Bungee Design and Testing

 Our team designed and tested a custom bungee cord system and developed a Python model to predict safe and effective configurations based on drop height, mass, and maximum acceleration. The goal was to ensure the jumper stopped as close to the ground as possible without exceeding a 4g acceleration limit. We characterized various rubber band configurations using the MTS machine, balancing durability and stiffness. The final knotless design used looped bands folded in half, providing strong elasticity without excessive stiffness or stress concentrations. MTS testing yielded a stiffness of 35.1 N/m per cord element, which we used to model cords arranged in series and parallel combinations. The Python model simulated energy balance and elastic extension to determine feasible cord setups meeting safety and stretch constraints. It combines experimental stiffness data with physics-based equations and drop data to predict required lengths and configurations. On demo day, the jumper’s 1 kg mass produced 2–3g acceleration, safely under the limit, with a 0.63 m clearance above the crash pad, closely matching the model’s prediction.