[3D Printing] Taking on a Pacific rowboat crossing with 3D-printed parts

3D Printed Parts Support the Maclean Brothers' Trans-Pacific Challenge

"Ocean rowing is a very interesting sport because it's relatively new. Very few people have rowed across an ocean, and there is still a lot of room for innovation and many problems to solve in this sport."

Ewan Maclean, Engineer

The three Maclean brothers—Ewan, Jamie, and Lachlan—who have rowed across the Atlantic Ocean and set multiple world records, have begun their challenge to cross the Pacific Ocean with the goal of fundraising for clean water projects.

As an engineer, Ewan leveraged his experience from previous Atlantic crossings to design and 3D print approximately 50 custom parts for the brothers' boat, "Rose Emily." This allowed them to overcome challenges related to operability, communication, rest, and ergonomics encountered during long voyages at sea.

Producing Custom End-Use Parts with the Form 4

The Maclean brothers continuously documented ideas for improvements to make their Pacific crossing safer and more comfortable. Ewan, with years of 3D printing experience, focused particularly on optimizing how equipment was used and every detail.

"Ocean rowing is a sport that emphasizes small gains. In every aspect, even if the daily efficiency improvement is less than 1%, it can reduce a lot of stress and challenges."

Ewan Maclean, Engineer

Complex geometries, the need for lightweight parts, and tight deadlines made 3D printing the most suitable method for manufacturing these custom end-use parts. Attempting to produce some parts by welding would not only increase weight but also make it difficult to achieve the ideal shape to conform to the boat's curves.

Ewan, having previously used Formlabs 3D printers, chose Stereolithography (SLA) technology to produce the wide variety of parts needed for the Rose Emily.

"A major advantage of Formlabs 3D printers is how easy they are to get started with. Once you complete the setup and follow the steps to fill the resin, you can start printing immediately, which was very convenient for us."

Ewan Maclean, Engineer

From Sketches and 3D Models to Print Preparation in PreForm

Ewan first sketched out the ideas generated by the three brothers, then created 3D models. Finally, he imported the files into Formlabs' free print preparation software, PreForm, configured the settings, and sent them to the Form 4 for printing.

1. Document challenges and usage needs requiring improvement during the voyage.
2. Sketch parts and confirm mounting positions and shape constraints.
3. Create 3D models that fit the dimensions of the boat and equipment.
4. Import models into PreForm and complete print orientation and support settings.
5. Produce parts with the Form 4 and verify actual assembly accuracy.

"Simply importing files into PreForm and sending them to the 3D printer allows us to produce parts that meet our needs and assemble with high precision. The print quality is truly remarkable."

Ewan Maclean, Engineer

Formlabs Engineering Resins: Combining Strength, Detail, and Application Needs

"What surprised me most was the advanced level of the new engineering resins. They possess excellent strength, sufficient to be applied as real-world parts."

Ewan Maclean, Engineer

For the Rose Emily's parts, three types of Formlabs resins were used: Tough 2000 Resin, Durable Resin, and Clear Resin. They were selected based on structural strength, durability, flexibility requirements, and mold-making applications, among others.

"The strength and detailed resolution these parts demonstrate are impressive. I have complete confidence in this printing process for this mission."

Ewan Maclean, Engineer

The Tangible Impact of Approximately 50 3D Printed Parts

Ewan designed and printed approximately 40-50 parts for the Rose Emily. These included ergonomic components tailored to the brothers' body types, specialized parts not available commercially, and complex shaped parts that needed to conform to the hull's hydrodynamic and aerodynamic curves.

Starlink Communication Mount

The Starlink terminal, which provides satellite communication, needs to be installed at a specific position and angle to ensure stable signal reception and prevent water accumulation. The mount was also required to withstand the impact of high waves hitting the stern and prolonged exposure to salt and UV radiation.

Jetboil Stove Gimbal

This last-minute addition to the design allows the Jetboil stove to remain level when boiling water. The part was completed about 12 hours before the brothers' departure, highlighting the strength of rapid custom manufacturing through 3D printing.

Removable Bed Frame

Consisting of 3D-printed connectors and carbon fiber rods, the removable bed frame can be installed in the stern, allowing the brothers to stretch out and sleep without having to enter the hot and cramped cabin.

Custom Ergonomic Seat

During long voyages, muscle mass can decrease, tending to exacerbate discomfort from rowing seats. The three brothers took molds of their bodies, performed 3D scans to create custom seat molds, and then cast and shaped them in silicone.

Oar Holder

When one rower temporarily releases an oar, the oar holder secures it firmly, preventing it from interfering with other rowers' movements or the limited workspace on board.

Form 4 3D Printed Parts to Be Tested on the Pacific Route

"We can take parts straight out of the 3D printer and put them directly into real-world operation. One of the best ways to validate the quality of a part is to have it experience a 120-day ocean voyage in harsh environments of salt, weather, UV, and repetitive use."

Ewan Maclean, Engineer

The Pacific crossing is not only a challenge to the Maclean brothers' physical and mental endurance but also a real-world test for the Rose Emily and its custom parts. Sunlight, seawater, salt, storms, and daily operation will demonstrate the durability and functionality of these parts in a real environment.

This project demonstrates that the Form 4, PreForm, and Formlabs' engineering resins are highly effective not only for prototyping and process validation but also for producing custom end-use parts that meet specific geometries, installation conditions, and ergonomic requirements.