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Single-Wire Potato Masher: One Length of Wire, No Solder
Wire mashers were made of many pieces soldered together, costly and weak where they joined.
Alanson Brown of Rochester, New York, received US 178,228, dated 6 June 1876, for a potato masher "from a single piece of wire": the middle of the length bent into longitudinal coils that form the bed, its ends crossed under them as transverse lengths, then brought up and twisted together into a shank set in a handle. "These coils and cross-lengths mutually brace and support each other," and "no soldering or other attachment is required."
This rung works out the wire needed, then bends the masher from one length of stainless wire, prints the handle, and mashes a pan of potatoes.
Beginner
About 1 hour, plus printing
Instructions
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One length of wire
One length of wire
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A wire masher before it
A wire masher before it
The embedded blueprint solders five braces to a wire coil. Brown makes the whole masher from one length with no solder.
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Read US 178,228
Read US 178,228
"The object of this invention is to make a potato-masher from a single piece of wire, thereby insuring great cheapness, and so arranged that proper stiffness and strength of the mashing-surface are obtained. To accomplish this I make the coils a a in the center of the length of wire and cross them with the transverse lengths b b. These coils and cross-lengths mutually brace and support each other, and prevent yielding and springing of the coils, which would occur if they alone were used."
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Bend the bed
Bend the bed
Take 1 m of 3 mm stainless wire, about his yard. Starting at its middle, bend six parallel coils 70 mm long and 12 mm apart, working out toward both ends.
Materials for this step:
Stainless Steel Wire1 pieceTools needed:
Round-nose Pliers
Flat-Nose Pliers
Bench Vise
Tape Measure
Leather Work Gloves5
5
Cross and twist
Cross and twist
Bend each end inward and cross it under the coils, bring it up the far side and over the top to the centre. Twist the two ends together for 120 mm as the shank.
Tools needed:
Flat-Nose Pliers
Bench Vise
Leather Work Gloves
Clear Safety Glasses6
6
Fit the handle
Fit the handle
Print the handle (/uploads/blueprints/single-wire-potato-masher-handle.stl). Print in PETG at 0.2 mm layers, 30 % infill, 4 walls; wash before first use. File the shank's end and epoxy it into the handle's bore.
Materials for this step:
PETG Filament1 piece
Two-Part Epoxy1 pieceTools needed:
FDM 3D Printer
Files (Hand File)7
7
The patent drawing
The patent drawing
US 178,228 drawing sheet, public domain (expired patent).

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Cook and mash
Cook and mash
Boil 500 g of potatoes, peeled and quartered, for about 20 minutes until a knife slides in; drain. Mash with the wire masher and time it to no lumps; press hard on one corner and check whether the bed springs.

Materials for this step:
Potatoes1 piece
Water1 pieceTools needed:
Saucepan
Stainless Steel Mixing Bowl (Large)
Stopwatch
Digital Caliper 6-Inch9
9
A bed that springs, a shank that turns
A bed that springs, a shank that turns
Single-wire potato masher troubleshooting.
Flow
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History and honest limits
History and honest limits
**Alanson Brown** of Rochester, New York, filed US 178,228 on 8 November 1875; it is dated 6 June 1876. Wire mashers had usually been made with a volute face stayed by separate pieces united at the handle; his is bent and twisted only. His drawings show modifications with other coil arrangements. He claimed the coils, transverse lengths and twisted shank from a single length of wire.
**Honest limits.** Stainless wire and a printed handle stand in for his. Your times are the result.
Materials
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Tools Required
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