Nutty Buddy Flex Athletic Cup 运动护裆 by Dosun Shin and Mark Littell

Nutty Buddy Flex Athletic Cup 运动护裆 by Dosun Shin and Mark Littell is a highly esteemed winner of the very prestigious 2017 A' Design Award 铁奖 in 安全服装与个人防护装备设计 Competition Category.

铁防护装备· 2017

Nutty Buddy Flex Athletic Cup 运动护裆

by Dosun Shin and Mark Littell

Client: Battle Sports Science

A' Design Award 铁奖 Winner in 防护装备 Category

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The Design

About Nutty Buddy Flex Athletic Cup 运动护裆

Nutty Buddy Flex 是一款专为男性运动员设计的运动护裆。护裆采用符合人体解剖结构的造型，通过注塑成型工艺制造，由聚碳酸酯外壳与热塑性弹性体包胶层构成。柔软的弹性体边缘沿两侧区域延伸，从而缓冲与皮肤的接触，在身体剧烈运动时提供更为舒适的贴合感。冲击力被有效吸收，并更均匀地分散至耻骨与软组织部位。产品提供三种尺寸，可适配现有的运动裤及运动护身带。

The Recognition

About the A' Design Award 铁奖

Nutty Buddy Flex Athletic Cup 运动护裆是 A' Design Award 铁奖得主，这是授予满足人们对设计精良的创作所期待的专业与工业要求的优良设计的声望认可。铁奖得主展现出其创作者的高超技艺、高度专业化、专家级的理解力和创造能力。预计Nutty Buddy Flex Athletic Cup 运动护裆将成为一件备受推崇、令人钦佩且被珍爱的创作，既实用又创新。这件赢得 A' Design Award 铁奖的设计整合了行业最佳实践，并拥有与专业知识和才华相结合的称职技术特性。Nutty Buddy Flex Athletic Cup 运动护裆因其严谨而受到尊重，旨在提供有助于让世界变得更美好的生活品质改善。

Behind the Design

Press Kit

Credits, team members and technical details provided by the designer.

Unique Properties: The Nutty Buddy Flex is a redesign of the original, anatomically-shaped athletic cup design. The original polycarbonate cup had a thin co-molded soft polymer perimeter edge to cushion the contact between the cup and the skin. The new Flex cup increases the content of the soft polymer edge to include the side areas on the cup, permitting a more comfortable fit during dynamic body movements. This Flex cup redesign absorbs and more evenly distributes impact forces to the pubic bone and soft tissues
Dimensions & Packaging: The cup comes with 3 different sizes.
Hog (small): 6.8x4x2.2 inch, Trophy (medium): 7x4.1x2.4inch, Mongo (large): 7.2x4.3x2.5inch
Tags: Nutty Buddy, Anatomical Cup, Killer Whale Cup
Production Technology: This cup was made by PC injection mold with TPE overmold.
Polycarbonate (Sabic 124R-701) for the cup and Thermoplastic Elastomer (GLS 1040X-1) overmolding for the flex side. OM 1040X-1 is a medical compliant overmolding TPE with very good adhesion to PC or ABS-based plastics.
Design Challenge: After 5 years of use, feedback and surveys, we knew which areas needed improvement. Taking those areas – 1) added comfort 2) more flex 3) increased ventilation 4) greater security of location – and turning them into CAD design was one of the most challenging tasks. At the same time, we needed to maintain structural integrity and superior protection.

In addition, collecting human body data and defining different sizes of cup were a challenge. The head and tale part rubber were pilled off from the cup body after several months of use. The designer added some contacts and punched holes on the over molding part, so the inner and outer rubber were connected together. The tale part was broken by the high impact of water surface from a water ski jumper. The designer added 3 ribs inside of the tale part, and also added circle rings in the center of cup to increase the durability.
Research: The difficult nature of observational research to get the measurements required the development of multiple sized vacuumed formed shells that were used to obtain user size and comfort feedback. Then, the designer collected and organized the human body data from the shell selections based on Large, Medium, and Small. Next, different sizes of prototype models were 3D-printed and tested by users. Again, feedback received from professional baseball players allowed the designer to modify the final shapes and sizes for each cup category.
Inspiration: The redesigned Flex cup continues to follow the anatomically-correct shape of the human male’s anatomy using the design principle of Form Follows Function. The original Nutty Buddy design has been on the market for seven years. Inventor and pitching coach Mark Littell has received feedback from players about possible revisions to the original cup. The Flex redesign is in response to the users’ comments and feedback and to give athletes increased range of motion and added comfort.
Project Duration: The redesign process started in July of 2014 and finished in February of 2015 in Arizona. After the design work, it took 8 months from the start of manufacturing to reach the market.
Operation Flow: The Flex cup high impact resistant polycarbonate material protects the male wearer’s genitals from external impact forces. The soft rubber wing provides cushioning comfort and absorbs any impacts. This cup can be easily installed into existing sport pants and jock straps.
Patents: Patented. Patent No: US 7,004,921. Mark Littell. 2006 & US 7,670,309. Mark Littell. 2010
Team Members: Designer: Professor, Dosun Shin
Designer: Former MLB Player and Pitching Coach, Mark Littell
Image Credits: Professor Dosun Shin, 2017