Design & prototyping of a safety release mechanism

Computer Numerical Control (CNC) machining was chosen as a production method, due to the relatively low volumes required at this stage. Concepts for the release mechanism were developed and some initial prototyping was carried out in-house using a SLA. These were tested for release force and then used as a guide for verification to develop a Finite Element Analysis (FEA) study. This FEA study allowed Headrite Sports to design an appropriate release force based on a chosen material and its relative flexural modulus and strength (Nylon 6). Further prototypes were built from CNC machining and further testing was completed in-house using tensile testing equipment to verify the functional release force.

The functional prototypes that were verified with testing with 3D CAD, plus 2D drawings with tolerances and material specifications allowed the company to produce a batch of release mechanism components. These release mechanisms were then fitted to the full apparatus which could allow the company to release the product to the market and for further user testing and development.