What is wrong (or right) with thighbands?
I would say my thigh bands make my belt very secure. I wear them mid-thigh and though the bands are made of steel they are lined with neoprene (I think - anyway its soft and rubbery). Noise would be an issue if I worked and if we go out, the chains sometimes have to be wrapped to stop then rattling. I did not like the original lock on the connecting chain since it had sharp edges that would dig into me. Angela found a small lock with rounded edges which is much better. At night she uses the same type of lock to connect the inside "D" rings together.
The thigh bands probably only work for me since Angela will unlock them to spell me and let me stretch my legs when desired and she will readily unlock them for a while if I need a rest or we go hiking etc. I do not know how other girls manage but without an attentive and almost always present keyholder, I imagine they would be items of torture. They just happen to work well for my situation.
Eventually, when Angela makes my new belt, it is her intention to remake the thigh bands with hoops of 3D printed plastic made to my thigh shape which will hopefully make them lighter and more comfortable.
Ok so rattling chains and sharp bulky locks seem to be some of the first problems I should be thinking about. Chains should be easy to solve. Locks might need a bit more thinking about, I was never happy with the side chains connecting to the waistband with padlocks that always seemed like an efficient but ugly way to do it.
3D printed thighbands are a good idea but I am not at all sure how you would measure that to get the right shape, or if you wanted this shape in metal how you would make it. I will think about that.
Seems to me all thighbands tend to hang at an angle unless supported via a chain between the legs to the bottom of the guard which adds other possibly unintended consequences. This looks wrong to me but is it actually a problem?
Thank you for your insights so far.
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Taz Locks might need a bit more thinking about, I was never happy with the side chains connecting to the waistband with padlocks that always seemed like an efficient but ugly way to do it.
Instead of a lock, you could also do the following. If you put the connection from the CB to the thigh bands through each and secure it from the body side, you wouldn't need a lock. When the CB and the belt are locked, they cannot be loosened. To secure it you could screw a plate above, or the end has a T-shape. You put is through and turn it around 90°. There is a recess in the band into which the T-piece fits. If the bands have no slack you could not get it off.
I expect at the waist it would work but I am not so sure a the thighs. From what I read here the thigh band should fit well but not as tight as at the waist.
Taz 3D printed thighbands are a good idea but I am not at all sure how you would measure that to get the right shape,
Use a 3D scanner and you get the shape. I think it will need some iteration to get the right tightness done but it should improve how they fit.
Taz Seems to me all thighbands tend to hang at an angle
Why not adopt the concept of a stocking holder. A secure connection is needed the other bands would have the task of holding it in the correct position. They can be placed in the front and in the back. For example, made of elastic material to adapt to movement.
How about a hinge in line with the hip joint, fixed rigidly to the belt at the top with a stiff band going down to the thigh band. This would stop the thigh band drooping and at least reduce twisting. It could be fitted near the knee without any chance of slipping it down.
The Carrera thigh belt design seems to accomplish something similar.
Securing the thighbands to the waist band from the body side can work and can be done several ways. 1). screws from the inside of the waistband. Needs the belt to be removed to attach the thighbands but the result is smooth and elegant. 2). Clipping the thighbands to the waistband with some sort of a half turn catch works well but again the belt has to be removed as it is not possible to use this sort of catch with the thighbands in place on the leg. (enough slack to do up the catch means enough to undo it too and we don't want that). 3). Screws from outside the belt could work if you use proper security screws and restrict access to the tool or use a plastic seal to make sure it stays in place (might be the smoothest and easiest) 4). I have some other ideas that I am still thinking of.
3D scanner is nice and I am thinking of LIDAR but most customers send a measuring chart instead of coming to see me. Most Android phones do not have LIDAR but it is something to investigate.
Stocking holder / suspender belt is a good idea I have done it with metal buttons on the waistband and elastic to suspend the thighbands. It works but is not an elegant engineering solution so I don't like it much.
Still it gives me lots more to think about.
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Taz 3D scanner is nice and I am thinking of LIDAR but most customers send a measuring chart instead of coming to see me.
LIDAR is not so common as a 3D scanner. Important is with both which resolution you get out of it.
To get the shape of the thigh the customer can cut two cardboards which fits to the cross section of the thigh where the thigh band should be. Is the easies and cheapest way.
