4-Way Horse Jump Cup

In 2021, I was approached by a client who needed a completely new type of jump cup for horse show jumping. Traditional jump cups only allow for a single pole to be mounted per post, but my client wanted a way to mount poles on all four sides of a post. Existing designs relied on the weight of the poles to stay in place, but this approach wouldn’t work for a four-sided cup—it needed to be stable in all directions, adjustable for varying post sizes, and easy to use without complicated assembly. With these challenges in mind, I set out to design a durable, simple, and manufacturable solution.

After numerous iterations and FEA testing, I developed a two-piece adjustable jump cup that could securely clamp around posts of varying sizes. The design featured a custom quick-adjustment mechanism that used interlocking ratcheting knob-levers, allowing for full adjustability with only 70 degrees of rotation. The final design met all the client’s criteria: simple to use, minimal parts, highly durable, and manufacturable via injection molding with no secondary operations.

The biggest challenge in this design was achieving stability in all directions while also accommodating posts that varied in size by nearly ½ inch. The solution was a two-piece clamping system that enclosed the post from both sides, secured by an integrated adjustment mechanism that ensured a tight fit regardless of post dimensions. This eliminated the need for exact tolerances while keeping the cup firmly in place.

The jump cups needed to withstand high impact forces if struck by horses while also being weather-resistant for outdoor use. The client also wanted a design that could be fully injection molded with as few separate parts as possible. Through extensive FEA testing, I validated that the chosen injection-moldable material could endure repeated impacts without failure, ensuring longevity and reliability in real-world use.

Standard thumb screw knobs would be inconvenient and time-consuming to tighten, especially one-handed. Instead, I developed a custom aggressive thread pitch system that allowed the jump cup to be fully adjusted with just 50 degrees of knob rotation. The interlocking teeth worked like a ratcheting mechanism, ensuring the cup stayed firmly in place without risk of backing off under pressure.

To minimize the risk of lost components, the final design only consisted of two large structural pieces. The knob-levers, which controlled the tightening mechanism, were designed as two halves that could be permanently adhered together after manufacturing. Once assembled, the entire system was a simple, durable, two-piece unit that was simple and easy to install so that anyone could use and appreciate.

At the end of the project, I provided the client with a fully functional 3D-printed prototype, allowing them to physically test the design before moving to production. Additionally, I delivered a complete CAD package with final models and engineering drawings, making it easy for the client to move forward with manufacturing.

To ensure scalability, I researched injection molding materials, considering both durability and cost. I obtained manufacturing quotes from vendors to assess feasibility at different production scales. With validated FEA simulations using the selected material, I ensured the jump cup would perform reliably in real-world conditions, giving the client confidence in the product’s long-term viability.