Recreating the Banned 1980s Popball: A Journey of Materials and Manufacturing

TLDR; The video discusses the recreation of a banned toy from the 1980s, the Popball, by exploring different materials and manufacturing processes.

⏳ Banned Toys of the 1980s

In the 1980s, several toys, including the yoyo, slap bands, hand blasters, and marbles, were banned from schools for various reasons.

The speaker recalls a particular toy, the Popball, which had a significant impact on him and was banned during his childhood.

The mystery and urban myths surrounding the disappearance of the black-colored Popballs from schools have persisted for over 35 years.

🔍 Origins of Popballs

The Popballs were traced back to the toys creator, Peter Fish, who added a safety airhole as a point of difference.

The speaker highlights that the original Popballs were of higher quality compared to the modern variations available for purchase.

🔩 Recreating the Popball

The speaker attempts to recreate the Popball in the workshop by experimenting with different materials and manufacturing techniques.

Initially, the 90A shore hardness TPU filament is used for the recreation, but it proves to be too firm to replicate the Popball's action.

Subsequently, the speaker turns to a new resin product from Monocure3D, which presents challenges in printing with flexible resin.

🛠️ DIY Injection Moulding

The speaker explores DIY injection moulding using 3D printed moulds and polyurethane rubber, aiming to improve the elasticity of the material.

After several attempts and adjustments to the material composition, the speaker successfully achieves the desired 'pop' action of the Popball.

⚙️ Exploring Flexible Filaments

The speaker discovers a company specializing in flexible filaments and decides to try a 60A TPU filament with high elongation for the Popball recreation.

Challenges arise during the printing process, including extruder gear jams and under extrusion, which require modifications to the printer and filament handling.

🎉 Success and Conclusion

Despite multiple failed attempts, the speaker eventually achieves a successful recreation of the Popball, which performs well but falls slightly short of the genuine Popball's performance.

The speaker expresses contentment in recreating the favorite childhood toy and looks forward to returning the genuine Popball to its original creator.