ISSUU

WEEK #12

For this final building week I bought neodymium magnets (3T 15 Ø) Euljiro 3 Ga to connect each parts together.

I also split each of the 3 parts horizontally in 2 pieces to make it easier for printing. 

And then I started the 3D printing. I had to learn how to use the 3D printer and to calibrate the plate, because what you'll see below is when the plate is not very flat. 

After correcting it I launched the 6 days printing process.

Each pieces took around 12 hours.

As you can see there are so many supports that need to be cleaned out.

After taking all the supports out and fixing some small broken parts. I had to weld the 2 sides of each part together.

       

            

                  

WEEK #11

This week I've finalized my 3d model, now it's ready to print.

I changed my plug system. Instead of having 2 cables tightening up all the 3 parts, I followed the professor's advice, I decided to connect the different parts with neodymium magnets. They are super strong, light and cheap.

Previous Cable System :

Each magnets are positioned inside a plug.

After modeling all of these I used an online service called "Make Printable". This simply fixed any kind of mesh problems.

Then I used Simplify 3d to generate the G code for the 3d printer.

But a problem came up, it generates a lot of supports and these supports I think will be very complicated to take them off in a clean way...

I guess, I have to modify the supports parameters to reduce the number and make it easier to pill off.
I also worry about the printer if it will be good enough for this complexity.

WEEK #10

This week I had to engineer the 3 parts modular plug system.

First I changed my base model. If I want to make it in real size one day, the parts would have been too big for most of the printers, thus I decided to use a smaller shape.

The shape of this board, more round, is also better to work with. Rails are easier to make, the tessellation can be a bit less dense.

I used the isolines of the original model to densify the mesh on the rail part. Also this allows the final shape to get smoother rails, that makes it easier for the laminating process.

 

The overall size of the board is around 141cm, I decided to cut it in 3 parts of 47cm each. Also I thought about assembling and connecting these parts with a simple "plug" technique. I choose to hide the plugs in the rails, because I want to cover the rails with carbon fiber, the plugs will be hidden under. In order to connect everything, I want to use a simple bicycle brake technique. 2 thin cables passing through the plugs and that you can tighten with a bolt positioned on the wingers.
And when you tighten the wires that rigidify the overall structure.

WEEK #9

This week I tried to make 2 small versions of this surfboard using 2 techniques. One is 3D print and the other is laser cut.

Before acid :

After Acid :


I wanted to use the 3D printer to get an idea of the tesselation in real life.

And I wanted to get a sliced model of my surfboard shape to learn how to get a quick representation of the volume in order to engineer and make some mock-up of the modular system I imagined last week.

I added some reinforcement on the rails. 

WEEK #8

This week I focused on ways to make this surfboard modular.

I wanted this surfboard modular for 2 reasons :

• We cannot print a 1.8m height object easily
• Make it foldable and easy to travel with

Each part will be 60cm each.

I thought about creating 2 plugs on each part and linking the whole thing with 2 wires passing inside the plugs.

The difficulty here is to avoid leaking. Each part must be totally water proof. So I have to think about making joints.
Also to prevent the fiber glass overlay of having inner pressure problem I have to add goretex valves on each of the 3 parts of the board I guess.

The good thing with 3d Printing is that I can include all the plugs (fins, leash, valves) inside the structure with some boolean techniques.

One more problem I had to solve was the density of the tessellation on the high curvature parts. Rails are really important parts of the board design and hydrodynamics. Rails must be smooth and straight not bumpy. My solution is to add manually, on the 3d model's rails, tubes to the structure after the tessellation process. These "tubes" will act as guide for the fiber on the rails.

Problem with my model (maybe normal problem or 3D printer problem).

WEEK #7

This week I tried to connect my previous week thoughts about noise with an object I really like, a surfboard.

These days, surfboard's cores is made of foam, either polystyrene or polyurethane.

These materials are light, very easy to shape, easy to cover with resin and fiber glass.

But in my opinion we can make surfboard's cores stronger, more aesthetic, and easier to build using new materials and techniques. I previously tried that with cardboard but even though I'm really happy with the aesthetic and the strength, a small problem remains. If the resin/ fiber glass overlay get a ding and the water goes inside, it takes a long time to dry the cardboard completely before fixing the hole.

In order to get rid of this problem I thought about using a hydrophobic material. The idea of 3d printing came to my mind. We can use strong filaments and maybe as sustainable as cardboard.
I then had to find a technique to fill a volume in a light and strong way, that's how I connected my idea with noise. Using noise we can randomly fill a volume with matter, we then have to interconnect these dots. If we think about it looks like random interconnected polygon cells. This is "Voronoi" tesselation.

Also this kind of technique allows to make a holed core. In my opinion "transparent" surfboard are beautiful.

From there I tried to generate Voronoi tessellation on a volume. It looked good.

Then I learned how to make a proper 3d Surfboard model on Rhino. (Now I can also use a CNC machine to shape polystyrene as my model).

Then came the most complicated part. I had to create this tessellation on my model. I followed a bunch of grasshopper tutorials and after around a week of trying different techniques, I succeeded !

The idea is to 3d print a small size prototype.

Later, because most of 3d printers are too small to make a full size board I thought about adapting my model to make a modular surfboard which can be perfect for traveling !