“What led us to 3D printing was a loaned FDM (fused deposition modeling) machine. This allowed us to take a closer look at the capabilities of this technology,” explained Philipp Horstenkamp, a member of Sailing Team Darmstadt. “There already was some familiarity among some members of the team who had dabbled with 3D printing outside of work.”
As this task has never been accomplished before, the sailing team set down a strategic plan, and split into different groups to focus on the areas of control systems, electronics, mechanics, navigation, organization, power supply, and software. The team chose the German RepRap X1000 3D printer to offer support in all of these areas, as its ability to fabricate parts with large dimensions fulfilled their requirements.
“The advantages we gain from using 3D printing technology are truly amazing. The capability of fast and straightforward fabrication gives us the freedom to experiment with different components,” said Horstenkamp. “This results in significant savings, since the fabrication of such detailed prototypes usually requires a lot of time, money and resources.”
The team is also working to 3D print a complete model of the sailboat’s hull, in order to demonstrate the finished boat’s performance at trade shows.
Another reason that the team chose the X1000 is its ability to use different materials. Since the sailboat needed a material that would be more resistant to slow thermal deformation, the team mostly used PET-G filament. The material is able to maintain strength and form at temperatures up to 176°F, and is just as easy to process as PLA. It also has PLA’s high surface quality, so no post-processing is required if it is applied correctly.
“With these parts, we took special care to use supporting structures only where absolutely necessary. This, in turn, saved us time,” explained Horstenkamp. “With so many small openings for fasteners, it was easier to print simple cover layers rather than openings with a solid support structure.”
PET-G also adheres well to standard PET film, and has very little warping or distortion. As the sailing team would be working on electrical installation, PET-G has another bonus in that it’s classified as flame-retardant according to fire code (Brandschutzvorschrift B1). PLA filament was also used to produce some smaller mounting parts, and for the transmission.
German RepRap’s verified partner, WDS Software & Service GmbH, also offered a helping hand with Sailing Team Darmstadt’s project.
At the upcoming Rapid.Tech 2017 trade show and conference, which will be held from June 20-22 in Erfurt, Germany, a sailboat prototype will be 3D printed live for everyone to see on a German RepRap X1000. In addition, the Darmstadt Technical University Sailing Team will personally introduce its prototype, already decked out transmission, motor, and electronics, at Booth #321 in Hall 2. Discuss in the Autonomous Sailboat forum at 3DPB.com.