The manufacturing process was split up into three main parts. The front plate would feature a detailed engraving of the school crest (see above). The back plate would have deep inset text with the school's slogan, and the shoulder spikes would be made out of flexible 3D filament in order to reduce potential danger. Both aluminum components required extensive testing (see right) due to the high quality expectation. The spikes were fastened to the pads by utilizing a two-stage fixture that bolted the black bases to the plastic and then glued the spike itself into the base.

The final results were beyond satisfactory. Both the front and back plates displayed exceptional finish quality. Both plates were manufactured entirely on the Tormach 24R. For the front plate I ended up using a Ø3/8" 90° chamfer tool at 50% of the default feedrate, and a Ø6mm 1-tooth end mill for the back plate (at the default feedrate). The spikes were firmly and effectively fastened on to the body of the pads. As far as improvements go, the project was not perfect. There were several visual imperfections on the front plate engraving, although small enough to be considered negligible. The spikes, although squishy, were not quite as flexible as I'd hoped they'd be. For future iterations, I may consider printing with a different infill pattern and/or lower infill density. However, the project still met my expectations and all of the components came together to form a project I am truly proud to wear upon my shoulders. 

Note: The pads successfully survived a rowdy football season in the stands without any necessary repairs or defections!