I want to create the "Best Sanding Blocks Ever"

Dean Jenkins

Dean Jenkins

Promoted Users
First, I talked with Barry and made sure this post was OK. Not only did he say it was OK, he enthusiastically encouraged me to pursue this. What a great guy!

In addition to being a car restoration enthusiast and amateur painter, I am an entrepreneur. I've started two businesses. One failed, one is thriving. I've learned a lot, the hard way, and I know what it takes to succeed.

I've been following several threads about sanding blocks. I've seen a lot of discussion about the benefits of using acrylic blocks to get panels really flat.
I also see many comments that "It is not the tool, it is the hand using the tool." Those are fair and accurate comments.

But, I think we can all agree, even if you can get great results without newer tools, having great tools makes things easier. (I've heard some guys just use a stir stick with sandpaper wrapped around it - and get show quality finishes, but c'mon!)

**Barry cracked me up. Even though he enthusiastically supported this idea, he confessed that he only uses a 4" X 6" "jitterbug" sander and the 4" rubber blocks from the '70's with the flaps and nails to hold the paper in place. And he gets great results because these tools are in an experienced hand. When I get these "Best Acrylic Sanding Blocks Ever" developed, I'm going to send him a set and challenge him to give them a try ;)

Can you just cut some blocks, of varying thickness's, from acrylic, wrap paper around them, and go to town? Sure. But the ergonomics are bad. They are hard to hold onto and to control.

I want to create the "Best Acrylic Sanding Blocks Ever"

I've looked very closely at all the Acrylic Sanding Blocks currently being offered.
Here are the top 3 most most visible suppliers:

Linear Blocking Tools

True Blox (I actually bought a set of these)
www.trueblox.com

True Blox

The Best Sanding Blocks and Methods for Remarkable Body Work.
www.trueblox.com

Big Kid Blocks
bkblocks.com

Big Kid Blocks

Your one-stop shop for custom sanding blocks, detail kits and body shop accessories!
bkblocks.com bkblocks.com

IMHO these products all have shortcomings and are ridiculously overpriced!

The biggest shortcoming are the ergonomics/shapes of the handles. Particularly TrueBlox and Big Kid Blocks. Linear Blocking has an innovative handle, but man, they are expensive, and the handle has "issues," notably they can pinch your hands on concave surfaces.

I've seen many comments that AFS blocks had awesome ergonomics. People loved them!
But, they were still foam blocks, albeit with steel tension rods, but did not have the acrylic base that seems to provide the ability for superior flattening.

So, I am going to develop the "Best Acrylic Sanding Blocks Ever" incorporating the ergonomics of AFS blocks with the advantages of an acrylic base.

Here are the stages of developing a product and then bringing it to market and the current status:
  1. Concept and initial design sketches (This is done)
  2. 3D CAD files created (This is done - I will share them as soon as I have the patent application filed - got to protect the IP)
  3. 3D printing of prototype (This will be done within a few weeks)
  4. Creation of molds for injection molding (This is expected within about 2 months)
  5. Volume production (This is expected within about 3 months)
  6. Launch and ship product! (This is expected within 3-6 months)
Once I have the patent submitted and have IP protection, I will post 3D images of the planned design. I have drafts now and they look awesome!

In the near future, I will be looking for;
  • Input on what real users of the product want in the "Best Acrylic Sanding Blocks Ever"
  • Feedback on the 3D draft product images.
  • Crowdfunding for the molds. This is the most expensive part of a product launch. I'm looking for early adopters to be a part of this launch. The current product offerings are priced at ~$150 for an entry set of blocks. I'm looking at a lower price point. Once the design is locked down, these can be produced (In the United States!) for pretty cheap. For the "Crowdfunding," I'm anticipating about a $50 "GoFundMe" contribution campaign that will get you in on the design of the product and a set of six blocks from the first production run. If I can get 50-100 people in on this, the molds will be funded.
So at this point, I'm just letting you know what is being planned.

Any thoughts and feedback are very welcome!

This should be fun . . .
 
If you can develop a handle that is comfortable and still allows range of motion that would be big. I make my own and have done the tape method like Astro showed in his posts and also used foam pipe insulation (what I had on hand) that I glued to the acrylic. Makes it more comfortable but doesn't last very long before it comes loose. Some type of foam and a good adhesive would seem to be the ticket to making an acrylic block more comfortable.
Good luck in your endeavor.
 
Chris_Hamilton said:
If you can develop a handle that is comfortable and still allows range of motion that would be big. I make my own and have done the tape method like Astro showed in his posts and also used foam pipe insulation (what I had on hand) that I glued to the acrylic. Makes it more comfortable but doesn't last very long before it comes loose. Some type of foam and a good adhesive would seem to be the ticket to making an acrylic block more comfortable.
Good luck in your endeavor.
Click to expand...
Thanks. That is absolutely the plan.
 
