DONKEYCALFRAISE: Concept 1

grabcad

This concept padding system aims to deliver a robust yet aesthetically pleasing design suited for gym environments. The primary clamping mechanism is a tried-and-tested friction cam style, which can be made from various materials including injected molded plastic, cold forged, or CNC machined aluminum. Injection molding offers the most cost-effective manufacturing option. Aluminum parts can be powder coated or anodized for color customization. The clamp accommodates bars ranging from 25mm to 28mm thanks to a modified screw dial system. Pivot joints can use standard off-the-shelf nuts and bolts or custom screws. The back support features a short spine made of chromoly steel tubing with curved ribs, which are padded for comfort. Foam padding can be removed for cleaning purposes. The design allows for easy attachment of the clamp to the back support using a large 9/16" linch pin, enabling tool-free removal and potential future expansion to other support systems. The rib system provides air circulation, reduces surface contact for sweat and germs, and allows for easy adaptation of larger or softer padding. FEA analysis testing was not conducted due to model limitations but the design's strength is expected to suffice based on the cromolly tubing and backbone materials. CAD files are available upon request.