LET'S TALK ABOUT 3D SCANNING

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.

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

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!

​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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Alignment is an important step for 3D scanning to ensure the 360 degree digital surface model generated by the 3D scanner accuractly replicates the physical object.

With Shining 3D scanners, there are several alignment methods that can be deployed, depending on the shape of the target object.  Let's go through them one by one.

Also important to remember is when you are 3D scanning a large object on a tripod without a turntable, you need to ensure there is at least a 30% overlap from one scan to the next to ensure alignment.

​So that's it.  Not as difficult as you thought, right?

Structured light 3D scanners use the projector light to project structured light patterns onto your target object, while the cameras capture the change in the structured light patterns and the 3D scan software generates the 360 degree digital surface model of your target physcial object. Therefore, for any structured light 3D scanner, adjusting the 3D scanner projector brightness level is very important. This enables the 3D scanner to project the sturctured light pattern adequately to capture the surface dimensions of the target object.

See below for guidance.

It is important to adjust your distance between the 3D scanner and the target object as well as the brightness.

Make sure you get the hang of the correct brightness as well as the distance between the object and the 3D scanner, so your 3D scanning process will proceed smoothly!