Here’s another source

Maintenance

Sanding Blocks for professional bodywork and detailing
luckymattsrodshop.bigcartel.com

I think the linear blocking parts are expensive due to their use of polycarbonate. At least that is their claim… :)

Don
 
The AFS empire all but folded when the owner died. The kids (heirs) didn’t want the work involved with the company so it may have just up and folded. The design was patent pending so you may be able to buy the patent and process info from the kids and start AFS up again.

On the acrylic blocks, I think you’ll find Polycarbonate less prone to cracks as the acrylic, so if you go that route you may have less product failure (and returns, bad press, etc) if you used the poly. To me there are quite a few doing the clear blocks now, I’d see about buying the AFS business. If I were doing it.
 
I am curious if you are applying for a utility or design patent.

I would spend some time researching prior art before investing too much money in patent costs. 3M in particular.

Don
 
Appreciate the comments and questions!

Here are a few answers:
  • The AFS patent has expired (along with the patent holder.) With that said, I still prefer the "bootstrap" form of business, rather than trying to buy and resurrect something. AFS had a loyal user base for sure. I'm confident (hopefully not unfounded hubris) that I can take what was good about their product and produce something as good or better. Why not try?
  • I used the term "Acrylic" generically and that caused confusion, my bad. Yes, Polycarbonate or "Lexan" is a superior material and that is what I've always intended to use as a base. It is more expensive, but I intend to produce a quality product and will willingly pay more for top quality materials. Manufacturing in the US can be more expensive as well, but I don't care, that is the only way I will do it.
  • Yes, I researched patents exhaustively before starting on this project. There is a clear field for what I have planned. I am in the process of filing a provisional patent application (which can only be done on a "Utility" patent, not "Design." A provisional patent application (PPA) is a document issued by the U.S. Patent and Trademark Office (USPTO) that helps protect a new invention from being copied during the 12-month period before a formal patent application is filed. It is intended to give an inventor time to pitch the idea, test its commercial feasibility, or refine a product before committing to the expensive and time-intensive process of a formal application. The "patent pending" label on a product indicates that a provisional patent application has been submitted.
  • As soon as I have the "patent pending" status I will post 3D drawings of the concept.
  • I think Chris Hamilton is correct. Success for this is all about the shape and composition of the "foam" (again a loose term) handle. If I can get this right it will make the product very awesome indeed! I am working with Polymer Engineers on dialing this in. There are so many cool materials available that I can confident we can find the perfect one that will constitute a great product and be able to be manufactured at low cost.
Stay tuned!
 
dhutton01 said:
Here’s another source

Maintenance

Sanding Blocks for professional bodywork and detailing
luckymattsrodshop.bigcartel.com


Don
Click to expand...
Yeah, I've seen the "Lucky Blocks." In fact, they were the ones who got me thinking about this project.
I've seen a YouTube video where the Lucky Block guy shipped samples to a body shop with the handles made out of 2" masking tape.
The body shop guy was so giddy about how great the poly block sanded that he didn't even mind the "T" handle made out of tape.
I think we can do better!
 
I wonder how an adjustable arm like on this light would work. Without the suction cup of course. It would flex but still be fairly stiff.
Screenshot_20220527-210135.png
 
I was rearranging my sanding block/hammer/dolly cart last week and had the thought that Acrylic/Poly blocks with an AFS style foam handle would be the best of both worlds. Its good to see someone working to make that a reality!

AFS had a good idea with adjustable flex but the spring steel face is so thin that it can flex enough to absorb localized high spots, and they don't bend in as constant of an arc. The AFS handle seem slightly too wide/chunky for me. I'm supposed to be scaling back and doing my last body/paint job now but I'd still buy a set to work on my own cars.

The tape handles "work" for but they're far from ideal both in durability and comfort.
 
I don't think I've seen other block companies offer half width blocks. I use half width blocks from 4" up to about 15" long fairly often, in a few different thicknesses. Not sure if it would be worth making extra molds though. Have you looked into extruded handles instead of molded, that might cut manufacturing costs?
 
theastronaut said:
I don't think I've seen other block companies offer half width blocks. I use half width blocks from 4" up to about 15" long fairly often, in a few different thicknesses. Not sure if it would be worth making extra molds though. Have you looked into extruded handles instead of molded, that might cut manufacturing costs?
Click to expand...
Extruded vs. injection molding will be determined by the final polymer choice for the handle. Stay tuned for that.
Either way, some type of mold is needed.
Half-width blocks are an interesting idea.
The is a concept, in new products, called MVP (minimum viable product.) It is important to get the MVP launched and get market traction.
If the core MVP product is successful, then build on it with additional features and variations, such as half-width and even various shaped versions.
 
What about blocks that interlock. To extend the length. So instead of needing a set of 10 blocks. U just need 4 of them and they all connect to each other to go from 6 inch to 4ft. Just thinking out loud. I'd throw in on the crowd fund
 
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