Design Case Study
Development of child’s mini hurl
Company Name: Loca Hurl Ltd
Funding Source & Value: 2 x 5k innovation vouchers
Profile of Company:
Loca Hurl is a start up company with a strong focus on developing hurls specifically designed to accommodate the physical characteristics of junior players.
Problem to Be Solved
In Ireland, children typically begin learning the essential skills of hurling in junior infants, which includes fundamental actions such as picking up and striking the sliotar. However, teacher Robert Murray observed that many young players were using hurls that were disproportionately large for their size. This mismatch in equipment not only hindered their ability to learn proper techniques but also led to poor form due to the need to compensate for the weight and size of the hurls. The repercussions of this issue extend beyond skill development, as improper handling can result in injuries and, ultimately, frustration that may deter children from pursuing the sport altogether. Addressing this concern is crucial to ensure that young players can acquire the foundational skills necessary for successful and safe participation in hurling.
How APT Delivered a Solution for Loca Hurl Ltd
Robert met with Gavin from the Applied Polymer Technology Gateway (APT) at the TUS Athlone campus to address the significant challenges faced by young hurlers. During this meeting, Robert presented his preliminary research findings, showcasing prototypes he had developed at home using repurposed hurls, which he tested at his local GGA club grounds in St. Thomas.
In the context of Voucher 1, they discussed various strategies to create a line of age-appropriate hurls specifically designed to accommodate the physical characteristics of junior players. An iterative design process was employed to develop detailed CAD models, facilitating thorough review and discussion..
Alongside the development of the mini hurl, colour-coordinated graphics were designed to assist in educating children on proper hand placement and hurl orientation..
The timeframe of Voucher 1 allowed for three design iterations to be evaluated before the overall design was approved for functional prototyping at scale, leveraging the advanced capabilities of the in-house HP Multi Jet Fusion 3D printer..
Loca Hurl successfully secured a second voucher to finalize the prototype for mass production. After a summer of testing the initial prototype, Robert identified several minor adjustments that could significantly enhance skill development using the mini hurl. A final prototype incorporating user feedback from Loca Hurl trials was fabricated, complete with updated graphics..
Upon approval of the prototype by Loca Hurl, the final stages of the project focused on identifying an Irish manufacturing partner to produce lightweight injection-moulded hurls with varying wall thicknesses, utilizing novel moulding techniques to achieve an optimal balance between functionality and weight. The project handover included the revised functional and scaled prototype, a comprehensive materials report, all iterations of Adobe Illustrator graphics, 2D production and IP drawings for manufacturing and patent purposes, as well as 3D universal CAD files for production and prototyping..
Impact for the Company
Throughout the collaboration with the APT design and engineering team, Loca Hurl accessed specialized expertise in polymer product design, material testing, and characterization, as well as advanced 3D printing and manufacturing facilities. This partnership allowed Loca Hurl to significantly reduce development time and costs through a streamlined iterative design process. Polymer scientists supported the selection of suitable polymers that optimized both performance and cost efficiency. The state-of-the-art 3D printing facilities enabled full-scale functional prototyping in-house, ensuring a secure investment in tooling prior to mass production. Moreover, this collaboration facilitated a smooth transition from prototype development to large-scale manufacturing with Irish partners. Overall, the process represented a substantial learning curve in product design, polymer materials, and manufacturing for Loca Hurl, greatly enhancing their capabilities and industry knowledge.
Company Testimonial
"When I decided to pursue my business idea, I had no knowledge of where to go or what skills would be needed. After a call to my Local Enterprise Office, they put me in touch with Gavin at TUS and things really took off from there. Gavin helped me in gaining 2 innovation vouchers from Enterprise Ireland and my hurley product went from idea to prototype to design to factory manufacture in no time. Gavin was always helpful, understanding and professional throughout the process and provided me with lots of support and guidance. Since passing on the project to manufacturing, Gavin still shows a keen interest in how the business is progressing. It was an absolute pleasure to work with Gavin and his team."
Robert Murray, LOCA Hurl Ltd
