3D Scanning and Reverse Engineering Project: Efoil Wing

In the ever-evolving world of watersports, efoiling has taken the spotlight with its thrilling combination of surfing and flying above water. Efoil boards, propelled by electric motors, offer an exhilarating experience, and at the heart of their performance lies the efoil wing. However, this industry is young and manufacturers struggle to survive such as FOIL Inc (getfoil.com)  as there is not enough demand out there leaving enthusiasts in a lurch when their favorite wing model is no longer available to purchase and the original designs may be lost. Fortunately, 3D scanning and reverse engineering offer a lifeline for reviving these designs. In this blog post, we'll explore how you can use 3D scanning technology to bring an out-of-production foil wing back to life.

Importance of the Efoil Wing

The efoil wing is crucial for the lift and stability of the board, directly affecting the rider's experience. Each wing model has its unique design that caters to different riding styles, water conditions, and skill levels. When a beloved wing is no longer produced, finding a suitable replacement can be challenging, making reverse engineering an appealing solution.  We have 3D scanned the efoil wing 200 of the FOIL series using the EinScan Pro HD with high accuracy as the initial step to enable full reverse engineering and manufacturing.

PART I: 3D SCANNNING TO CAPTURE THE ACCURATE SIZE AND CURVATURE

Step 1: Preparing for 3D Scanning
​Before diving into the scanning process, you'll need the right tools and a suitable environment.  Here is what we used.

• EinScan Pro HD 3D Scanner
  • This scanner is suitable for mid to large objects, thus was chosen to scan the efoil wing.  For smaller objects, we would recommend the EinScan Pro 2X V2.
  • This scanner captures black and shiny surfaces well too without having to spray its surface.  Also can capture intricate details but in the case of the foil wing, there were none.
  • It save digital files in STL, OBJ, ASC, PLY, P3, 3MF file formats.  For details about the file formats, read the blog here.

EinScan Pro HD and the Wing prepared with markers

• Markers
  • 3mm reflective markers that come with the EinScan Pro HD.
  • Placed markers in a random, non-linear pattern. 
  • While scanning, we made sure at least 4 markers in each frame were captured.

Step 2: 3D Scanning the Efoil Wing​

• Calibrated the EinScan Pro HD according to the instructions provided on the screen.  This is very simple.
• Placed the efoil wing on a stable surface in a room with consistent lighting.
• Scanned the wing in Handheld Rapid Scan mode with Hybrid Alginment using both features and markers. Usually, the tracking is lost when there are not many features, thus starting from where there are a lot of features so the 3D scanner.  I started from the middle top part then went right and left.  Also if you hold the EinScan Pro HD at a 45 degree against the surface you are trying to capture, it works better. Also on the EinScan Pro series software, you can check the scan quality as you scan so you can tell what quality of scan you are capturing.
• Once I had scanned one side of the wing, saved it as a project group.  Then flipped the wing over, scan the other side similarly, and saved it as a separate project group.

​Step 3: Post Processing 

• Cleaned up each scan and point cloud data for each project (delete floating parts etc)
• Aligned the 2 scans using manual alignment. Due to the thinness of the wing, the automatic alignment was slightly off.
• Generated a mesh model using the mesh optimization parameters which will remove spikes, fill marker holes etc.
• Cleaned up the mesh (used the advanced features available in the post-processing stage such as deleting floating parts, filling holes, reducing file size etc) then saved as .stl.

Aligning the Front & Back Scans

Post-Processed 3D Scan Mesh File

Here is the STL file so you can further reverse engineer and manufacture via 3D printing!

wing_aligned.stl
File Size:	40403 kb
File Type:	stl

Download File

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PART II: REVERSE ENGINEERING
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1. Import the 3D scan into the reverse engineering software/CAD software of your choice - such as SolidWorks, Fusion360, or Quicksurface. Analyze the model's dimensions, curves, and features. Understanding the wing's design characteristics is crucial for accurate replication.
2. Using the CAD software, recreate the wing's design. This step may involve tweaking the original design to improve performance or adapt it to new materials. Ensure that the redesign maintains the key features that made the original wing perform well.
3. Simulation and Testing: Before moving to production, use simulation tools within the CAD software to test the wing's performance. Simulating the wing's behavior in various conditions can highlight potential issues and areas for improvement.

PART III: MANUFACTURING

Once satisfied with the redesigned model, it's time to manufacture the wing.

1. Material Selection: Choose materials that match or improve upon the original wing's properties. Common materials for efoil wings include carbon fiber, fiberglass, and various composite materials. FOIL was manufactured using forged carbon fiber.
2. Prototyping: Create a prototype using techniques such as CNC machining, 3D printing, or traditional molding. Prototyping allows for physical testing and fine-tuning before full-scale production.
3. Testing: Conduct rigorous tests on the prototype to ensure it meets performance expectations. This might involve real-world testing in various water conditions to validate the wing's lift, stability, and durability.

CONCLUSION
3D scanning and reverse engineering provide a powerful combination for resurrecting discontinued efoil wings. By capturing the precise geometry of a classic wing and using modern tools to refine and replicate its design, enthusiasts can continue to enjoy their favorite efoil experiences. Whether you're an efoil aficionado or a watersports innovator, this technology opens up a world of possibilities for preserving and enhancing the sport. So, don't despair about FOIL Inc going bust, let technology breathe new life into it!

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​Growshapes the official U.S. distributor of Shining 3D EinScan 3D scanners. We now carry the eviXscan 3D scanner from Evatronix as well!

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