To create and manufacture the I-assist, we first had to develop the shape. Initially using modeling wax, and then transferring the design to the more stable pollyeurothane plastic, we evolved the shape you see here. To create a testable prototype, we then milled the shape out of solid stainless steel, no mean feet as stainless is rock hard and the shape we had come up with is….as you can see quite curvy and complicated.

The metal prototype was then used by our chiropractors on real patients over a 4 month period, being tweaked here and there along the way until they were totally happy with the final shape.

The next stage was to digitally scan the shape, transfer the ‘real’ design into the virtual world, so that we could use the computer data to CNC machine a die (mould). Up until this point the shape was completely created by hand, and therefore, once transferred to the computer, we took the opportunity to clean up all the radii, curves and surfaces, making the digital tool in effect a perfect interpretation of the free formed shape.

Only when we were completely happy with every aspect of the shape, did we cut the die, machined from a solid block of aluminium.

Casting Stainless Steel requires extremely high temperatures and quite a convoluted manufacture process. Each tool is first individually cast in wax (using the aluminium die), and then the wax master is then repeatedly dipped in ceramic slurry and allowed to air dry. The clay coated wax is then fired to simultaneously harden the ceramic and melt away the wax leaving the ‘I-assist’ shaped cavity, into which molten Stainless Steel is then poured. After natural cooling the ceramic is then broken away to reveal the raw cast tool, which is then shot blasted to remove any casting flash. The tool is then highly polished to a mirror finish, creating a hard exterior skin, before the textured grip detailing is added by bead blast etching with Aluminium Oxide.

It is a skilled, hand made and time consuming process, but it is also the best way to ensure the best results in the best material.