How can this be done?

[Pete123]

I have a friend that is an inventor.  She needs to develop some prototypes and has found the cost to be prohibitive.

 

I’ll bet some folks here would have ideas on how she can achieve what is needed and would appreciate any input. 

 

The first two pictures show a green material which has velcro on the bottom.  She purchases the green material and knows how to form it to the needed shape.  She needs a filler material so that it won’t collapse when pressure is applied. I thought about plaster, though there may be something better.

 

The amount of pressure it has to withstand is what a person can apply to it.

 

This part of the project is pretty straight forward.  Once she determines the needed shape and size, she needs a more sturdy and professional solution to provide to prospective customers, which you can see in the third and fourth pictures.

 

The device in the pictures shown was prepared professionally and was expensive.  While I don’t know the solution, I have to think that is some kind of plastic material where she can form it using heat or some kind of solvent which will then meet the requirements outlined above. 

 

Any input would be greatly appreciated!

 

[vontar]

would it be just for a mock up?

 

Make Form Rubber (would be soft but could hold shape with out much pressure).

 

If it needs to be a little stronger, not much maybe carve from balsa wood blocks.  If my memory from when I was a cub scout is right,  it was very easy to work with.

Edited January 7, 2016 by vontar

[MacGyver]

I'd 3D print it setting the fill at some lower percentage to make it strong enough, but also speed up production.

[vontar]

I thought 3D printing but thought it might be outside the budget.   But cost is coming down in that area.

 

Thinking in that directions.  There are some online companies that 3D print to order for prototypes.  I don't know the cost involved though.

[Pete123]

Great input - thanks.

 

The form rubber and balsa wood aren't strong enough for the amount of pressure that will be applied.

 

3D printing would potentially be a great solution, though how would she tell the printer what to print?  She isn't set up to use CAD/CAM type software.  I would think that telling the printer how to print what is effectively a little mountain, where the height, angles, etc...  all have to be exact.

 

Does anyone have ideas on how to achieve this with things she can purchase at Home Depot or somewhere similar?

[gjohnsoniv]

Might be able to link up with some of the maker spaces that have all that equipment already. Not sure if there are any in the area or not though.

[Possumslayer]

Double boiler melt some Teflon washers .....may be able tooo get into a decent shape before hardening .....
Walk around hobby lobby the have wood balls made of pine....

[peejman]

Use Great Stuff for the filler.

[gunwhatgun]

The product you are looking for is called Instamorph. It was developed for prototyping and very easy to work with.

[gregintenn]

Anybody besides me wonder what the hell this is? :wave:

[Pete123]

This is all great info - thanks.

 

Greg, I agreed that I wouldn't say what it's for as she's still working on the patent.

[Trekbike]

Anybody besides me wonder what the hell this is? :wave:

I think I saw one of those one time late at night on HBO...

[Jeb48]

Didn't completely follow what all she needs but the last two photos reminded me of some plastic stuff that they use for making custom braces for arms, backs and such. It is white and comes in sheets. They put it in hot water and it becomes very bendable and can be formed into the shape you want then it hardens when it starts to cool. Very strong and stiff. If it isn't right, just put back in hot water and adjust shape.

[gregintenn]

This is all great info - thanks.

 

Greg, I agreed that I wouldn't say what it's for as she's still working on the patent.

I figured as much, but I can't help but wonder. I've got nothing so far.

[peejman]

How thick does the filler material need to be?   Fill up the whole inside of that ball?  Will it always be the same size?

 

How firm does it need to be?  A little give, no give? 

 

 

There's all kinds of types of foam that could be used as filler.  I was serious with the Great Stuff suggestion (because it really is great stuff  ;)  ).   She could get various types of foam and glue layers together and then shave it down to the desire shape/size.  Could even use different types/densities to control how much and where it gives, if that matters. 

 

http://www.mcmaster.com/#standard-foam-sheets/=10lhzd8

[E4 No More]

Didn't completely follow what all she needs but the last two photos reminded me of some plastic stuff that they use for making custom braces for arms, backs and such. It is white and comes in sheets. They put it in hot water and it becomes very bendable and can be formed into the shape you want then it hardens when it starts to cool. Very strong and stiff. If it isn't right, just put back in hot water and adjust shape.

I actually had some forearm/wrist braces made for me with that stuff. The physical therapist did it to help support my forearms while performing curls.

[Pete123]

Awesome, thanks for the additional input

[No_0ne]

Didn't completely follow what all she needs but the last two photos reminded me of some plastic stuff that they use for making custom braces for arms, backs and such. It is white and comes in sheets. They put it in hot water and it becomes very bendable and can be formed into the shape you want then it hardens when it starts to cool. Very strong and stiff. If it isn't right, just put back in hot water and adjust shape.

 

The type of this I order is called PlastiForm, both medical supply and athletic training sites stock it ...