Instructable

Our product is finished. If you want to make your, own check this link:

https://www.instructables.com/id/BikeAid/

Thank you!

Prototype 13

Prototype 13

So, taking into account the conclusions from last prototype, we started creating a mold for the silicone. We laser cut plexy glass with the same shape and size of the 3D print pattern. And we poured the silicone there.

About the 3D print, we changed it, deleting the part of the connection and creating a space to assembly the metal part. We made some holes there and we assembly it.

The silicone was difficult to get out of the mold and we had to cut the borders of the hexagones to be able to assembly it.

After puting the velcro straps we went to test it with Sander and the biggest problem was that the connection was too small so it could not fit in his bike; so we decided to take off the rubber part to be able to test it. 

+	–
The strength is okay	The silicone part must be changed
	the support must be more in the front (change the CAD model).
	To big connection to the bike

Prototype 12

Prototype 12

After prototype 11 we reached some conclusions as it can be seen in the previous post, so we decided to change a little bit the 3D printed part. We made the thickness double, 4 mm concretely. Also, we made the cylinder stronger, so we made it thicker too and added some material and edge blends.

Even if the product was stronger this way, we saw that is not enough. We need a stronger connection to the bike, and the PLA is not a good option.

+	–
Lot of support	Still weal connection to the bike
Easy to slide of the handlebar	Still not enough room for silicone
Adjustable to every hand	To big connection to the bike

So, for the next prototype, the most important aspect to have into account is that we must make a stronger connection to avoid break. Also, we decided to pour the silicone all over the 3D print, and not just in the middle part. Another conclusion was, that the holes for the straps must be bigger, and they must have more material around to make it stronger.

Prototype 11

Prototype 11

In the prototype 9 we made a cast out of fiberglass and polyester. The client liked this, but would really like to use silicone because of the way this feels. In prototype 10 we tried to make a glove out of the silicone by making a mold of his hand and pouring in the silicone. This was too complicated so we decided to combine the two.

We used the principle of the fiberglass, but we decided to 3D print it. We found out that PLA can be molded when heated. This is ideal, because every person can mold it to his or her hand. 

+	–
Lot of support	Too thin
Easy to slide of the handlebar	Not enough room for silicone
Adjustable to every hand

Next steps:

Make a new, thicker and more sturdy print

Make more room for the silicone

Make a parametric slide for the handlebar, different widths

Prototype 10

Prototype 10

After the feedback from prototype 9 we reached different conclusions with Sander. 

1) Firstly, we should make the whole shell with a soft material (similar to the silicone). 

2) It will be interesting to create a one piece product, casting the silicone with the attaching parts. 

Sander was interested in the next steps, so we decided to work together with him in the Atelier. This way, he could see the next steps we were going to take and give us feedback at the moment. 

Thanks to this, we saw that he likes the idea of having a one piece part attached to his arm and the possibility of attaching it to the bike and taking it off.

Then, we decided to make a mould of his arm to have the exact shape.

To make the one piece shell, we thought about different options. 

1) Casting the whole shell with silicone

+	-
The whole shell will have the same feeling, and Sander likes it.	The shell will not have a strong structure.
Thanks to the elasticity, there is no need of a closing system.	Depending on the type of silicone, the price may increase.
We could use the exact measures of his arms by using the mold.	It will be difficult to cast the silicone together with the attaching system.
We could create a shell with a stronger material and then cast the silicone in it, making it much stronger.

2) 3D printing the shell in a rubber material

+	-
The shell will have a strong structure.	The material is flexible but not soft enough (not the feeling that Sander likes).
Thanks to the elasticity, there is no need of a closing system.	The connection with the attaching system will have to be different.
We could use the exact measures of his arms by using the mold as a reference to model it in CAD/CAM.	It would be more difficult to respect all the measures when modeling.
Possibility of adding another material to make it softer.

3) Contacting a prothesis company

When the concept was defined this way, we thought about the possibility of contacting a prothesis company to help us develop the concept. This way, we found that the company Aqtor! was interested in our project.
So, we are making an appointment to meet them to discuss about it and see which options we have.



Company link: https://nl.aqtor.be/?SID=oeuukstk5tebkn6e2uqg2epaq2

Results of the mold:

Once the silicone mold was cured, we poured the plaster in.

Now we have an exact replica of his hand.

Prototype 9 & protomorphing

Prototype 9

With this prototype we try to use the best options tested. So, we used the sliding system to attach it to the handlebar and a strap to make it stable. As we had different aspects to test, we decided to make this prototype protomorphable.

This way, we created to different shell shapes, one smaller than the other:

We created three different straps:

Silicone

Silicone

Strap and silicone

And we used the connection to the handlebar that he liked most but we also tried two different lengths, that way he can test his reaction when taking his arm off.

----------------------------------------------------------------------------------------------------------------

+	–
Shell shape; smaller, big enough to be comfortable, but still safe feeling	Shell shape; bigger prototype too big
Strap; silicone feels good, also no closing system needed	Shell shape; sharp edges, should be more rounded
Attaching system; easy to connect	Attaching system; small one too small, left side of the slide should be closed