These prototypes were built with Arduino to experiment with how the device would be received in a classroom setting. I based the sound effects on characters from WALL-E and Stars Wars.
We decided it was best to use cast urethane rubber, so when it was time for "real" prototypes I worked in CAD. I made the splints I wanted to try out then made them into negatives.
I used the SLA machine (a rapid prototyper) to make the CAD models into molds to cast rubber into, then poured the splints and tested them out.
As you can see, there were lots of issues to work out, such as fit and wall thickness. Eventually the molds got more complicated with more features to help the splints come out consistently.
The design we settled on was one where the splint rolls over itself to slide onto the finger easily and painlessly. After it is on stiff batons could be inserted to straighten the joint. It was my belief that by shaping the splint in a curve the plastic alone would be enough and we could do without the batons. After I left, that's what they decided to do.
Once I settled on a basic idea I made a prototype for Garrett to try. Of course, the process was full of surprises, especially because this was my biggest building undertaking so far.
I tested this prototype with Garrett, then moved on to the one below, which will become the one he used.
