WIP - the C-Wing Fish Kite Surfboard

[kiteboardshaper]

I have a bit of a project on the go - need to make some new kite surfboards for the development team.

Here is the WIP of the C-Wing Fish:

Boards are going to be shaped from XPS foam on a flatbed 3 axis CNC router. All toolpaths will programmed with KaroroCAM.

Plan is for the boards to be vacuum infusion laminated in epoxy resin with Basalt Fibre reinforcement.

I’m hoping to document the whole build as a ‘real world’ application of KaroroCAM.

Cheers

DK

[martynjhogg]

Nice!

I’ve tried a few times to do GH boards but never quite managed to finish. I’d get stuck on how to close the surface at the nose or tail for example.

It would be interesting to do a Shapediver version so people can shape their own boards and output plans for a wood build / self build or order just the CNC’d blank or a finished product.

The 3d printed cores look interesting too…
https://swellcyclesurfboards.com/?fbclid=PAZXh0bgNhZW0CMTEAAaZAUjs96w1zkWF-9zveIo2L7CzWbVW4gT8p1HOcdaEi0IfALcJqLF_SWy4_aem_xRsKvITv13KVx_IQRM5iOQ

[kiteboardshaper]

Wait for it @martynjhogg - this project is going to get its own video series.

Here is a teaser:

[laurent_delrieu]

Hello,
I work for them, I make the Rhino/Grasshopper tool to do the 3d core. We are at the 4th version of the tool !
And I worked a little for Wyve !

Wyve: Ride the Future with 3D-Printed Surfboards

[kiteboardshaper]

Shaping a surfboard on a 3 axis flatbed router using KaroroCAM:

Part 1 - The Board:

Part 2 - The Rocker Table:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 2 - The Rocker Table

Part 3 - The Machining Index:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 3 - The Machining Index

Part 4 - Cutting the Fin Box locations:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 4 - Cutting the Fin Box locations

Part 5 - 3D Roughing and Finishing:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 5- 3D Roughing and Finishing

Next to come - Materials sourcing!

Cheers

DK

[kiteboardshaper]

Part 6 - Trimming out using a 3D Trace toolpath:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 6 - Trimming out using 3D Trace

Cheers

DK

[shaun_c (Shaun)]

Massive fan of WYVE, such sick innovation to a sport that often hates non-traditional methods. I have to ask how hard is it to glass the board? The infill seems very tricky to smooth around.

[kiteboardshaper]

Thanks @shaun_c

Good question, if I was hand laminating the area around the wings and swallow tail would be a pain, but ok with the right resin.

This project is going to be a single shot (top and bottom laminate in one go) resin infusion. This means I’ll be dry loading the reinforcement (in this case basalt fibre) onto the core and have vacuum pressure to hold everything in place.

First day of filming for the project has been done- video out as soon as I’m done with the editing.

Cheers

DK

[kiteboardshaper]

Part 7 is live this morning - actual dust being made:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 7 - Making the Machining Index

Cheers

DK

[kiteboardshaper]

Parts 8, 9 and 10:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 8 - The Machining Index file updates

CNC Shaping a Kite Surfboard in KaroroCAM - Part 9 - Rocker Top and Laminate Pattern

CNC Shaping a Kite Surfboard in KaroroCAM - Part 10 - The Leash Plug Recess

Back into the workshop this morning to make more dust…

Cheers

DK

[kiteboardshaper]

I love workshop days…

Excellent day @moniquelovestokite factory.

Dave Kay on Instagram: "Excellent day @moniquelovestokite factory."

Cheers

DK

[kiteboardshaper]

Part 11, making dust and rocker tables:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 11 - Building the Rocker Table

Cheers

DK

[kiteboardshaper]

Part 12, Cutting the laminate marking pattern;

CNC Shaping a Kite Surfboard in KaroroCAM - Part 12 - Cutting the Laminate Pattern

Cheers

DK

[kiteboardshaper]

Part 13: Parts and Materials:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 13 - Parts and Materials

Part 14: The Shaping Stand:

CNC Shaping a Kite Surfboard in KaroroCAM - Part 14 - The Shaping Stand

Cheers

DK

[kiteboardshaper]

Part 15: Building the Shaping Stand

CNC Shaping a Kite Surfboard in KaroroCAM - Part 15 - Building the Shaping Stand

Cheers

DK

[kiteboardshaper]

Been busy for a couple of months, but back at it on this project.

Part 16: Machining the Foam Core

CNC Shaping a Kite Surfboard in KaroroCAM - Part 16 - CNC cutting the board core

Cheers

DK

[David53 (David)]

I am very stupid here.

I have some experience in metal cutting, but in this process, are there no such tools to rough mill single depths in huge passes? Do they just clog?

For some of those blind holes, I got used to just helical milling holes out in one pass, straight to depth, in most steels and certainly aluminium. Does foam have other properties that make this process hard or otherwise inappropriate?

[kiteboardshaper]

Hi David,

Mostly decent long reach tools (80mm cutting depth) that are great at mowing XPS foam are WELL outside the budget of this build - these cheap Ali-express source cutters are fine as long as you don’t push them hard.

Also was using a borrowed machine and its been a while since I did this process - I was very happy to be conversative on all my toolpaths - I could half the time on the next one with toolpath choices alone.

Cheers

DK

[kiteboardshaper]

Part 17 is out today, a very important part of the process, but not super technical this time - Sanding the Core:

Shaping a Kite Surfboard in KaroroCAM - Part 17 - Sanding the Core

Hoping to dive into the vacuum infusion lamination in the next couple of weeks.

Cheers

DK