Full sized kayak verification prototype printed in recycled material and milled At RISE. Kayak is printed in one continuous path with no travel moves making a consistent and robust process to validate most materials.
The material used here is a recycled kayak, shredded and recompounded together with polyethylene fishing nets found on the west coast of Sweden, and PLA from Finnish pine forests. The shredded kayak was originally printed in recycled polyethylene wood fiber composite.
General hull shape by Melker of Sweden and adapted to fit the printing process by Woodrow Wiest. Certain overhangs were removed and support structure modeled to assure successful printing and milling.
Adaxis AdaOne software used for printing and milling preparations by Emil Johansson. A 45 degree planar tool path is used. Hull bottom extrusions are increased by 50% to facilitate future milling. Paths are also generated for printing hatch rings directly onto the previously printed kayak, eliminating the need for gluing commercially available injection molded hatches. Milling paths are created to cut open all hatches, and eventually the part will be flipped and the hull bottom milled smooth (not seen in this video).
Project made possible at RISE by Researcher Ting Yang Nilsson through funding from Vinnova under LIGHTer.