CUSHION PROTOTYPE CREATION
SUPPLIES
- TRANSPARENT VIYNL
- ALPACA FIBERS
- OPEN CELL FOAM
- 3/8” FELT
- HOT GLUE GUN
- EXACTO KNIFE
To make my prototype I first cut a 3”x 3” square of the felt pad to get the base of my cushioning system. I had some 3/8” acoustic felt paneling, so this is what I used for the prototype but in the actual system the felt pad should be made from alpaca fibers and dense, but just soft enough to contribute to attenuation.
Next, I created the transparent tubes from a foggy transparent vinyl that I had. I cut each pice to be 3”x3” and sewed the tube using white thread. While this was the only type of material I had that could resemble what I was going for, ideally if manufactured, to stay eco friendly could use a recycled material or a look alike made form cellulosic materials.
Using alpaca fibers cut from an old alpaca seat cushion I stuffed the tube to a desired fill amount. I then repeated this process with the two other tubes.
The amount of fiber fill and how it interacts with the felt pad underneath is is what is giving the impact attenuation. The fill amount and felt pad density would need to be thoroughly tested to determine the best options. With my design idea, the amount of fill could vary per tube giving a zoned support structure to areas of the foot that will create higher forces. The tubes also do not need to be linear but could also curve along the foot natural shape. Diagram of peak force locations on the foot during stride shown blow.
Next I needed to finish the sides and glue all of the pieces together. In manufacturing, the tubes could be closed objects in their own that may not need side finishing. I felt that it would be a cool feature to see these natural fiber shoes. I also thought that a rubber dip that wraps around the sides of the tubes to show their shape could be cool too. However, with building this prototype I knew it needed to be finished off so I stuck with a more solid material using an open cell foam that visually resembled a recycled rubber material. I cut thin strips 3” long.
The final step was gluing all of the elements together.
THE PROTOTYPE
TECHNICAL SPECS
