![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/IMG_20210608_202244_777.jpg)
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In 2021 I developed a new design of jam plugs for roller skates. Jam plugs are used by roller dancers instead of toe stops.
I found that there are no jam plugs on the market that are the right size for my needs, which were: deeper plugs for skaters on 62 mm wheels, with short plate and long toe on the boot, and with good toughness and the right friction. So I created my own and used the project to learn about resin casting, which is something I have wanted to do since 2001 when I was at the RCA.
![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/IMG_20210713_175348_675-1080x1080.jpg)
![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/PXL_20210411_203104951.jpg)
I went through a couple of iterations of the designs of the plugs, here is the 3D printed template before clean up next to a standard Powerdyne Jam plug.
I smoothed out the 3D printed templates, including using a die to refine the precision thread on the 3D print (and for the skater nerds that tool on the right is a Shore A Scale Durometer).
![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/PXL_20210609_115937575.jpg)
![](https://drewbatchelor.com/wp-content/uploads/2023/12/PXL_20210425_sq.jpg)
Learning how to make a silicone moulds with a vacuum pot (thank you Georgie).
![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/PXL_20210702_072156425.jpg)
Learning how to cast resin with a pressure pot.
![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/PXL_20210504_114955913.jpg)
There was a lot of experimenting to find a resin with the best combination of strength, friction and wear resistance, and lots of fun product testing by me and several other skate dancers in Bristol. 🙂
I learned about mould shrinkage the hard way, having made a 4 impression mould and 24 jam plugs that all had to go in the bin because the thread were too small. Doh!
![](https://www.drewbatchelor.com/wp-content/uploads/2022/06/IMG_20210908_184451_533-1080x1080.jpg)
July 2021 – I have made about 20 prototypes and have finalised the design, I’m calling this project done for the moment.