Universal Jack Pad

Brief:

A jack pad capable of fitting the Halfords low level floor jack, whilst suiting the largest range of vehicles. Pad must be capable of supporting an equivalent weight to the floor jack whilst minimising the chance of slipping or misuse.

Shape

There are 3 main types of surface this jack pad needs to suit. These are a uneven piece of subframe, a dedicated jacking point and a pinch weld. Below is my iteration to ensure that it fits the broadest range of these. The voided areas allow for increased deformation without the need for a weaker material. Circular, since most jacking points are, with a groove to assist in positioning along a pinch weld.

Material

To ensure the product deforms slightly to suit the shape of the surface, while ensuring it is not so weak as to break apart, I have decided to use Shore 95A Polyurethane. Modelling shows this can withstand the necessary weight while allowing for some elastic deformation. It has the added benefit of coming in multiple colours which would allow it to be branded.

Manufacture

This design will need to be cast in a 2 part mould. This can be secured together by an appropriate size screw (I have selected M5). In order to ensure quick removal from the mould, the voids serve to reduce any suction to the metal parts. Furthermore, an air gun could be used if necessary to ensure swift detatchment.

Final Design

Below is the final design, rendered into several scenarios.