Foot Guard, Whirlwind Wheelchair

Digitally fabricated vacuum-forming tooling

I built this prototype foot guard for Whirlwind’s cargo trike from a CAD surface which I then interpreted and translated into a cardboard tool to use for vacuum forming several ABS panels. I used Autodesk’s 123D Make to translate the CAD into 2-dimensional slices for laser cutting and putting back together to build the 3D shape. This assembly technique was ideal for vacuum forming due to the rigid but porous properties of cardboard and allowed me to create a rapid prototype that can also be used and tested in the field.

Whirlwind Wheelchair International is a non-profit whose aim is to enable and empower people with disabilities living in the developing world by giving them the tools to reach their full potential while also contributing to the development of the local economy. Visit their website to learn more.