People always tend to push the boundaries of what is doable with a 3D printer. This is also true for [AndrewW1977] when he decided to 3D print a full-sized functional surfboard.

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With just over nine full days of printing time, 95 individual pieces, and using 3.1 kg of PLA (not counting all the test prints), this is certainly a monumental project. One of the bigger issues [AndrewW1977] had to solve was avoiding air pockets inside the board. Ideally, you would want to end up with only one continuous hollow chamber in order to easily vent all the air inside the board when it heats up. [AndrewW1977] chose to overcome this problem by using zero infill for each individual piece. The pieces were then connected with the help of alignment pins that have a central hole thereby connecting all hollow chambers. By using a triangular shape, he managed to […]

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