The hydrofoil project

Doing this mostly for my own liability so I don't drop this project when it gets hard.

Currently designing a ~1400cm^2 surf foil, 80cm span, eppler-817 profile with some serious anhedral at the tips.

STLs attached. The biggest problem I'm dealing with is stiffness across the span. 4 layers of kevlar and 3 layers of fiberglass was not enough to hold my weight. V2 (this one) has longer spars across the span, and I'm hoping to get it professionally carbon wrapped.

Any inputs on reinforcing? This thing is massive, and has to hold my weight by the mast attachment point in the center while getting beaten by waves, also has to be printable, as thin and as light as possible.

(note the attached STLs are for one half of the wing)

[Ayydan]

Honestly, aside from more infill structure and walls to try and help, I'm not sure what else you could do. I feel like the limit really is going to come from the fact that the unit is fairly hollow

Honestly, aside from more infill structure and walls to try and help, I'm not sure what else you could do. I feel like the limit really is going to come from the fact that the unit is fairly hollow

What could I fill it with that would add long-grain strength? I was thinking of doing an epoxy fill, but I don't think that would get me anywhere.

Hard mode: think we could cast this out of aluminum? Would be fun to make an absolute death machine

[Ayydan]

Honestly, aside from more infill structure and walls to try and help, I'm not sure what else you could do. I feel like the limit really is going to come from the fact that the unit is fairly hollow

What could I fill it with that would add long-grain strength? I was thinking of doing an epoxy fill, but I don't think that would get me anywhere.

Hard mode: think we could cast this out of aluminum? Would be fun to make an absolute death machine

Honestly, with the extreme sweep of the foil, I don't think there will be an easy printing orientation for you here. Maybe if you split it like in this image you can print the layers in an axis with less load to reduce the reliance on layer adhesion. I'd also give you a place to insert cross struts with more support material around them to possibly stiffen it some more

Honestly, aside from more infill structure and walls to try and help, I'm not sure what else you could do. I feel like the limit really is going to come from the fact that the unit is fairly hollow

What could I fill it with that would add long-grain strength? I was thinking of doing an epoxy fill, but I don't think that would get me anywhere.

Hard mode: think we could cast this out of aluminum? Would be fun to make an absolute death machine

Honestly, with the extreme sweep of the foil, I don't think there will be an easy printing orientation for you here. Maybe if you split it like in this image you can print the layers in an axis with less load to reduce the reliance on layer adhesion. I'd also give you a place to insert cross struts with more support material around them to possibly stiffen it some more

Dude, that's a smart way to split it. Could probably build a spar all the way into it. Will have to play with that tonight

[Ayydan]

Honestly, aside from more infill structure and walls to try and help, I'm not sure what else you could do. I feel like the limit really is going to come from the fact that the unit is fairly hollow

What could I fill it with that would add long-grain strength? I was thinking of doing an epoxy fill, but I don't think that would get me anywhere.

Hard mode: think we could cast this out of aluminum? Would be fun to make an absolute death machine

Honestly, with the extreme sweep of the foil, I don't think there will be an easy printing orientation for you here. Maybe if you split it like in this image you can print the layers in an axis with less load to reduce the reliance on layer adhesion. I'd also give you a place to insert cross struts with more support material around them to possibly stiffen it some more

Dude, that's a smart way to split it. Could probably build a spar all the way into it. Will have to play with that tonight

haha glad to have given you an idea!

pid='35' dateline='1686853472']

[Ayydan]

Daaaamn that's slick, I can't wait to see how it holds up haha

Its freaking yuge!

Carbon goes on today. Hopefully rideable by the weekend!    

[Ayydan]

Hopefully the fiber stiffens the joint, fingers crossed!