D4E1- Redesign- FLIPPERBOARD

THE FLIPPERBOARD is an innovative tool designed to make juggling accessible for individuals with motor limitations. Featuring a customizable grid system, pins, rubber bands, and ramps, it enhances rhythm and coordination by creating structured pathways and dynamic challenges.

With adjustable borders and height settings, the Flipperboard accommodates various physical abilities, making it suitable for solo or group use.

It promotes inclusivity, skill development, and provides a fun, engaging experience for all ages. Ideal for rehabilitation, educational programs, and recreational activities, the Flipperboard opens a new era of accessible and enjoyable juggling learning.

#D4E1 #WOESH #IPO #Howest #Circus

Melike Temel / Toon Van der Gucht / Luca Vervenne

Keep in mind that The FLIPPERBOARD's main body can be made with both a CNC or a LASERCUTTING machine. Though regardless of the makers choice, a lasercutter is still used for the making of the ramps.

Tools:

1.CNC machine or Lasercutting Machine

Used for the production of the board and its holes.

2.Wood Cutting Tools

Crafting the wooden blocks for height.

Crafting the wooden walls.

Crafting the height (slope) adjustment blocks.

Cutting the wooden rods to pins.

3.Oscillating Sander or Dremel Tool:

Creating the groves on the wooden pins, so the rubber bands can stay on the pins easily.

4. Wood Glue

Attaching the wooden blocks for height.

(OPTIONAL) IF used lasercutter for the body:

Gluing the laser cut plates together for the main body.

5.Drill (Press)

For making holes in the edges, height adjusting blocks, and ramps.

6.Lasercutter

Cutting out the plates for the ramps.

Materials:

IF CNC:

Multiplex Populier, 12mm (Main Body)

IF LASERCUTTING MACHINE:

Multiplex Populier (60x120), 9mm, (Main Body)

Multiplex Populier (60x120), 5mm, (Main Body)

Wooden Plank

For wooden walls, height (slope) adjustment blocks, ramps

Wooden Rods (10mm diameter)

For wooden pins

Rubber Bands

Mdf Board, 3mm

For plates of the ramps

Screws

For ramps

Colored Stickers

For a better product language

IF CNC:

Materials Needed

Multiplex Populier (12mm)

CNC Machine

Preparing the MDF Board:

1. Secure the 12 mm Multiplex Populier to the CNC machine bed.

CNC Cutting:

1. Load the designed grid pattern into the CNC machine. (Use the "CNC file.dxf")

2. Initiate the CNC machine to begin cutting the MDF board according to the specified grid pattern. This process will create the holes needed for the Flipperboard's customizable setup with the right depth as the holes are not supposed to go all the way through. The holes' depth is 9mm.

IF LASERCUTTING:

Materials Needed

Popular Multiplex (9mm) & Popular Multiplex (5mm)

Lasercutting Machine

Laser cutting:

1. Use the "Top Plate.ai" file to lasercut Popular Multiplex (9mm).

2. Use the "Bottom Plate.ai" file to lasercut Popular Multiplex (5mm).

IF LASERCUTTING:

Use wood glue put together one top and one bottom plate together.

Use clamps to secure the plates together and leave to dry fully.

Result: Two plates (60cmx60cm) that are each made of one top and one bottom plates.

IF CNC:

Cut the board from the middle.

Result: Two plates (60cmx60cm).

Materials Needed

Sanding machine

Sanding paper

Sand down the edges and the surfaces for a better finish and consistency.

Materials Needed

Piano Hinges (600mm)

Drill

1. Putting on the Hinge:

IF LASERCUT:

Each plate is originally 60 cm x 60 cm but to make sure the plate fits in the machine we brought it down to 58cm x 58cm so the hinge has to be cut 1 cm from both sides.

IF CNC:

Just can align the 60 cm standart piano hinge on the bottom plates.

Align the hinge on the bottom plate. ( if lasercut there is an indicator line that shows where the hinge is supposed to go.)

Use the screws and drill in the hinge.

Materials Needed:

Wooden Plank (21x44mm) (210cm)

Wood Glue

Wooden Pins

Drill

Table Saw

1. Cut Planks:

Use a table saw to cut the wooden plank into two 90cm pieces for the edges of the Flipperboard.

2. Drill Holes:

Drill two holes in the bottom of each plank, ensuring they align with the board's grid pattern.

3. Insert Pins:

Apply wood glue to the holes and insert the wooden pins securely.

4. Attach Walls:

Align the pins with the holes in the board and press down to attach the edges.

Materials Needed:

Stickers

Glue

1. Cut the stickers to size using the lasercutter.

2. Stick the stickers on the board according to the chosen colors.

Materials Needed:

Wooden Plank

Bandsaw/Table Saw

Wood Glue

Wooden Rods (10mm diameter)

Drill



1. Prepare Plank:

Use the same wooden plank as for the edges.

2. Measure and Mark:

Mark the plank for the height adjustment blocks, ensuring uniform size.

3. Cut Blocks:

Cut the marked sections with a bandsaw to create the blocks.

5. Drill Holes:

Drill two holes in the bottom of each block.

6. Insert Pins:

Apply glue to the holes and insert the wooden pins.

7. Allow to Dry:

Let the glue dry completely to secure the pins.

Materials Needed

Wooden Rods (10mm diameter)

Bandsaw

Oscillating Sander or Dremel Tool

1.Cut Wooden Rods:

Use a bandsaw to cut the wooden rods to the required lengths for pins, height-adjusting blocks, and longer pieces for rubber bands.

2. Create Rubber Band Grooves:

Use an oscillating sander or Dremel tool to carve grooves at the top of each rod to hold rubber bands.

3. Sand Smooth:

Sand the rods thoroughly to eliminate rough edges and achieve a smooth finish, preventing splinters and ensuring a clean look.

Materials Needed:

MDF board (3mm)

Wooden Blocks

Screws

Drill

Lasercutter

Illustrator Software

Wood Glue

1. Design Ramps:

Use Illustrator to design the ramps, ensuring they guide the ball effectively.

2. Prepare MDF Board:

Secure the 3mm board on the lasercutter bed.

3. Lasercutting:

Cut the ramp shapes from the board using the lasercutter.

4. Prepare Wooden Blocks:

Cut wooden blocks to use as spacers between ramp plates.

5. Drill Holes:

Drill 3 holes in the wooden blocks, aligning with the Flipperboard's holes.

6. Assemble Ramps:

Sandwich a wooden block between two plywood plates, aligning the holes.

7. Secure with Screws:

Attach the wooden blocks to the plywood plates using screws.

8. Attach to Flipperboard:

Insert a wooden pin through the blocks using wood glue so the ramps can be attached to the flipperboard.

9. Adjust Ramp Angle (Optional):

Modify the ramp angle to control ball speed and trajectory.