A couple of years ago, I started experimenting with different materials to create juggling sticks that would better meet the needs of movement and durability. Through this process, I also realized that the handle design was just as important as the materials themselves. From the beginning, I knew I wanted a wider handle for several reasons, which I’ve confirmed through practice. Now, after several tests and improvements, I have new versions that I want to share.
First, a larger diameter makes the sticks more visible on stage, which is essential for performances. I’ve also noticed that throws feel more stable, and the trajectory of releases is more controlled, especially in my style of play.
Regarding weight, while many people prefer lighter sticks, my slower-paced style means that I don’t mind working with sticks weighing between 90 and 120 grams per pair. In fact, this extra weight gives them more presence in the air and helps me feel the movement better.
One thing I didn’t expect is that, after getting used to a thicker grip, I’ve experienced less muscle fatigue. Instead of keeping my hands tightly closed, the wider handle allows for a more natural and ergonomic grip, making long sessions more comfortable and reducing strain over time.
These are some of the reasons why I’ve chosen this design, and so far, the results have been very positive.
Index
Testing Different Materials
Until now, I had mainly used 7.9 mm fiberglass with a 3 mm inner diameter. I always found it to be a balanced material between flexibility and control, but I wanted to explore lighter and more durable options.
After the EJC in Portugal, I started testing Play D-LITE 7075. They worked well for me, but the aluminum tip would eventually break the string. I replaced it with a rubber one, like in my designs, and the difference was significant.
I’ve also been experimenting with 8 mm carbon fiber and plan to test some 10 mm versions. The weight reduction with carbon is immediately noticeable, making them much better for training multiple diabolo techniques, as you get a better feel for the string and increased precision.
Comparing Materials: Aluminum, Carbon Fiber, and Fiberglass
Each material behaves differently:
- Aluminum: Solid and not very flexible, providing a sense of control, but can be harsher on the string.
- Carbon fiber: Very light and responsive, but perhaps too flexible for certain styles.
- Fiberglass: A middle ground between the two, balancing rigidity and adaptability.
The Impact of Diameter on Usage and Durability
The tube diameter, both inner and outer, affects how the sticks perform.
- Thick-walled tubes, like fiberglass ones, require a single string running through and are more durable.
- Thin-walled tubes, like carbon or aluminum, allow for internal knots and reduce string usage—a trick I hadn’t been able to use for a long time.
I know people who have broken 10 mm carbon sticks (Sundia), but I use 8 mm carbon fiber and haven’t broken any yet.
I’ve also noticed differences in stability:
- 10 mm sticks provide more stable throws and better visibility.
- 8 mm sticks make grinds easier and allow for specific tricks like locks in the middle of the stick.
Over time, I’ve found that a conical handle of 16-24 mm might be too thick for diabolo juggling. A handle of 14-18 mm could be more practical and ergonomic for sticks that you hold for long periods.
With thin-walled sticks, you can tie internal knots to secure the string inside the tube, reducing wear and increasing durability with each replacement.
Comparison of Play vs. Henry’s Materials
Handles and knobs are key to the experience of juggling sticks. Since the core of the sticks is usually thinner and only counterweights are placed at the ends, it’s important that the handles are rigid to ensure control and stability.
The Handles
Play handles are more rigid. Within their range, Wrapped handles have a thinner wall and can break with intensive use. I recommend Smooth handles, which are more durable. On the other hand, Henry’s handles are softer and more flexible, which I don’t like as much for diabolo.
The Knobs
Regarding knobs, Henry’s are lighter (5 g), making them ideal for agile sticks. Play’s knobs are heavier (7.5 g), but they better conceal the string knot, which can improve certain balances.
3D-Printed Connectors and Central Joint Solutions
To connect the sticks with the handles, I designed 3D-printed connectors, which I previously discussed in a blog post. This solution allows for easy customization of the connection and adaptation to the needs of each model.
However, for the central joint, what has convinced me the most so far are synthetic cork plugs cut in half. They offer a good balance between firmness and flexibility, helping to maintain a stable connection without adding too much weight or unnecessary rigidity.
What’s Next?
With these tests in progress, I’m eager to keep refining the designs and exploring new material combinations. One idea I have in mind is testing a slightly narrower handle. Right now, the stick ranges from 20 mm to 24 mm, but it might be interesting to explore a transition from 16 mm to 20 mm. This reduction could make control more precise without sacrificing comfort, and for diabolo, it could be even more practical.
I’d also love to find time to visit Italy and collaborate on improving these sticks with Play.
If you’ve been experimenting with juggling sticks, I’d love to hear about your experience! Do you think weight and flexibility are key factors in your play? Would you prefer a thinner handle for certain uses? Leave a comment and let’s share ideas!
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