Sports Use Prototype Chair - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Day Use Prototype Chair - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Day Use Rendering - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Basketball Use Rendering - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Tennis Use Rendering - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Track Use Rendering - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Details of Adjustment Casting - A fully adjustable youth wheelchair that can quickly convert from daily use to sports use. It's unique design allows it to qualify for government funding grants for daily use wheelchairs, but also allows youth access to sport they may otherwise be unable to have.
Research into Adaptive Sports - User research was conducted focusing on those living with disabilities who are engaged in adaptive sports. Games were visited and participants interviewed to determine how sport impacted their lives and how their equipment functioned. Multiple interviews with the owner of a local wheelchair distributor were performed to understand how the industry functioned, how existing technology and designs both helped and hindered users, and insight on how to improve current products.
Initial Conceptualization - After concepts were ideated on paper, quick CAD "sketches" were done in Rhino 3D to determine the range of motion of certain mechanisms. Initial design concepts focused on ways a wheelchair could be adapted to maximize an athlete's performance potential. A chair that was fully adjustable, much like the suspension on a sports car, was envisioned. Continued refinement of the design saw it evolve into a chair for youth; one that could convert between various sports uses.
Plywood Testing Mock Up - A plywood test rig was constructed to gain insight into proper positioning of the chairs centre of gravity and the range of adjustment required. Various volunteers were asked to ride the chair and measurements of its stability and COG were taken.
Plywood Testing Mock Up - Aluminum blocks were machined that allowed the wheels to be cambered, the hallmark of a highly manoeuvrable sports chair. Additional tests to determine the overall optimal centre of gravity of the chair were performed.
SolidWorks Development - SolidWorks was employed to develop the wheelchair for mass production. Advanced surfacing techniques were used to ensure C2 curvature continuity across the entire frame. Draft analysis was performed on all parts, to make sure that a clean parting line for die casting operations could be established. SolidWorks Simulation was employed to perform FEA analysis on the wheelchair. Various casting alloys were tested, with AA380.0-F chosen. The design has been tested to withstand 600lbs of weight.
Completed Chair in SolidWorks - The full wheelchair was built in SolidWorks. Clearances were tested, fasteners chosen, and final design decisions made. Having a rigorous CAD model greatly helped in the manufacturing of the first prototype.
Detail of SolidWorks Manufacturing Model
Exploded assembly drawings and detailed Bill of Materials were used throughout the prototyping process as a way to organize parts being machined and off the shelf components that needed to be purchased.
Casting of Prototype Parts - Die casting a single prototype would be unfeasible. Lost styrene foam sand casting was an economical way to manufacture the first prototype. Styrene foam copies of the frame design were cut on a CNC machine. They were then assembled into completed mold cores. The styrene cores were packed in casting sand, and sprues were made to facilitate pouring and proper cooling.
Machining of Prototype Parts - Numerous machining operations were performed on the rough castings, in order to ensure clean mating surfaces of the various parts. Other components were also machined by hand from 6061 aluminum billet. After manufacturing of the parts was completed, assembly was quick and easy thanks to the previously completed SolidWorks model detailing all required steps and fasteners.
Overlay Rendering of Camber Adjustment
Track Use Rendering
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