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Windsurfer Clip - Reverse Engineering
This project centered around an old windsurfer that my family owned. The windsurfer was in great shape, however, one critical piece was broken; a plastic clip that helped secure the mast to the board.
This component did not transmit force from the sail to the board, that was done by a metal shaft that ran through the plastic clip and into a metal rail on the board itself. However the clip helped orient and position the shaft on the metal rail.
While the clip did not have to be able to withstand the full force that the wind puts on the sail and board, it still had to be very robust. Attempting to replicate it using 3D printing was an exercise in reverse engineering and a test in the durability of PETG components.
After careful measurement of the original part, a model was created in SOLIDWORKS. An assembly and motion study were done to ensure proper function and fit of components.
One notable part was a partial ring of metal that acted as a buffer between the plastic clip and the metal shaft. This piece could not be 3D printed.
In order to replicate this metal ring, a steel washer was modified. Then, during the printing process the print was paused, and the washer glued to the print using a strong adhesive. The print was then resumed overtop of the metal ring, effectively replicating the original clip.
The final components were modified slightly from the original design to allow for easier manufacturing using FDM 3D Printing. Both pieces were printed using PETG, a robust and UV resistant plastic.
All components worked effectively when tested with the original windsurfer board and sail. They have stood up to multiple uses in light to medium winds.Â
The inner portion of the clip was printed flat to allow for the complex shape, the addition of the metal ring, as well as greater strength and flexibility in the arms of the clip.
The outer portion of the clip was printed upright, to allow for the hollow interior as well as to provide greater strength in the z direction.
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