The Reed Hackathon: From idea to product development

Introduction 

The environmental impact of plastics has increased the need for alternative materials that support sustainable and circular product development. Plastics nowadays are widely used due to their low cost and versatility, but their fossil-based origins and challenges related to recycling and end-of-life management raise significant environmental concerns (European Commission, 2020). 

The Reed hackathon at Arcada UAS was organised as a part of Baltic Reed project, and as an applied learning and innovative process running from September to January. The main goal of the hackathon was to explore how Reed (Phragmites australis), an underutilised natural resource, could be considered as a more sustainable alternative to conventional plastics in product development. 

This blog post is a part of blog series examining different aspects of the Innovate Reed Composite Hackathon at Arcada UAS. While other contributions in the serie focus more specifically on 3 D design, additive manufacturing or sustainability aspects, this blog post concentrates on the hackathon process itself as a method for innovation and early-stage product development.  

The blog post presents the Reed Hackathon as a design-based case, focusing on the practical process from idea generation to digital design and prototyping. The aim is to describe how these stages supported sustainability-oriented product development within the limited timeframe of a hackathon. From research perspective, the hackathon can be viewed as a small-scale innovation environment where early-stage sustainable product development methods can be explored. This case study examines how ideation, digital design, and rapid prototyping contribute to sustainability-oriented product innovation within a constrained development timeframe.  

Background 

Hackathons are becoming increasingly popular in education as intensive learning activities where participants work together to solve real world problems within a limited given timeframe​ (Kayode Oyetade, 2024)​. These activities promote collaboration, creativity, and the real-world application of theoretical knowledge. They are used in engineering and innovation education to replicate early stages of research and development, from idea generation to testing prototypes. Studies show that hackathons enhance student motivation, engagement, and the growth of abilities like critical thinking, problem-solving, and teamwork​ (Arnab Nandi, 2016)​. 

Brusila –Meltovaara (Brusila-Meltovaara, 2026) discusses in a recent innovation blog how hackathons function not only as educational activities but also as innovation platforms that support open innovation and interdisciplinary collaboration. By bringing together students, companies and other stakeholders, hackathons create environments where ideas can be explored through rapid experimentation and co-creation. This collaborative format allows organisations and educational institutions to access diverse expertise and accelerate the development of early-stage innovation concepts. As such, hackathons can act as a bridge between education and innovation ecosystems, enabling participants to work on real sustainability challenges while simultaneously developing practical skills and exploring potential technological solutions.  

One such sustainability challenge addressed through hackathon-based innovation is the environmental condition of the Baltic Sea. Eutrophication of the Baltic Sea is widely recognised as a significant environmental problem in northern Europe, which is majorly caused by human activities​ (GustafssonII, 2025)​. Nutrients such as nitrogen and phosphorus enter the sea through different sources such as agricultural runoff and wastewater discharges. when these nutrients sum up in marine ecosystems, Algae and cyanobacteria grows excessively and when the biomass decompose, oxygen in the water is consumed which leads to hypoxic or anoxic conditions often referred as “dead zones,” where marine organisms cannot survive​ (HELCOM, n.d.)​. Hence, eutrophication is considered one of the major threats to biodiversity which affects water quality, fisheries, and coastal ecosystems. Common reed (Phragmites australis) which grows densely in coastal areas due to a high amount of nutrients level in water. Harvesting these reeds can help to remove some of the extra nutrients from the ecosystem. At the same time, those harvested reeds can be used as a renewable source of raw materials for various applications. 

At the same time, continued reliance and increasing use of fossil-based plastics has created significant environmental problems due to its challenges with recycling, waste management, and long-term environmental persistence​ (Agency, 2021)​. As a result, there is a growing shift towards a circular economy, which encourages waste reduction and the creation of materials using renewable resources. This shift brings new engineering challenges, particularly in the development of alternative materials that can replace conventional plastics in product design and manufacturing. One promising approach is the development of bio-based composites, which combine bio-derived polymers with natural fibers to improve material properties while reducing dependence on fossil resources. For example, polylactic acid (PLA), a biodegradable material made from renewable resources and reinforced with reed biomass can form composite materials with improved strength and reduced dependence on fossil fuels​ (Natalia Kubiak, 2025)​. From an engineering perspective, such materials represent an important research direction for sustainable product development.  

Within this context, the Innovate reed composite Hackathon at Arcada University of Applied Sciences explored the potential of combining PLA with common reed fibers to develop bio-based composite materials for additive manufacturing and sustainable product design. The hackathon therefore served as an experimental environment where environmental challenges, material innovations, and engineering design could be investigated through collaborative prototyping and rapid iteration.  

