D4E1 - DIY - Assistive Technology - Boccia Aid

Manolito had a brain stigma infarct and is half-sided paralysed as a result. His hobby is playing boccia and he would like an aid to put in bocciaballs. From the beginning he played boccia with 6 balls between his left arm and his body. Now, as he wants to play competition, he would like something where he doen't need to do this anymore as this is very "not comfortable".
And from now on he doesn't have to do that anymore.

The Boccia aid is a product made for Manolito and Kris. We, a productdesigner and two ergotherapists have been searching for a solution for him. We wanted an aid that is easy in use and strong enough to hold 6 to 7 balls.

In the first step we explain wich materials and tools are used.

Materials:

• 1 panel of Multiplex (600 mm x 450 mm x 8 mm)
• 1 Metal tube with outer Ø20 mm
• 6 nails
• 2 x M5 nuts
• 2 x M5x40mm bolts with countersink head
• 1 x M5 pallet nut (see picture)
• 1 x M5x30mm bolt with countersink head

Tools:

• Lasercutter
  We used the lasercutter for fast results. You can search for a lasercutter on the website from a Fablab nearby you. Fablab worldwide

• Metal saw
  We used an electric metal saw, but a common metal saw is well enough.
• Hammer
• Wood glue
  Wood glue is ideal for multiplex.

• Metal drill Ø5 mm
  
• Wood drill Ø6,5 mm

• Countersink 45°
  We used the countersink for the nuts with the countersunk head. The head of the nuts will be sunken in the wood to avoid damage to Bocciaballs later on.

• Ruler

• A pen or pencil

• Pillar type drilling machine or an accu drilling machine

The lasercutter is used to create the different parts in multiplex.

Lasercut files for multiplex:

The files are for creating the base for the whole aid. The aid is designed so the parts fit perfectly together.

The different parts can't be placed wrong, it's an easy jigsawpuzzle.

The files are available in various formats:

• Illustrator (editable)
• PDF

Remarks:

• When you use the illustrator file, you can edit if you want. You can change the width or the length as desired. We tested and changed our first prototypes and now the dimensions on this file are perfect for our customers.
• When you change the heigth or the width, take into account the distance from the parts will also change.

Cutting the metal tube:

Cut the metal tube on the lenght of 480mm.
You can cut it with an electric or with a common metal saw.

DRILLING TWO HOLES

Prepare before drilling:

Before you drill the two holes you need to be sure that the two holes are on the same line at the round tube.

1. Draw a straight line on the top of the tube.
2. Mark a point at 2 cm from the end on the line.
3. Mark a second point at 9 cm from the first mark.

Prepare drilling:

1. Take a metaldrill Ø5 mm.

We used a pillar type drilling machine, because it's more stable than an accu hand drilling machine.

Drilling:

Be sure to fix the tube very firm so doesn't roll during your work. Drill the two holes you marked earlier. You have to drill trough the whole tube.

Glue the parts together.
Be sure you place the parts on the right place and in the right direction. (as seen in the pictures)

1. The longest side needs to be placed on the longest side on the plate.
2. The part with the round corner needs to be on the opposite side.
3. The last part needs to fit between these previous parts.
4. put glue where the two parts come togheter.

After you glued take some clamp to keep the parts in the right place.

Let it dry for an hour.
Take away the clamps.

If you want a realy strong and durable aid you can use nails.

1. Mark on the bottom 6 different spots for nails.
2. Put the nails in the multiplex.
   Keep in mind that if the nail is hammerd in crooked, it will appear on the outside from the wood. This is dangerous for injuries.

DRILLING TWO HOLES for the tube

Prepare before drilling:

Before you drill the two holes you need to be sure that the two holes are on the same line.

1. Mark a straight line at 2 cm from the middle of the plate.
2. Mark a point in the middle of the 2 circles on the line.
3. Mark a second point at 9 cm from the first mark.

Prepare drilling:

1. Take a drill with Ø5 mm.

We used a pillar type drilling machine, but a accu drilling machine also works for wood.

Drilling:

Drill the two holes you marked earlier. You have to drill trough the plate.

DRILLING ONE HOLE for the little plate

Prepare before drilling:

Before you drill the hole you need to be sure that the pallet nut fits on the little part. (see picture)

Mark a point on the plate. (see picture)

Prepare drilling:

Take a drill with Ø5 mm.
We used a pillar type drilling machine, but a accu drilling machine also works.

Drilling:

Drill the hole you marked earlier. You have to drill trough the plate.

DRILLING ONE HOLE in the little plate

Prepare before drilling:

1. Mark a point on the plate.
   keep in mind: the hole in the big plate has to be straight above the hole you are going to drill in the little part (see picture)

Prepare drilling:

Take a drill with Ø6,5 mm.
We used a pillar type drilling machine, but a accu drilling machine also works.

Drilling:

Drill the hole you marked earlier. You have to drill trough the plate.

Before you can assemblage the tube you need to do one step more.

For the aid we will use two bolts with a countersink head. It will give no dammage to the bocciaballs.

1. Take the accu drill and place Countersink with 45° on it.
2. Make a chamfer from 45° on the 3 holes in your big multiplex box.
3. When you are not sure if it's 45° place a bolt on that place.

This is an optional step. You can do it if you want.

For a durable aid we finished the wood with matt varnish.
Let the varnish dry on the first side. When it's dry you can start with the other side.

All steps are documented in the pictures.

1. Take the little part and put the pallet nut in the wood with a hammer.
2. Place the bolt M5x30mm in the hole and turn it around until the little part is fixed. You may need a screwdriver.
3. Take two bolts M5x40mm and place it through the two holes in the multiplex.
4. Slide the tube on the other side on the two bolts.
5. Put two nuts on the bolts.

It's finished!