Disc Deburrer
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Problem:
Disc golf players throw discs across outdoor terrain, where collisions with rough surfaces create cuts along the disc edges called burrs. These burrs irritate players' hands and alter a disc's flight pattern, sometimes rendering it illegal under Professional Disc Golf Association rules. No specialized tool exists for safely removing them, so players resort to sandpaper, knives, or lighters. They are all imprecise methods that leave uneven edges and remove excess material. Our client asked our team to design a safe, low-cost device that removes burrs without compromising the disc's evenly weighted edge.
Initial Idea:
Our initial concept was a handheld tool combining three components: an adjustable deburring blade, a hollow handle for sandpaper storage, and a snap-on safety cover. The defining feature was a worm gear and screw mechanism that would allow users to fine-tune blade depth and handle burrs of varying sizes without removing excess material. However, we eventually removed this feature because the adjustable blade proved impractical in use. A detachable plastic casing molded to the blade's exact shape would enable easy replacement when the blade dulled. We selected a standard household razor blade for availability and chose plastic for the body to balance durability with low cost.
Prototype:
We progressed from low-fidelity prototypes to a 3D-printed functional model, simplifying the worm gear into a fixed 11-degree blade angle that proved more reliable and easier to manufacture. We tested the prototype against criteria covering safety, PDGA compliance, portability, durability, ease of use, and deburring quality, using user-defined 1-to-3 scales for the subjective measures. Testing spanned three disc types: putter, midrange, and driver. The device passed safety and durability checks, but testing revealed that insufficient blade support near the cutting edge could cause the blade to dig deeper than intended.
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Final Design:
The final Deburrinator 3000 is a fully 3D-printed handheld tool made from carbon fiber filament, with a standard replaceable razor blade as the only non-printed part. The device weighs 87.3 grams, fits easily in a disc golf bag, and costs under $5 to manufacture which is well below our $20 target. Its fixed 11-degree blade shaves burrs when the user places it on the disc, tilts slightly, and pulls gently. A ridged hollow handle stores sandpaper, while a sandwich-style casing secured by screws and threaded inserts holds the blade in a precise cutout. A detachable safety cover protects the blade when not in use, and replacement requires only a screwdriver. The final prototype was delivered to the client with an instruction manual.
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