Methodology: Hackathon as a design-based case study 

The hackathon followed a design-based methodology consisting of ideation, digital design, prototyping, and iteration. This structure enabled the team to explore sustainability-driven product concepts systematically and experimentally. 

Ideation phase 

The ideation phase was based on problem identification through observation of user behaviour, with a specific focus on common challenges in gaming desk setups. Observations showed that accessories such as cup holders, headphone holders, and cable organisers are often used as separate products and are typically made from fossil-based plastics. 

Based on these observations, the ideation goal was defined as reducing material use through functional integration. Rather than creating a new standalone product, the concept aimed to combine multiple functions into a single solution, aligning with circular design principles. 

Digital design phase 

The selected concept was a 3-in-1 desk-mounted holder designed to support a cup, headphones, and cable organisation simultaneously. The product was modelled using SolidWorks, enabling iterative development of geometry, dimensions, and assembly features. 

Digital modelling supported early evaluations of usability, spatial efficiency, and manufacturability at an early stage. From a methodological perspective, CAD functioned as an analytical tool that translated abstract sustainability goals into concrete design decisions. 

Prototyping phase 

Prototyping was used to evaluate the feasibility of the digital design and to explore how different material choices influence product performance and manufacturability. Prototypes were selected to assess aspects such as form, fit, and functional integration, as well as to identify limitations related to material behaviour and design constraints. This phase supported iterative improvement of the concept by identifying design limitations and areas for refinement. 

Prototyping and 3D printing 

Prototyping is an important step in product development, allowing ideas to be tested early, potential problems to be identified, and improvements to be made before full-scale production. It also helps to better understand how a product will look, feel, and function in real use. In this project, prototyping was conducted as part of the hackathon, which provided a hands-on, collaborative learning environment that emphasised iteration, problem-solving, and practical application. To address sustainability challenges, such as reducing plastic use and supporting a circular economy, a bio composite material consisting of 90% PLA and 10% reed fibres was used during the second hackathon stage. A new reed material—fine reed flour—was piloted to produce 3D-printable granules. The fine reed flour is the result of a pelletising process in which chopped or long winter reed is ground and compressed into pellets at Ruokomestarit’s pellet facility. Fine reed particles are removed from the process using airflow to prevent clogging, and this reed flour (< 30 µm) is collected into separate bags. The fine reed flour was extruded with PLA into bio composites by Trifilon, using both 10% and 20% biomass infill. This material was 3D-printed at Arcada Sustainability and Tech Lab. 

In the filament 3D printing stage, the process starts with small-scale prototypes made from PLA using filament 3D printers. Different parts are printed separately at about 40% of the original size, which saves time and material. This stage allows quick checking of the shape, fit, and basic function of components like cups, holders, and twisters. Especially the twister requires careful attention due to its small size and threaded design. Different support materials are also tested to make sure each part works properly and is not damaged by printing. This stage also served as a practical learning step in the hackathon, allowing team members to experiment with designs and identify potential engineering challenges before moving to full-scale production. 

Once the design is confirmed with PLA filament prints, full-size prototypes are made using a granular 3D printing machine. Full-size prototypes were printed using the 90% PLA and 10% reed fibre bio composite, combining sustainability with different structural behaviour compared to standard PLA. Printer settings are adjusted through several rounds of printing, testing, and fine-tuning to achieve the best results. This iterative process reflected the hackathon methodology, where feedback from each prototype informed the next design iteration. The key 3D printing machine parameter settings that were observed during the printing is presented in table 1.  

Table 1. Key parameters for 3 D printing.  

Prototyping is done in multiple rounds. Each version gives feedback that helps improve the design, gradually refining it into the final product. Moving from filament PLA prints to full-size granular 3D printing ensures the design is functional, reliable, and ready for production. Printer settings and design details are adjusted continuously to achieve the best possible results. 

Results  

The outcome of the hackathon was the development of a multifunctional 3-in-1 desk-mounted holder designed for gaming workstations shown in figure 1 The product integrates three functions into one compact structure: a cup holder, a headphone hanger, and a cable organiser. By combining these functions into a single design, the number of separate plastic accessories used on gaming desks can be reduced. This functional integration supports more efficient material use while maintaining usability for everyday setups. 

From an engineering perspective, prototype demonstrated that the integrated structure could support the required functions while maintaining structural stability during testing. The digital design process enabled optimisation of geometry. During prototyping, several iterations were required to ensure that the printed parts maintained dimensional accuracy and sufficient strength, particularly in areas subjected to load such as the cup holder and mounting components.  

