The team was tasked with designing the second generation Xtreme Force curling broom handle based on market feedback from the first generation handle. The existing handle features two angled grips built on market feedback from the first generation handle. The existing handle features two angled grips built into the straight shaft, with the intention of allowing the userto apply force vertically downward while sweeping. The result is an increase in pressure applied by the broom head onto the ice, especially during the back stroke which is usually lacking in pressure.The most common complaints about the first generation handle were that the grips are too large, are too restrictive on hand placement, have too large an angle with respect to the shaft, and cause blisters on the user’s hands due to rubbing on the lips. The team generated concepts with the primary goals of improving comfort and adaptability to the user while maintaining the sweeping effectiveness of the first generation handle. The selected concept was to have only one grip, and to reduce the grip diameter to equal that of the shaft. Since the ideal grip angle is subjective, the team decided to proceed with three variations on the design: one with a 19ogrip, a 38ogrip and 51ogrip.To help in selection of materials and manufacturing methods, and because the client did not have information of how the first generation handle was produced, the team performed mechanical testing on a sample Xtreme Force handle. Through analysis of the internal structure and mechanical properties of the handle’s components, the team determined that the first generation handle consists of carbon fibre composite with foam cores in the grips. The shaft sections are hollow, and the grips are bonded to the shafts using an adhesive.After consideration of the benefits of various methods of production, the team decided to produce the part asa single body, eliminating the need for adhesives and improving mechanical properties due the lack of joints. The part is manufactured using oven prepreg. The prepreg is layed up around a core consisting of a permanent foam section for the grip, and two removable aluminum rods for the hollow shaft sections. The selected materials are NB301 carbon fibre epoxy prepreg...