The A4 test sample
Let's create a real sample at the size of an A4 paper to see, feel, and test our design proposal. A tangible representation will help us assess material performance, weight distribution, and structural integrity. Material choice shall be either recycled or natural. We are aiming to reduce the CO2 footprint with at least a factor of 3 over the typical standard windsurf board.
Materials of choice
Core Structure: A 4 mm 3D-printed lattice structure made from recycled PETG, keeping the CO2 footprint As Low As Reasonably Practicable (ALARP). This lightweight, intricate framework provides structural support while promoting sustainability.
Rails: 3D-printed PETG rails, laminated on the outside with flax fiber—a naturally grown, biodegradable material. This enhances both durability and eco-friendliness.
Deck Plate: A 10mm Econcore honeycomb deck, made from recycled polypropylene. The interior is laminated with basalt fiber (sourced from volcanic rock) for enhanced rigidity, while the exterior is finished with natural flax fiber for a sustainable touch.
Initial Findings:
The resulting sample is undeniably strong but heavier than anticipated. Despite this, it remains workable, proving that the material choice is effective. The Econcore deck plate stands out as an exceptional weight-saver, providing remarkable structural integrity without unnecessary bulk. However, most of the weight is concentrated in the PETG core and rail structure.
The challenge now lies in redistributing weight efficiently while maintaining durability.
How its done
For this A4 test sample, we've chosen a combination of innovative and sustainable materials to achieve a balance between strength, weight, and environmental impact. All designed in shape3d and fusion360. The PETG structure is printed and assembled @YUYO Montpellier in France.
Bottom Layer: On the left picture, a Paulownia wood base, laminated on the outside with glass fiber to preserve the wood's aesthetic while adding an extra layer of resilience.
Next Steps:
Potential solutions continue to emerge—perhaps refining the lattice density, adjusting fiber reinforcements, or experimenting with alternative bio-composite laminates. With further testing and iteration, we move closer to a design that balances performance, sustainability, and weight optimization.
This A4 test sample is just the beginning. Every insight gained brings us closer to a breakthrough in lightweight, high-performance, eco-conscious design.