D4E1 - Juggle Trestle V2

#D4E1 #WOESH #IPO #Howest #circus

-The team industrial designers-

Casper De Pauw

Jules De Bie

Kevin Masschelein

In collaboration with Woesh, a circus workshop

Our story

Our team has developed a tool that introduces people to the world of the circus. Suitable for all skill levels, it teaches the art of juggling while enhancing hand-eye coordination. We prioritized strength and stability without compromising on ergonomics and functionality.

Based on the project Juggle Trestle.

Materials

• 2500 x 1250mm 18mm multiplex birch board
• 50 x 200 mm 0,4mm aluminuim sheet
• 2x M10 x 70mm bolts
• 2x M10 wing nuts
• 4x M10 washers
• 2x M4 x 20 bolts
• 2x M4 nuts
• ± 1500mm Ø100mm PVC ventilation pipe
• 5x tennis bals
• 3500mm Ø4mm PP rope
• 2x cord stoppers
• 2x screw hooks
• 2800mm strap with 4 male/female clips
• A bag

Consumables

• Sandpaper

Tools

• CNC milling machine (6mm drill bit)
• Bandsaw
• Drill machine
• Drill of 5mm
• Scissors
• Lighter
• Embroidery machine
• Sewing machine

Find the bill of materials and services at step 4 of this Instructable.

Below, you will find a parts list of the items to mill and the technical drawings.

1. Place the 18mm birch multiplex board on a CNC milling machine and use a 6mm drill bit. (Time estimation: 1 hour) Mill 6x Hook, 4x Foot, 4x Leg_Plank, 2x Circle and 1x Top_Plank to obtain a full tool set.
2. After milling, you need to clean all pieces with sandpaper until you achieve an overall smooth finish and correct assembly.
3. Assemble everything as described in the exploded view. Using 2x M10 x 70mm bolts; 2x M10 wing nuts and 4x M10 washers
4. Drill 5mm holes and apply a 45° chamfer to the 6 hooks as depicted in the technical drawings.

Follow steps and pictures.

Tool Single-ball (2x) and tool Pairs-of-balls (1x)

1. Drill 2x tennis balls with a 5mm drill.
2. Cut PP rope into 2x pieces of 1m length and 1 piece of 1.5m length.
3. At the ends of the rope, tie knots and insert the knots into the balls.
4. With 2x cord stoppers imitate the assembly on the 2nd picture. Through the wooden hook, the cord stopper and then you make a knot
5. For the Pairs-of-balls tool using 2x wooden hooks and 2x screw hooks (close them with the rope in it using pliers)

Tool Pipe (1x)

1. Cut the aluminum sheet in half (25 x 200 mm) and bend it to fit in the ventilation tube. Drill a hole with the mesh of 5mm.
2. Fix the ventilation pipe using 2x M4 x 20 bolts and 2x M4 nuts at the hooks.

Follow steps and pictures (after the presentation pictures)

The transport strap

1. Cut a strap of 600mm long, take a slider and sew it closed.
2. Take a male buckle and pass the strap through it, like on the picture.
3. Pass the end of the strap a second time in the slider. (See picture 3 and 4)
4. Finally sew the strap to the female buckle to close the strap.
5. Repeat this.
6. Now cut a 1600mm long strap.
7. Sew the 2 extremities closed on the 2 first buckle straps.

The bag

To embroider a logo on the bag contact a company or find an embroider machine in a FabLab. Embroider letters aren't difficult but complex logo's are.

Net Price estimation of 1x Juggle Trestle V2

(Attention, these are estimates, prices may vary)

Materials

• 2500 x 1250mm 18mm multiplex birch board - €75,00
• 2x M10 x 70mm bolts - €4,89
• 2x M10 wing nuts - €1,40
• 4x M10 washers - €1,40
• 2x M4 x 20 bolts - €0,15
• 2x M4 nuts - €0,05
• ± 1500mm Ø100mm PVC ventilation pipe - €6,90
• 5x tennis bals - €6,25
• 3500mm Ø4mm PP rope - €2,32
• 2x cord stoppers - €0,25
• 2x screw hooks - €0,50
• 2800mm strap with 4 male/female clips - €3,30
• A bag - €10,48

Consumables

• Sandpaper - €5,00

Tools

• CNC milling by a professional - €70,00
• Bandsaw - /
• Drill machine - /
• Drill of 5mm - /
• Scissors - /
• Lighter - /
• Embroidery machine - /
• Sewing machine - /

Total

€207,89

/ = You can find this tool in a FabLab or at your home. Or doing it by hand.