Design Update
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One of the main motivations for updating the previous design was that I originally needed to bandsaw sharp internal cuts into sheet metal and use a sheet-metal bender for a large number of folds.
After I finished fabricating six copies of the old design, I wanted to make sure that we updated it, to be less labor intensive and bulky.
Once I researching cloth-tension structures, I determined that we probably only needed two sheet metal bends and that curved edges would help ensure that the stretched fabric didn't cave inward. Additionally, I made sure that the design would not require any internal or sharp corner cuts (Although we switched to waterjet cutting, this was very helpful for prototyping)
One of the main motivations for updating the previous design was that I originally needed to bandsaw sharp internal cuts into sheet metal and use a sheet-metal bender for a large number of folds.
After I finished fabricating six copies of the old design, I wanted to make sure that we updated it, to be less labor intensive and bulky.
Once I researching cloth-tension structures, I determined that we probably only needed two sheet metal bends and that curved edges would help ensure that the stretched fabric didn't cave inward. Additionally, I made sure that the design would not require any internal or sharp corner cuts (Although we switched to waterjet cutting, this was very helpful for prototyping)
Pre-Final Thigh Pads
The version you see below is somewhat difficult to tighten because the pull strap is a little short. The versions we sent out had longer pull tabs to aid with tightening. While I'm still proud of the design, I think it would heavily benefit from printed explanation text or images, because without having seen it stretched, it isn't self-apparent how to set it up.
