Adaptive One-Handed Kickboard D4E1

This Instructable explains how to make a modular swimming kickboard designed to support swimmers with limited use of one arm or hand. The project focuses on accessibility, adaptability, and ease of use.

The kickboard was developed to help users maintain a straight and stable swimming position during training. Through its modular design, different attachments can be easily added or removed, allowing the kickboard to be adapted to the specific needs and abilities of each swimmer.

The design is intentionally simple, making it easy to manufacture, customize, and further develop. By providing additional support during swimming exercises, the kickboard helps users train more comfortably and confidently while improving their swimming technique.

This project was developed as part of a student design assignment in collaboration with BOAS (Belgian Organisation for Adapted Swimming), a Belgian organization that promotes and supports adapted swimming for people with disabilities.

Project Team

• Alexandru Ivan (alexandruivan355@gmail.com) – Product Designer

• Berthe Missant (missant.berthe@gmail.com) – Product Designer

• Zeynep Karamete (Karametezeynep@gmail.com) – Product Designer

• Milan Verhulst (milanverhulst3@gmail.com)– Product Designer

• Eva Dornez – Occupational Therapist

• Jade Vandeputte – Occupational Therapist

Tools needed

1. 3D printer
2. Scissors / craft knife
3. Dremel or sandpaper (p120 and p240)
4. Caulking gun
5. Laser cutter

Materials required

1. Sikaflex adhesive (multi-purpose construction adhesive)
2. High-density EVA foam (10 mm)
3. 3D printed parts
4. ABS sheet (3 mm)
5. Super gleu

Materials:

1. High-density EVA foam (10 mm)

Tools:

1. A3 paper with a pattern (you'll find the pattern at the end of this step)
2. siccors or carft knife

The first step consists of cutting out all the parts. For this, you can use the file provided below. Print the shapes on A3 paper and cut them out. These paper templates can then be placed on the EVA foam and used as guides for cutting.

In total, the design consists of three layers of EVA foam that will later be glued together. The number of each template is as follows:

Base shape

TOP: 1x

Middle: 1x

Bottom: 1x

Wings

Wing Small: 6x (left and right side combined)

Wing Middle: 6x (left and right side combined)

Wing Large: 6x (left and right side combined)

These quantities are also indicated on the paper templates to avoid confusion. All parts can be arranged on a single EVA foam sheet measuring 950 × 450 mm.

Materials:

1. ABS sheet ( 3mm)

Tools:

1. Laser cutter
2. Laser cutter files (at the end of this step)

Set aside the EVA foam parts and laser cut the middle component using the provided file. The part is cut from 3 mm ABS sheet.

Tools:

1. 3D printer
2. 3D print files (at the end of this step)

3D print the slide parts that allow the wings to be attached, removed, and swapped to change the board’s shape. Each wing and the base require slide connectors on both sides.

All slide components have the same dimensions, regardless of wing size, to ensure full compatibility between parts. Each slide also includes a small hole where a rectangular 3D-printed locking piece is inserted to keep all materials securely connected.

Required parts:

1. Small wings: 2x (left & right)
2. Middle wings: 2x (left & right)
3. Large wings: 2x (left & right)
4. Base: 2x (left & right)
5. Blank (no wings): 2x

All parts are available in the provided files for 3D printing.

Be sure that the following parameters are set correctly:

1. Top Distance (Z): 0.2 mm
2. Set all objects to Adaptive: 0.50
3. Set Supports to Tree (Auto) and Tree Slim.

Material:

1. ABS sheet
2. 3D printed parts

Tools:

1. Super gleu

Glue the ABS parts into the slots of the 3D printed pieces using super glue. Make sure enough adhesive is applied so the ABS is securely fixed inside the groove.

Also glue the small rectangular locking piece in place. This ensures all parts are properly aligned and firmly connected.

Material:

1. Assembled ABS and 3D printed parts
2. sikaflex gleu

Tools:

1. caulk gun

Use Sikaflex adhesive applied with a caulk gun. Each module is assembled in the same layer structure:

2 layers of EVA foam (top)

1 layer of ABS

1 layer of EVA foam (bottom)

Start with the 3D-printed piece with the ABS already attached as the base. Search the matching parts for each wing type.

Apply a layer of Sikaflex on the ABS surface, then place the correct EVA foam layer on top. Use the rectangular locking piece to ensure proper alignment. Repeat this process for the second foam layer on top and the bottom foam layer underneath, ensuring all layers are securely bonded

ATTENTION: The adhesive needs 24 hours to dry before proceeding to Step 6. Make sure all parts are properly clamped so they can dry correctly and bond securely.

Materials:

1. Assembled parts (final product)

Tools:

1. Sandpaper (p120,p240)
2. Dremel (optional, for handle finishing)

Sand the edges of the assembled parts where needed to create smooth and even edges. Make sure all edges are as even and cleanly finished as possible. Surfaces do not need to be sanded.

The handle can be refined using a Dremel if available, or manually with sandpaper as an alternative.