Flipperboard

Meet the Flipperboard—an ingenious tool revolutionizing juggling for individuals with motor limitations. This modular board, equipped with a 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 borders and height adjustments, the Flipperboard ensures an inclusive and enjoyable juggling experience for everyone. Welcome to a new era of accessible and engaging juggling learning.

Tool list:

CNC Machine:

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

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

• Purpose: Used for various cutting tasks.
• Cutting wooden planks to size for the edges of the board.
• Crafting the height adjustment blocks.
• Cutting the wooden rods to size.
• Cutting out the 6 wooden blocks to put under the board.

Oscillating Sander or Dremel Tool:

• Purpose: Employed for creating grooves in the wooden rods for the pins to secure rubber bands and sanding away the supports used during the cnc process.

Wood Glue:

• Purpose: Used to attach the wooden blocks for height adjustments to the Flipperboard.

Drill (Press):

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

Lasercutter:

• Purpose: Cutting out the plates for the ramps.

Screwdriver:

• Purpose: Assembling the ramps.

Materials:

MDF Board (12mm):

• Main material for crafting the board.

Wooden Plank (20x30mm):

• Used for edges and height adjustment blocks.

Wooden Rods (10mm diameter):

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

Rubber Bands:

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

MDF Board (6mm):

• Material for crafting the plates of the ramps.

Screws M6x12

• Used to attach the plates and wooden block of the ramps securely.

Bolts, washers and Nuts M10x80:

• Employed to secure the ramps to the Flipperboard.

Wood Glue:

• Used for gluing small wooden blocks to raise the height of the Flipperboard.

Materials Needed: MDF Board (12mm), CNC Machine

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.

Prepare the MDF Board:

• Secure the 12mm 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 needed for the Flipperboard's customizable setup.

Materials Needed: MDF Board 12mm (for feet), Bandsaw, Wood Glue

Cut MDF Board:

• Use a bandsaw to cut the board into 6 identical squares of 3x3cm. Ensure that the dimensions are consistent for uniformity in board height.

Sand Edges:

• Sand the edges of the wooden blocks to smooth any rough surfaces and create a finished appearance.

Apply Wood Glue:

• Apply wood glue to the bottom of each wooden block.

Attach Blocks to Board:

• Position the wooden blocks under the Flipperboard, distributing them evenly to provide stability. Press each block firmly to adhere it to the board.

Allow for Drying:

• Let the wood glue dry completely. This step is crucial to ensure a strong bond between the wooden blocks and the Flipperboard.

Materials Needed: Wooden Rods (10mm diameter), Bandsaw, Oscillating Sander or Dremel Tool

Prepare Wooden Rods:

• Using a bandsaw, cut the wooden rods into pieces of the desired length. Prepare both short pins for the edges and height-adjusting blocks, as well as longer pieces for the rubber bands.

Create Grooves for Rubber Bands:

• Utilize an oscillating sander or a Dremel tool to carve grooves at the top of each wooden rod. These grooves will serve to secure the rubber bands later in the assembly process.

Sand and Smooth:

• Thoroughly sand the wooden rods to achieve a smooth finish, ensuring there are no rough edges. This step is essential for preventing splinters and ensuring a polished appearance.

Materials Needed: Wooden Plank (20x30m), Wood Glue, Wooden Pins, Drill, Table saw

Cutting the Edges:

• Use a wood cutting tool, such as a bandsaw, to cut the wooden plank (20x30mm) into 2 pieces 130cm long and 1 50cm long that will serve as the edges of the Flipperboard. Ensure they match the dimensions required.

Drill Holes in the Edges:

• Use a drill to create two holes in the bottom of each wooden plank. Ensure the holes are positioned to align with the grid pattern on the MDF board.

Insert Wooden Pins:

• Apply a small amount of wood glue to the holes in the wooden planks, and then insert wooden pins into these holes. The wooden pins should fit snugly.

Attach Edges with Detachable Pins:

• Align the wooden pins on the edges with the existing holes in the MDF board. Press down to secure the edges in place.

Materials Needed: Wooden Plank (20x30x130mm), Bandsaw/Tablesaw, Wood Glue, Wooden Rods (10mm diameter), Drill

Prepare Wooden Plank:

• Use the same wooden plank that was used for the edges (20x30x130mm) to maintain material consistency.

Measure and Mark:

• Measure and mark the desired length for the height adjustment blocks on the wooden plank. Ensure uniformity in size for a balanced adjustment.

Cut Blocks Using Bandsaw:

• Utilize a bandsaw to cut the marked sections from the wooden plank, creating individual height adjustment blocks.

Sand Edges:

• Sand the edges of each block to achieve a smooth finish and remove any rough surfaces.

Drill Holes in Height Adjustment Blocks:

• Use a drill to create two holes in the bottom of each height adjustment block.

Insert Wooden Pins into Blocks:

• Insert the glue into the holes on the bottom of the height adjustment blocks and insert the wooden pins

Allow for Drying:

• Let the wood glue dry completely. This step is crucial for ensuring a strong bond between the wooden pins and the height adjustment blocks.

Materials Needed: MDF Board (6mm), Wooden Blocks, Screws M6x12, Bolts Nuts and Washers M10x80, Drill, Lasercutter, Illustrator Software

Design Ramps:

• Use Illustrator or a similar software to design the shape and dimensions of the ramps. Ensure they are suitable for guiding the ball's controlled motion.

Prepare MDF Board:

• Secure the 6mm MDF board on the lasercutter bed, ensuring it is tightly fixed and ready for precision cutting.

Lasercutting:

• Utilize the lasercutter to cut the designed shapes from the MDF board. This process creates the plates of the ramps.

Prepare Wooden Blocks:

• Make wooden blocks of 6x4x5cm that will serve as spacers between the two plates of each ramp.

Drill Holes in Wooden Blocks:

• Use a drill to create a hole in each wooden block. The holes should align with the holes on the bottom of the Flipperboard.

Assemble Ramp Components:

• Place a wooden block between two lasercut MDF plates, aligning the holes. This creates a space where the ball can roll between the plates.

Secure with Screws:

• Use 4 screws M6x12 per ramp to attach the wooden block to the MDF plates, ensuring a secure and stable assembly.

Attach Ramps to Flipperboard:

• Insert bolts M10x80 through the holes in the Flipperboard and the wooden blocks, securing them with nuts M10x80 on the top side. Place washers between to not damage the wood.This ensures the ramps are securely attached and cannot be easily knocked over.

Adjust Ramp Angle (Optional):

• Adjust the angle of the ramps, influencing the speed and trajectory of the ball.