Taz It works but is not an elegant engineering solution
I think you have to make a compromise. Not all good engineer solution is also nice in the eyes of those who wear it.
Joh
PolyCam on Apple seems to be a very good LIDAR scanner but I have only seen it once as I have Android. It looks like it might be a possible was for a customer to scan the leg with a few marks on it to show the location. Perhaps it would be exportable to SolidWorks or similar. More to think about. CAD (Cardboard Assisted Design) is also a good way to go especially for prototyping.
Yes sometimes engineering is a compromise but I still don't like it but may have to look more at this.
Taz It seems to me that the current range of thighbands from all makers Tollyboy included are really a bit rubbish. I think in terms of comfort, wearability, security etc they are all lacking.
I'd start the process by looking at garter belt design. I think the locks on the front of the bands have got to go, but it's clear from users here that the bands do have to be removable w/o removing the whole belt. Eg, they're often just used at night. Maybe a step into and pull up design with Tolly style locks on the sides of the waist belt would give lower overall profile?
Jonas No that doesn't work the profile is much smoother but not overall lower. I used the small 4 pin cam locks in an experimental version. Looks better, smoother when the thighbands are not there but no D-ring on the side so nowhere to anchor a handcuff if required. When the thighbands are locked on the lock is about 20mm high and round so still quite bulky.
as an involuntary wearer i have to say that i find them just awful, but i'll try to shed some light on a neutral aspect and that is the noise level, if i don't want to be noticed in public i have to encase the chains in rubber, something could be done about that
Taz From there it is possible to get your leg out of it.
If you connect the chain to the belt (D-ring in the crotch), this is not possible.
Angelina Chains are a problem but also easy which is why I guess they are used by almost everyone. I am away from home at the moment and don't have chain to experiment with but have some ideas on how to stop it rattling. When I can I will try them and see how practical they are. Ultimately the chain needs replacing but then there are problems of connecting and adjusting it.
I can see another advantage (disadvantage) of partly supporting the thighbands from the D-ring at the bottom of the guard. As this is not in line with the centre of hips when bending forward or sitting down it will pull the connecting chains between the thighbands pulling the legs together. Good if this is what you wish to achieve but I guess this support chain gets a lot of urine on it when using the toilet and is hard to clean? If that is the case another design problem that needs fixing.
Jonas Front and back support would look nice when standing but when bending or sitting the front support gets shorter, the rear support gets longer but I guess not by the same amount. Will have to take a whole lot of measurements and think about it. Also whatever is supporting the back of it will get sat on so have to think about that too.
Taz but I guess this support chain gets a lot of urine on it when using the toilet and is hard to clean? If that is the case another design problem that needs fixing.
indeed, i always pee against the chain and have to clean it afterwards, but the problem would be easy to solve if i didn't have to wear this "additional fixation". 
Taz Chains are a problem
Why not use stainless steel ropes? It strength has to be high enough that you can't pull it apart. To withstand tools is another class. A rope doesn't rattle. It's job would be to prevent to get it off.
To hold the bands in place elastic bands in front and back would do it. They do not have to prevent the bands from being removed. They would expand and shorten when you sit down. I suppose if it the same type as on garter belts you will not feel much if you sit on them.
Taz No that doesn't work the profile is much smoother but not overall lower. I used the small 4 pin cam locks in an experimental version. Looks better, smoother when the thighbands are not there but no D-ring on the side so nowhere to anchor a handcuff if required. When the thighbands are locked on the lock is about 20mm high and round so still quite bulky.
As far as I see all women who wears thigh bands wear skirts during this time or be at home. To get the thigh bands on and off would following idea work?
The connection to the CB to hold the thigh band could have an end-device which could only fit in an opening at the waist band from top. At the thigh band would be a look where the cable is connected and hold the band in place. Also it prevent that you move the cable up to get it out of the opening in the waist band.
The fastening system can turn out relatively flat in opposition to a lock. The lock on the thigh bands is hidden by the skirts during the day and at night it does not matter how thick it looks.
To get the thigh bands off you open the lock at the thigh bands remove them and push up the connection cable out of the belt.
Taz I guess a plate over the waist band with a couple of threaded holes, attached by c/s screws from the inside. The hinge could be part of the plate or clamped by the screws.