Cast Mold for Replacement Rubberpads for Aerobic Step

thingiverse

This project aims to provide a solution for repairing aerobic exercise steppers when rubber pads wear out or are missing, preventing slips and accidents that could damage floors or health. I've struggled to find suitable replacements, but existing options often proved too difficult, small, or unsuitable, leading to excessive slipping. Therefore, I designed my own replacement system from scratch. I created an adapter to insert smaller pads and crafted a custom mold to cast new pads. To produce 13 sets of eight pads each, plus four additional smaller ones, I used Biresin as the casting material from Sika (1404 at one volume part and 1434 at two volume parts). The mold was coated with liquid wax for anti-tack purposes. Through trial and error, I achieved excellent results. For a precise fit, Ø5mm cylindrical dowel pins were used instead of bolts. To cast the pads efficiently, I placed the mold in a vice, securing it moderately. Demolding occurs best after 24 hours, but I expedited the process to achieve a faster production rate, producing 16 main pads and 10 medium pads daily. This project should inspire you to create your own custom replacement pads for Erhard Sport steps, which have proven effective. Good luck with your endeavors!