in dozens of test builds to check for play and fitment.
-
This build was used to check how well the drawer traveled along its rails and bearings. The grey parts are PLA, with the exception of the water tank in the back (printed with Grey Formlabs resin).
-
The rails are printed with Formlabs' Rigid resin, and use retention brackets (FDM Nylon 6) to keep the bearings in-placce. Wings printed with Duable resin engage the drawer to the rails, allowing it to slide effortlessly.




To guarantee persistent brew quality, all components that come into direct contact with boiling water or coffee contain zero plastics. This prevents chemicals from leaching into a brew, ensuring only pure flavors fill your cup.


One Button, Zero Guesswork
A series of sensors detect precisely how much water is in Alii's tank, so you get a perfect full cup every time. Simply fill your favorite mug or thermos with up to 24 oz of water and pour it into the tank.


No-Mess Brew Cup


Cones, Not Pods
Alli uses Oxygen-Bleached paper cones that allow grounds to bloom, properly developing all of the flavors in a particular blend. And if you have a personal favorite that isn't available in a pre-filled cone, just use an empty one or any generic conical coffee filter.


Ready? Set: Jet!
To ensure all grounds are properly soaked, Alii uses a 3D printed Stainless Steel jet array. Three nozzles precisely direct water around the entire cone, completely saturating the grounds. A computer checks the brewing process using temperature and weight sensors, ensuring every brew starts with a perfect bloom.


Modern Manufacturing
Instead of using expensive tooling, a majority of Alli's components are 3D printed using resin and recycled Polycarbonate. This cuts down on production time, cost and resources, comprehensively reducing Alii's environmental impact.

Photo Copyright 2015 Counter Culture Coffee.

Sustaining Growers Around The World
In partnership with Counter Culture Coffee, Alii's selection of pre-filled cones feature fair-trade, organic grounds and blends from around the world. By supporting independent farmers and rosters, users are contributing to sustainable economies around the world.
Photo Copyright 2015 Counter Culture Coffee.


To Subscribe,
or Not To Subscribe?
Get 15 vacuum-sealed cones delivered to your door every two weeks with Alii Club. Discover new flavors from around the world, expertly curated to brew perfectly with Alii. Board, or discover your "one true blend"? No worries, you can cancel anytime.
Andrew Balboni, Forrest Sheared
Mindy Magyar, Senior Capstione, RIT
May 2015 - May 2016

Andrew Balboni, Forrest Sheared
Mindy Magyar, Senior Capstione, RIT
May 2015 - May 2016