Color Bounce - Remake (CNC)

Meet the Color Bounce - an ingenious tool revolutionizing juggling for individuals with motor limitations. This modular board, equipped with a color grid, pins, rubber bands, and ramps, fosters rhythm and coordination. Its adaptability, from single-person setups to multi-person challenges, caters to all skill levels. With features like adjustable borders and different levels, the Color Bounce ensures an inclusive and enjoyable juggling experience for everyone. Welcome to a new era of accessible and engaging juggling learning.

https://www.youtube.com/watch?v=WV7YDC5eELA

- Tom Thysens, Alexander Tessitoire, Kamiel Theunis, Raf Machtelinckx

Tool list:

CNC Router Machine:

• Purpose: Precision cutting tool for creating the grid pattern and holes on the board.

Wood Cutting Tools (e.g., Bandsaw):

• Cutting the wooden rods to size.

Oscillating Sander or Dremel Tool:

• Purpose: Employed for creating grooves in the wooden rods for the pins to secure rubber bands.

Drill (Press):

• Purpose: For making holes in ramps.

Lasercutter:

• Purpose: Cutting out the plates for the ramps and the templates.

Nail gun:

• Purpose: Assembling the planks with each other.

Pliers:

• To squeeze the elastic cord in place.

Sewing Machine with some threads:

• To sew the tarpaulin.

Clamps:

• To clamp the wood when using wood glue.

3D printer:

• Making the aiming system for the ramps

Extra handtools (e.g. Box cutter, scissors, rotary cutter, pins, ruler, ...):

• Used to make some tweaks and makes it easier to cut certain things.

Grommet pliers + hammer:

• To secure the grommets onto the tarpaulin.

Materials:

MDF Board (1220 mm x 610 mm x 18 mm):

• Main material for crafting the board.

MDF Plank (1220 mm x 610 mm x 12 mm):

• Used to make the inner walls.

Plywood Plank (1220 mm x 610 mm x 3.6 mm):

• Used for finish and strength on the bottom of the main board.

Plywood Plank (1220 mm x 610 mm x 5.5 mm)

• Used for finish and strenght on the outer walls + cut out the ramps.

Extra MDF planks (6x 400 mm x 600 mm x 6 mm)

• Used in the lasercutter to make the templates for the walls and the holes.

Wooden Rods (Ø 10mm, 1000 mm):

• Material for crafting pins that hold rubber bands; cut to size with a bandsaw.

Wooden stick (Ø22 mm):

• Material for crafting the sticks that hold the tarpaulins in place.

Elastic cords (Ø7 mm):

• Used for creating bumpers on the Flipperboard; attached to grooves on the wooden rods.

Elastic cords (Ø3 mm x 3000 mm):

• To secure the tarpaulin to the wooden box.

Wood Glue:

• Used to connect the wooden planks with each other.

Tarpaulin (2x 800 mm x 700 mm):

• Used to cover and protect all parts inside.

Colored Stickers (8x):

• Indicate the different sections of the grid.

Hooks (12x):

• To secure the tarpaulin to the wooden box.

Wire:

• To make a loop in the elastic cords.

Heat shrink:

• To make the elastic bands safer to use.

Vinylspray:

• To spraypaint the symbols and logo onto the tarpaulin.

Materials & Tools needed: MDF Board (18mm), Plywood plank (3.6mm), CNC Machine, 3D printer

Start the 3D printer:

• Start the printer using the .stl files in the attachement (16x the bottom one and 2 times the upper hexagon part).

Lasercutter:

• Laser out the provided icons that later will be used to mark the pouches and letters/numbers on the board.

Design the Grid Pattern:

• Utilize a 3D modeling software to create the desired grid pattern for the Flipperboard. This design will guide the CNC machine during the cutting process (look at the attachement).

Prepare the MDF Board:

• Secure the 18mm MDF board to the CNC machine bed, ensuring it is tightly fixed and ready for precision cutting.

CNC Cutting:

• Initiate the CNC machine to cut the MDF board according to the designed grid pattern. This process will create the holes and cut-outs needed for the Flipperboard's customizable setup.

Glue:

• Use the wood glue to secure the bottom plywood plank to the main board.

3D prints:

• If the glue has dried, put the bottom parts of the 3D prints inside the Ø35 mm holes and make sure it fits right up to the surface.

Stickers:

• As final step of the main board, stick the stickers on the same place as the templates and make sure everything fits together nicely without any gaps. Finally, poke out all the holes of the main board so the pins can slide in.
• Stick the letters and numbers each to one side from A-H and 1-8 underneath the aiming system.

Materials & Tools needed: MDF Plank (1220 mm x 610 mm x 12 mm), Plywood Plank (1220 mm x 610 mm x 5.5 mm), CNC Machine.

