【3D Printing】Crossing the Pacific with 3D-Printed Parts

3D Printed Parts Help Maclean Brothers Take on Pacific Crossing Challenge

"Ocean rowing is a very interesting sport because it's relatively new. Very few people have rowed across oceans, so there's still a lot of room for innovation and many problems that haven't been solved yet."

Engineer Ewan Maclean

After rowing across the Atlantic and setting multiple world records, the three brothers, Ewan, Jamie, and Lachlan Maclean, are preparing to challenge themselves to cross the Pacific Ocean and raise funds for clean water projects.

Ewan, an engineer, drew on his experience from the Atlantic crossing to design and 3D print approximately 50 customized parts for the brothers' boat, the "Rose Emily." These parts address operational, communication, rest, and ergonomic issues faced during long sea voyages.

Using Form 4 to Produce Custom End-Use Parts

The Maclean brothers continuously documented ideas for improvements that would make the trans-Pacific journey safer and more comfortable. Ewan, with years of 3D printing experience, focused particularly on how equipment functions and the potential for optimizing every detail.

"Ocean rowing is a sport where small improvements matter. In any aspect, even if it's less than one percent efficiency gain each day, it can significantly reduce frustration."

Engineer Ewan Maclean

Complex geometries, lightweight requirements, and tight deadlines made 3D printing a suitable method for producing these customized end-use parts. Some parts, if manufactured by welding, would not only be heavier but also difficult to achieve the ideal shape to conform to the hull's curves.

Ewan had previously used a Formlabs 3D printer, so he chose Stereolithography (SLA) technology to produce the various parts needed for the Rose Emily.

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

Engineer Ewan Maclean

From Sketch, 3D Model to PreForm Print Preparation

Ewan first sketched the ideas proposed by the three brothers, then created 3D models, and finally imported the files into Formlabs' free print preparation software, PreForm, for setup before sending them to the Form 4 for printing.

1. Document problems and usage requirements that need improvement during the voyage.
2. Sketch parts and confirm installation positions and geometric constraints.
3. Create 3D models that match the size of the boat or equipment.
4. Import models into PreForm to set print orientation and supports.
5. Use Form 4 to produce parts and physically verify fit.

"I just needed to import the files into PreForm and send them to the 3D printer, and I could produce parts that met our needs and fit precisely. The print quality was amazing."

Engineer Ewan Maclean

Formlabs Engineering Resins Balance Strength, Detail, and Application Needs

"What surprised me most was the development of new engineering resins. They demonstrated excellent strength, sufficient for actual functional parts."

Engineer Ewan Maclean

The parts for the Rose Emily were made using three Formlabs resins: Tough 2000 Resin, Durable Resin, and Clear Resin, each chosen for different purposes such as structural strength, durability, flexibility requirements, and mold making.

"The strength and detail presented by these parts are amazing. For this task, I have great confidence in this printing process."

Engineer Ewan Maclean

Approximately 50 3D Printed Parts Bring Real Change

Ewan designed and printed approximately 40 to 50 parts for the Rose Emily, including ergonomic components tailored to the brothers' physiques, specialized parts not available off-the-shelf, and complex geometric parts that had to conform to the boat's hydrodynamic and aerodynamic curves.

Starlink Equipment Bracket

Starlink equipment for satellite communication must be installed at a specific position and angle to receive stable signals and avoid water accumulation. The bracket also needs to withstand the impact of waves hitting the stern, as well as prolonged exposure to salt and UV rays.

Jetboil Stove Gimbal

This temporary addition helps the Jetboil stove stay level while boiling water. The part was printed approximately 12 hours before the brothers set off, highlighting the advantage of 3D printing for rapid production of customized parts.

Removable Bed Frame

The removable bed frame, composed of 3D printed connectors and carbon fiber rods, can be installed at the stern, allowing those resting to stretch out and sleep without having to enter the hot and cramped cabin.

Custom Ergonomic Seat

Prolonged voyages can lead to muscle loss, further increasing discomfort in rowing seats. The brothers took body impressions and performed 3D scans to create custom seat molds, which were then cast in silicone.

Oar Holders

When one rower temporarily releases their oar, the oar holder helps secure it, preventing interference with other rowers' movements and the limited operating space on board.

The Pacific Crossing: A True Test for Form 4 3D Printed Parts

"You can take parts directly off the 3D printer and put them into actual use. One of the best ways to test the quality of parts is to subject them to the harsh environment of a 120-day ocean voyage, with salt, weather, UV, and continuous use."

Engineer Ewan Maclean

The trans-Pacific crossing is not only a test of the Maclean brothers' physical and mental endurance but also a practical test for the Rose Emily and its customized parts. Sunlight, seawater, salt, storms, and continuous operation will collectively verify the durability and functionality of these parts in real-world conditions.

This project demonstrates that Form 4, PreForm, and Formlabs engineering resins can support not only rapid prototyping but also the production of customized end-use parts that meet specific geometric shapes, installation conditions, and ergonomic requirements.