How would you make small metal copies of handheld objects?

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SUMMARY

The discussion focuses on creating a durable, unibody version of a handheld device, specifically a metal or alternative material copy of the TLC Tugger. The user seeks a solution that ensures the hook remains intact and does not twist or flake, emphasizing the need for medical-grade materials that are safe for prolonged skin contact. Key considerations include the thickness of the hook for added durability and the requirement for the material to have some softness while maintaining structural integrity. The user is looking for services or machines capable of producing this custom design.

PREREQUISITES
  • Understanding of medical-grade materials suitable for skin contact
  • Knowledge of metal casting techniques
  • Familiarity with 3D printing technologies and materials
  • Basic principles of mechanical engineering related to durability and design
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  • Research metal casting services for custom medical devices
  • Explore 3D printing options with biocompatible materials
  • Investigate the properties of various metals and plastics for durability and safety
  • Learn about design software for creating prototypes of custom devices
USEFUL FOR

This discussion is beneficial for product designers, engineers, and medical device developers interested in creating durable, skin-safe handheld devices. It is particularly relevant for those exploring custom manufacturing techniques and material selection for medical applications.

LongApple
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I want to make a unibody, durable version of the above that won't chaffe skin and survives/resists getting distorted even if you try to twist the metal hook loop. Basically I have the above device. I pulled an twisted on the hook and the hook ripped out. I'm looking to create perhaps a metal or other material version of it maybe using caste out of the existing one I have.

What kind of service, website, or machine do I need to find to make a unibody version of the above?

It is okay to make the hook thicker if it gives it more durability. Doesn't have to be unibody as long as the hook stays in place and doesn't twist. And preferably it should not flake or leave bits of it coming off.

If you google TLC Tugger, you will know it's purpose but that leads to a bit of an awkward situation going to the materials lab at university, not being a material student, and asking if I can make this object. Let's just be mature about this, keep it scientific, and not talk about the purpose of the device- just know that it has to be safe medically with skin contact and being lodged in a certain place for many hours at a time.
 

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At least the upper part of the cone cannot be too slippery or it will fall out. It has to have some traction without chaffing skin.

I don't know about what kinds of plastics, metals, or other materials would be suitable. In my ideal world, it has some softness but cannot be damaged or torn (so it could be solid metal or could be another material that can be twisted but 100% always goes back ot original)

Again let's just stick to the science and engineering about this issue. I, for one, consider this a medical device
 

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