Maize shelling is essential for maximizing maize productivity and minimizing postharvest losses. In Ethiopia, traditional labor-intensive methods and costly machinery pose significant challenges for small-scale farmers, making these methods impractical due to high costs and complexity. This thesis addresses these issues by designing and analyzing an affordable, solar-powered maize shelling machine tailored to Ethiopian farmers' needs. The primary objective is to design a cost-effective shelling machine that integrates solar power and utilizes locally sourced and recycled materials to improve accessibility and sustainability. This design approach incorporates recycled materials into non-critical components to lower production costs and reduce environmental impact while maintaining functionality and performance. A detailed 3D model of the solar-powered maize shelling machine was created using SolidWorks to ensure that all components meet engineering standards. Detailed analytical and numerical analyses using ANSYS software validated the machine’s efficiency, structural integrity, and performance. The machine features a hopper for maize input, a specially designed shelling disk for effective processing, and a solar power system with a 160 W solar panel, a DC motor, and a 12 V, 18 Ah battery. This setup enhances the machine’s performance and reliability, enabling it to operate efficiently in areas with limited electrical access. The proposed machine offers several benefits, including significant reductions in fuel costs and emissions, the ability to shell maize in remote areas, and a decrease in postharvest losses. Its efficient design speeds up the shelling process, saving time for farmers and allowing them to focus on other essential agricultural tasks. The machine’s reduced reliance on manual labor and fossil fuels makes it particularly suitable for rural areas with limited electricity. The use of locally sourced and recycled materials ensures affordability and ease of maintenance. In conclusion, this research provides a practical and sustainable solution for maize shelling in Ethiopia. The machine’s affordability, efficiency, and eco-friendly design offer substantial benefits to local farmers, enhancing productivity and contributing to sustainable development. The integration of recycled materials and solar power exemplifies an innovative approach to addressing the needs of small-scale farmers while promoting economic and environmental sustainability Keywords: Affordable shelling Machine, Sustainable Design, Local Materials, Solar