Learn the way 3D printing can improve your hobbies. Watch Dave as he designs, prints, and assessments his customized surfboard fins.
This challenge began off as filling a necessity and rapidly developed right into a extremely nerdy endeavor with enormous quantities of experimentation and design iteration. I had damaged a surfboard fin and appeared round to switch it. The fin I wanted was solely obtainable in units of three or 4, however I solely wanted one. Having a 3D printer readily available, I dove into the world of foil design, flex, and surfboard fin design.
To print this surfboard fin, the recordsdata are hosted within the MatterHackers Digital Design Retailer right here.
The Design Course of:
I took a take a look at all my surfboards, analyzed the fin shapes and foils of every of them – sadly no two fins had been alike. A couple of of them appeared fairly complicated, others amazingly easy. I used to be in a position to break down the design into bitesize options that I used to be in a position to concentrate on. I began with a easy sketch on a bit of paper (as a result of I’m old style like that) which allowed me to wrap my head round how I might convert the design digitally. I take advantage of SolidWorks (certainly one of many design software program choices which can be on the market) which is extra of an ‘engineering’ CAD program the place I used to be in a position to create the fin design digitally.
Profile Define –
Many of the fins had the same define so I took a median of my two favourite fins that I take advantage of most ceaselessly. The most important consideration to be careful for was to keep away from any overhang better than 35 levels or so to make sure the fin might print with none help. The fin define was sketched utilizing the ‘spline’ software in SolidWorks on a single aircraft.
Floor and Foil –
For the complicated and natural floor of the fin, the design needed to contemplate printability and hydrodynamics. A foiled floor is used to create a low stress when shifting via a fluid. I do not intend to dive into that too deeply, however I used to be in a position to take some measurements off of the fins I had and recreate a foiled floor. The foiled floor was a mix of three splines – two cross sections and a backbone to loft throughout.
Fin Base –
My damaged fin had just a few attachment factors that wanted to be included within the design so the fin connected to the surfboard. These small options had been created roughly, and optimized after just a few printed iterations. The fin base options had been created utilizing primary extrusions and cuts.
Left and proper fins –
This is likely one of the greater cheats pulled. To design the left fin, the profile of the middle fin was break up in half, tilted at a 5 diploma angle and ensured. The fitting fin was mirrored from the left. Hooray for brief cuts!
The Printing Course of:
Materials decisions had been more durable than anticipated for this challenge. I attempted many choices: PLA, Nylon, ABS, and PET. On the finish of the day PET and PLA labored nice, my concern with PLA is that it might warp within the solar – however after just a few months of testing, that has not occurred but (fingers nonetheless crossed). Nylon is a powerful materials, however far too versatile to keep up form as a surfboard fin in use and subsequently not advisable for this challenge. ABS had its benefits and I used to be in a position to vapor polish the fin properly to create a easy floor, however layer adhesion was an issue.
One of the best performing fin was printed on the Pulse XE machine utilizing NylonX – the mix of Nylon and Carbon Fiber makes for superb power and sturdiness with a stiffness that’s unmatched.
Testing:
Ahhh – probably the most satisfying a part of any activity. I used to be in a position to take out just a few boards – every with totally different 3D printed supplies. The carbon fiber nylon fins that had been printed on the Markforged labored implausible. So nice that they had been useful, strong, and really stiff. PLA and PETG fins labored nice as nicely, PLA has the potential to grow to be malleable if left within the solar. I acknowledge that danger, however after just a few journeys to the seashore and some afternoons of the fins laying behind the truck on a scorching southern California summer time day – they’ve survived. The nylon solely printed elements had been disappointing, the fin design is simply not thick sufficient to be inflexible in nylon. Nylon is versatile when skinny, and if designed thicker could be stiff – surfboard fins don’t seem like a wonderful selection except paired with the lengthy strand carbon fiber.
Conclusion:
Not solely a enjoyable and satisfying challenge, however an opportunity to contribute to the 3D printing group in addition to the browsing group. I’ve uploaded the recordsdata to the MatterHackers Digital Design Retailer and they’re free for anybody to obtain and print for themselves. This can be a challenge that basically highlights the flexibleness and energy of desktop 3D printing. I used to be in a position to design and iterate rapidly whereas engaged on a passion that I’ve an excessive amount of ardour for. On the finish of the day 3D printing facilitated the one thing I had in my head as an thought into actuality.