The transition of filament-based PLA prototypes to the PLA-reed reinforced bio composite required additional adjustments. These adjustments helped improve print quality and layer adhesion, demonstrating the feasibility of using bio-based composite materials in additive manufacturing for functional product components.  

Insights 

While the results describe what was developed during the hackathon, the insights focus on what the process revealed about early-stage product development. The hackathon provided an opportunity to observe how design decisions, material choices, and manufacturing constraints interact during the initial phases of product development.   

Analysis of the process highlights that early-stage design decisions strongly influence sustainability outcomes. Functional integration, material consideration, and manufacturability were shaped primarily during ideation and digital modelling, before physical prototypes were produced. By integrating multiple functions into a single product, the design aimed to reduce the need of several separate plastics accessories, thereby potentially lowering material consumption. This demonstrate how sustainability considerations can be embedded directly into the conceptual design stage rather than being evaluated only after a product has already been developed.  

Another key insight: the use of CAD modelling tools  

Digital modelling allowed the team to experiment with different geometries, evaluate attachment mechanisms for desk mounting, and identify design limitations before physical prototyping. By adjusting dimensions, testing alternative forms, and analysing assembly constraints in SolidWorks, several design iterations could be explored quickly, improving both functionality and manufacturability of the final concept. 

Finally, the hackathon format itself proved valuable as an innovation method. The intensive and collaborative environment supported fast iteration and knowledge exchange, while also revealing technical and material limitations. Further material testing, optimisation of printing parameters, and long-term evaluation of product performance would be necessary for real-world implementation. These observations highlight how hackathons can function as early-stage innovation environments that generate promising concepts while also identifying areas requiring further research and development.  

Reflection and conclusions 

This blog post highlights  how a hackathon can function as a small-scale research and development environment, where theory, experimentation, and collaboration intersect. The process illustrates both the opportunities and constraints of using bio-based materials within additive manufacturing and product design. 

The hackathon format also provided a different learning experience compared to traditional university courses. Instead of following a fixed assignment structure, the hackathon encouraged rapid experimentation, teamwork, and iterative problem solving. Students were able to test ideas quickly, receive feedback, and improve designs within a short period of time. This hands-on approach helped connect theoretical engineering knowledge with practical design challenges. 

This approach reflects Arcada’s commitment to integrating Research, Development, and Innovation (RDI) into applied learning, showing how structured experimentation and interdisciplinary collaboration can contribute to real-world sustainable solutions. 

A key learning outcome was the importance of treating sustainability not as a final evaluation step, but as a guiding principle embedded throughout the design process. Overall, the Reed Hackathon illustrates how design-based methods, supported by digital tools, can contribute meaningfully to early-stage sustainable product innovation. 

Acknowledgements 

The Innovate Reed-bio composite Hackathon and the work presented in this blog post were partially funded by the Interreg Central Baltic Programme as part of the Baltic Reed project. Additional support was provided through TUF funding for the Circular Economy Principles lecture, which contributed to the educational activities connected to the hackathon. 

The authors would also like to acknowledge Arcada Entrepreneurship Hub (AEH) for their support in enabling the hackathon process. Finally, we extend our sincere thanks to the teachers, colleagues, and staff at Arcada University of Applied Sciences who contributed to organising and supporting the hackathon activities and student learning process.

Co-writers: Hussein El Doukhi, Li Xie, Prakash Regmi and Paula Linderbäck, Principal lecturer in circular economy

​​References 

gency, E. E. (2021). Plastics, the circular economy and Europe’s environment: A priority for action. Copenhagen: Publications Office of the European Union. 

​Arnab Nandi, M. M. (2016). Hackathons as an informal learning platform. Proceedings of the 47th ACM Technical Symposium on Computing Science Education (SIGCSE), (p. 6). 

Brusila-Meltovaara, K. 2026. Hackathons: Bridging Education and Innovations. LAB Pro. Cited and date of citation. Available at https://www.labopen.fi/en/lab-pro/hackathons-bridging-education-and-innovations/

​GustafssonII, L. M. (2025). Waterborne nitrogen and phosphorus inputs and water flow to the baltic sea 1995-2023. helsinki: Helsinki Commission –HELCOM. 

​HELCOM. (n.d.). Eutrophication. Retrieved from HELCOM Baltic Sea Trends: https://helcom.fi/baltic-sea-trends/eut… ;

​Kayode Oyetade, T. Z. (2024, august). Evaluation of the impact of hackathons in education. Retrieved from ResearchGate: https://www.researchgate.net/publicatio… ;

​Natalia Kubiak, B. S. (2025). Sustainable PLA Composites Filled with Poaceae Fibers: Thermal, Structural, and Mechanical Properties. Materials, 21.