Some more thoughts. It looks like your design is already 90% there compared to the best commercial ones and in some respects already exceeds them, kudos!
A couple of improvements to the size genetics that I’ve already thought of that might be doable in this project. Just throwing them out there off the top of my head for people to brainstorm on.
1) quick release - it’s a pain to get on and off. maybe some sort of lever that could tension / release tension immediately or at least capture latches for the bars (as opposed to the solid tubes you have to stretch to get into like the size genetics). Both the gripper and the extension bars need this.
2) smaller profile for stealth. The goal would be to be able to wear this with tight pants with the outline not showing anything mechanical.
3) lighter weight. I think both #2 and #3 could be accomplished with some creative use of other materials. if you are looking for 3-5 lbs of tension those steel rods are total overkill from an engineering point of view. I know that cost is another important variable, but if you have a local tap plastics store…
4) tension sets length. most of the designs I’ve seen have a way of detecting tension, but i would like to set the tension and have it automatically go to the right length based on that and continually adjust length to provide the set tension. I accomplish this now by monitoring and adjusting the length of the sizegenetics, but would prefer to set and forget.
5) failsafe release or tension limiter. I notice a lot of times my unit may become overstretched as I move about. #4 and #5 might be contained in the same mechanism, ie set the tension and never go over it, sort of a shock absorber and limiter.
6) better/stable base. this might be accomplished by custom molds, different materials, etc.
10/2010: ~bpe 6.2x4.8, 1/2011: bpe 6.5x5, 2/2011: bpe 6.75x5.1, 3/2011: bpe 7x5.1, 4/2011: bpe 7.25x5.1, 6/2011: bpe 7.38x5.1
My status thread