Prepare the MDF Board:

• Secure the 18mm MDF plank to the CNC machine bed, ensuring it is tightly fixed and ready for precision cutting.

CNC Cutting:

• Initiate the CNC machine to cut the MDF board according to the designed pattern. This process will create the holes and cut-outs needed for the Flipperboard's customizable setup.
• Use a sanding paper to smooth out the surface.

Outer walls:

• Glue the outer walls onto the main panels with woodglue and put some weights on it to let it dry.

Materials & Tools needed: Wooden Rods (Ø10 mm), Wooden stick (Ø22 mm), Dremel tool/oscillating tool or multitool, wood cutting tools

Cut to Size:

• Saw the wooden rod (Ø10 mm, 1000 mm) into 12 pieces, each 8 mm long.
• For the wooden stick (Ø22 mm), cut 2 pieces, each 590 mm long, to be used as tarpaulin holders.

Cutting Grooves:

• Cut grooves approximately 7 mm deep on both sides of the wooden sticks (Ø22 mm), leaving a 20 mm prominence in the middle. This allows the stick to be twisted and locked in place.

Sanding and finishing:

• Use a bandsaw and a Dremel tool (or multitool) to sand down the rough edges. Make a groove around the entire circumference of the wooden dowels (12x) 8 mm from the top, providing an anchor point for the bands to lock in when setting up the game.

EXTRA: You can spray 2 dovels white so you can use them as the finishline.

Materials & Tools needed: grommets(16x), Tarpaulin (2x 1000 mm x 700 mm), 2 magnet strips, elastic cord (Ø3 mm x 3000 mm), hand tools, Sewing machine and threads, grommet pliers, vinylspray.

Prepare the Tarpaulins:

• Cut the tarpaulin to the appropriate size so the ends meet in the middle of the board. Fold one edge over by approximately 50 mm and sew the two layers together to create a loop for the wooden stick. Repeat this process for both covers. Then, cut out two squares on both ends of the stick (refer to pictures) to ensure the cover fits nicely over the sides.

Attach the grommets:

• Decide on the placement of the grommets, ensuring one is positioned in the middle of the box and one on the side. There should be four grommets on each side of the tarpaulin. Cut out a design you like around the grommets so only these will hang over the box.

Cut the elastic band to the right size:

• Take the elastic cord (Ø3 mm x 3000 mm) and cut it into 4 equal pieces. Make a knot on 1 side and put a little stick with a hole in at the end. String it through the grommets and make a knot at the other end with a little stick aswell so the cord can't fall out.

Magnet Strip:

• Sew the magnet strips to the ends of the tarpaulins so they make perfect contact in the middle.

Pouches:

• Cut out three rectangles, each measuring 500 mm x 200 mm. Fold over the edges to make them stiffer. Fold one side over by about 200 mm and sew the edges together. Finish the top with a strip of velcro to ensure the bag can seal properly. Attach a velcro circle on the backside of the pouches.

Spraypaint:

• Finally, use the templates to spraypaint the logo on the inside of the cover and the icons onto the pouches.

Materials & Tools needed: Elastic cords (Ø7 mm), (steel) wire, heat shrink, hand tools.

Cutting to Size:

• Cut the elastic cords into 6 pieces, each approximately 450 mm in length. Burn the edges to prevent fraying.

Make Closing Loops:

• Wrap wire around both ends of each elastic cord to create loops that fit over the wooden dowels. Ensure the wire is wrapped tightly so the loops stay securely in place.

Apply heat shrink:

• To make it safer to use, apply heat shrink on the wire.

TIP: Use a vise to secure the wire, allowing you to tighten it more effectively.

Materials & Tools needed: Laser cut ramp pieces, nail gun, 3D print (top parts), lasercutter.

Lasercutting:

• Laser out all the parts for the ramps (see attachement) and the icons.

Assembly:

• Position both sides next to each other and place the plate with the hexagon hole at the bottom. Secure these plates together using a nail gun. To ensure stability, place the other plate halfway onto the ramp, ensuring the ball can still pass without touching the piece. Secure this plate with the nail gun as well.

Materials & Tools needed: Wood glue, MITTBACK Ikea trestles, All parts.

Assembly:

• Take the main board and glue both sides onto it. Tighten the assembly using clamps and other objects to hold it in place. Once the glue has dried, place the piece on two trestles. Attach the covers in the predesigned gaps, fill the pouches with the dowels, elastic cords, and playing cards, then put the ramps and balls in place. Finally, close the entire box.
• Make a handle with some leftovers of the tarpaulin and secure it to the bottom of the box to carry it around.

Closing and Transportation:

• Stretch the tarpaulin tightly over the box. Nail the hooks to the bottom of the box, placing each one between two grommets so the elastic cord can easily be hooked over them. Add a handle or carrying strap to the box for easy transportation.

Take a look at the drawings (see attachments) to view the dimensions.

(Only for Woesh)