Project Scope
CNC-machine the foam core for a friend's experimental hydrofoil board design before fiberglass and carbon fiber layup.
Project Considerations
- Smooth finished surface ready for fiberglass and epoxy
- Standardized mounting for commercial foils
- High precision to represent the experimental geometry of the deck
Machining Strategy
- Toolpaths programmed in VCarve
- Full-contour machining on a ShopBot CNC router
- Machined reference corner and locating rails to orient for second operation
Assembled Project
- Fiberglass and carbon fiber plys laminated to core
- Finished with paint and foam traction pad
- Finished board performs great out on the lake
Project Summary
During high school a friend designed an experimental hydrofoil board and needed a foam core machined to build it. I programmed the toolpaths in VCarve and full-contour machined the core on a ShopBot CNC router. I planned for two setups with locating geometry so the rocker, rail, and deck surfaces stayed plumb to each other. The board was then layered with fiberglass and carbon fiber before sanding and paint. The board worked fantastic on the lake and was a huge success.
Board in Action
