How are bendy straws created?

Some inventions may appear to be simple at first glance, but beneath their simplicity lies a complex web of engineering. Consider the self-balancing unicycle, for example. It looks easy to design a wheel that stays upright, but try it yourself and you’ll quickly realize that you’re not just dealing with a wheel—you’re facing the forces of physics and technology.

The bendy straw, however, is not one of those deceptively intricate creations. It is, in truth, remarkably straightforward.

A straw that can bend or flex, forming that familiar upside-down L shape which is far more enjoyable to sip from than a straight straw, is created with surprising ease. But don’t be deceived by its simplicity—sometimes, it’s the straightforwardness of an invention that makes it even more impressive and cool.

Let’s begin with a bit of history about straws. While we may never know who first thought to add a bit of fun to drinking by sucking liquid through a tube, the earliest known use of straws was found in a Sumerian tomb, dating back to about 3000 B.C. [source: Thompson]. Through history, people crafted straws from all sorts of materials, from paper to gold. It wasn’t until the 1880s in Washington, D.C., that Marvin Stone grew tired of the brittle, easily damaged ryegrass straws popular at the time and patented a more durable solution made from wax paper.

However, it was Joseph Friedman, an inventor from San Francisco, who truly revolutionized the straw by adding a bend to it. His motivation? To help his young daughter, who had trouble reaching her milkshake at the soda-fountain counter in the 1930s. In a remarkably simple yet genius move, Friedman took a paper straw, inserted a screw about a third of the way down, wrapped dental floss around it, and created indentations by pulling the screw out. The result was an accordion-like pattern that allowed the straw to bend, making it easier for his daughter to drink. He later patented and began producing this clever creation.

Yes, it really was that easy. But let’s take a closer look at how modern flexible straws—and their many variations—are made today.

Bend It Like Friedman

Wax paper straws are now largely a thing of the past. Nowadays, plastic is the primary material for straws. The process begins with melting a plastic resin powder, which is often mixed with colorants, and forming it into pellets (which are easier to mold than the raw powder). These pellets are then dried and cooled, before being heated to about 500°F (260°C) to melt into a liquid. This liquid resin is then extruded into a long tube, pushed through by a device called a 'puller,' which helps maintain the straw's shape as it undergoes a cooling water bath.

Crazy straws—those whimsical designs with loops and twists resembling a roller coaster—are shaped using molding equipment before taking their cooling bath.

Flexible straws, with their signature accordion-like bend, are made through a slightly different process. After they are cooled and cut, the straws are placed in trays with individual slots. Pins with ring-like grooves are inserted into the straws, and these pins guide them into parallel jaws, which clamp down on the neck of the straw. This clamping action creates the characteristic corrugation of flexible straws, without sealing them shut. The straws are then ready to be packaged.

The straw industry is accelerating rapidly; in 2010, Tetra Pak Tubex in Virginia produced around 4 billion straws and was looking to further boost production speed [source: Blackwell]. However, there is also growing interest in alternatives to plastic straws. Metal and bamboo straws are now common, as well as bent glass straws, which are likely shaped when heated. Just be careful not to try to bend a glass straw back and forth, unless you're hoping to shatter it.

For a truly nostalgic touch, you could even craft your own wax paper straws. All you need is a screw and some dental floss, and voilà—your very own piece of American ingenuity.