When I approached Dr. Spencer
Magleby, PhD., Dean of the Mechanical Engineering Department of
Brigham Young University, Provo, Utah, with the proposal that I
wanted to improve upon the quarter-fold rebounder mini trampoline we
had perfected and made available in 1995, he surprised me by saying,
“All of the technology necessary to develop your quarter-fold
rebounder was available to us during the First World War.”
He was talking about the bending, welding, painting, drilling and
milling of steel to create the frames that are being used in all of
the rebounders today.
“Your next step is to bring rebounder equipment into the new
" Six weeks later I was able to see a three
dimensional digital drawing of the Ultimate Rebound™. To me, it was
I wanted to frame the drawings, place them on the wall and stare at
“How do we do that?” I asked.
“Use polymer - composite materials,” he answered.
“Aren’t polymers brittle, soft and cheap looking?" I inquired.
“They can be, but they can also be harder than steel, immaculately
crafted, lighter, and stronger. The stealth fighters are made of
composite polymers; polypropylene and fiberglass. Many automobile
parts - including engine parts are made of polymers. There are over
fifty different combinations of materials that can go into the
production of products each with their own specific characteristics.
All you have to do is find the combination that fits your needs. A
rebounder is an ideal devise to be constructed of composite polymer
“Is it expensive?” I asked.
“Only in the beginning, but I believe the investment will be well
“Well, let’s explore its potential, then.”
That was my beginning of a great adventure into a world previously
unknown to me of composite materials.
Professor Magleby appointed me as the head of the project. The six
students were there to get a grade. I was there to receive the
benefit of what would come of the mechanical engineering project
called “Ultimate Rebounder.” I presented the primary specifications.
It is an exercise device that
will be used on a daily basis.
It provides an efficient
The 28½ inch diameter Baycor®
Permatron™ mat is circular and parallel to the floor.
(Made in the U.S.A. by the Ten Cate Nicolon Corp.)
It is supported by eighteen
aluminum mat/spring attachments, which, in turn is supported by
36 wide bellied springs.
It has to support 400 pounds
of dynamic weight.
The 36 springs are connected
to a frame that has 4 uniquely designed hinges and is capable of
twice into a quarter-fold.
The frame is 40 inches in
diameter and supported by 6 permanently connected aluminum legs.
Each leg must have the
ability to "unlock" and be folded out of the way, into the frame
itself, if possible.
With that information and a review of the original Quarter Fold
ReboundAIR™, a steel rebounder, the students went to work on a new
composite polymer hybrid rebounder. Six weeks later I was able to
see a three dimensional digital drawing of the Ultimate Rebound™.
To me, it was museum art. I wanted to frame the drawings, place them
on the wall and stare at them.
The design was such that it made a frame cover obsolete. There was
no need for springs in the leg. You simply slid them
into their slots and turned them by 30 degrees to lock them in
They even designed a built-in compartment for each leg to fit in
when the frame is folded. Very useful!
The students were great, but they were only students. To perfect the
design we needed to go to the experts - the engineers who were going
to create the actual mold for the frame.
This was a real challenge because we couldn’t find a factory in the
United States who would design and produce the mold for under
$150,000.00 up front.
Our search culminated in a high-tech factory in Korea which was
perfectly equipped for the project. They were so confident in the
outcome, they were willing to guarantee their workmanship and back
up every component produced!
We even included a good looking, custom fitted, double zippered
nylon carrying case and its own transport dolly. However, what we
thought was going to take 90 days from design to production has
taken over two years due to meticulous product test improvements!
Was it worth it? You decide. After 12 years of Quarter Fold
rebounder evolution, I proudly present to you,
The Ultimate Rebound™.
Revolutionary materials and
workmanship. The ultimate in convenience and portability. The
"ultimate" rebounder mini