One of the projects I worked on while at EPE was a golf club cover concept to replace traditional socks marketed towards older golfers who find it difficult to use due to strain/arthritis after hours on the golf course.

This concept is pressure molded from a high density foam for light weight but durable material and a hinge system which would allow a quick spring back, but gentle opening mechanism acutated by cupping the back and gently pinching to open. The opening would allow the user to simply slide the club into the clamshell while open and spring tension closing in one motion.

The biggest challenges were figuring out the correct amount of tension needed to fully secure the club inside holder but not be too tight as to cause fatigue or be too difficult to pinch open. The other problem was figuring out a parting line that would follow the form language but also allow the club to slide into the holder without causing undercuts during manufacturing.

To solve this problem I utilized Rhino Sub-D surfacing to be able to “sculpt” the parting line while being able to evaulate the draft angle. I started working through some sketches to try and solve 3 problems from the beginning:

Making sure the club can freely slide in and out of the holder with enough gap to slide open the shaft part of the holder without any interference.

Making sure keyways around the lip of the holder engage without issue as to prevent from sliding side to side once closed.

Maintaining a minimum 6mm wall thickness that will give a balance of strength without making the outershell so thick that it becomes less ergonomic and overly bulky.