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SB Community OEM board ?

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Created by Macroscien > 9 months ago, 13 Oct 2012
cammd
QLD, 3716 posts
18 Oct 2012 11:37AM
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Macro's thread has been at the top of the charts for while now and on its fourth page, and its not the first time he's achieved such popularity. Is there some sort of Sea Breeze award for that.

Macroscien
QLD, 6806 posts
18 Oct 2012 11:54AM
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Sorry mate, but since we have termites in QLD wooden board is not not me
So maybe you have stainless steel or aluminium or made of recycled paper ?
Do you realize how time time-consuming is such construction ? At Aussie labour cost say $70 hour you could buy new shop full of new boards.
Time will come for brand new windsurfing boards at $500-700 as I strength requirements are not so extreme as you think.
If we send this project with body shape outline and no restriction what is inside to NASA engineers that are released from workload after grounding space shuttle - people that never saw windsurfer before - so don't have any inhibitions -
they will come with honeycomb pressurised construction,
Board will weight less then five kilo and will be stronger that you need.

Jezstrt
TAS, 1471 posts
18 Oct 2012 3:07PM
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New windsurfing equipment reminds me of cars, the stuff looses half its value as soon as you use it..

russh
SA, 3025 posts
18 Oct 2012 3:03PM
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Summary Of my understanding of previous 4 pages
Expensive ........ Something china built ......something......honeycomb.............somethingsomething............crazy dude........something......something. Whinge moan something something Cyber bullies - something something



baldrick
QLD, 146 posts
18 Oct 2012 2:49PM
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I for one am dying to meet a female NASA Engineer with no inhibitions!

FormulaNova
WA, 14560 posts
18 Oct 2012 5:57PM
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Macroscien said...

<snippo>

If we send this project with body shape outline and no restriction what is inside to NASA engineers that are released from workload after grounding space shuttle - people that never saw windsurfer before - so don't have any inhibitions -
they will come with honeycomb pressurised construction,
Board will weight less then five kilo and will be stronger that you need.



As long as you don't get the NASA engineer in charge of gluing the tiles on the shuttle. Of course, the NASA version will be light, and super strong, but with a budget to match.

For what its worth, today's type of construction appears to be a good compromise. It's cheap, relatively strong, not too stiff, and easy to repair. Given all the variables, I am not sure you could do too much better.

Macroscien
QLD, 6806 posts
18 Oct 2012 9:27PM
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FormulaNova said...
I am not sure you could do too much better.


Could be made much easier, faster and extremely cheaper.
Like Pepsicola plastic bottle. One mould , blow up to the shape, fill with super strong but cheap foam, pump some pressure and board done. This technology could provide board at $50 max and you still not be able to brake it. Read the space in 5 years and we will see who was right.
BTW I wonder if somebody did already poly carbon ( pepsi bottle) sheet reinforced with carbon nano tubes (not one of us but in right laboratory)?
For me such material looks indestructible in our conditions.

FormulaNova
WA, 14560 posts
18 Oct 2012 7:46PM
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Macroscien said...
FormulaNova said...
I am not sure you could do too much better.


Could be made much easier, faster and extremely cheaper.
Like Pepsicola plastic bottle. One mould , blow up to the shape, fill with super strong but cheap foam, pump some pressure and board done. This technology could provide board at $50 max and you still not be able to brake it. Read the space in 5 years and we will see who was right.
BTW I wonder if somebody did already poly carbon ( pepsi bottle) sheet reinforced with carbon nano tubes (not one of us but in right laboratory)?
For me such material looks indestructible in our conditions.



See, that's where you need to actually try these things. Some things sound good on paper, but in practice may not work so well. On the other hand sometimes things work better than expected.

If you are talking about PET in the above example, with just normal foam, I don't think it would be stiff enough.

For all the disadvantages, the current construction techniques are good.

With ASA(?) plastic boards, they still use fibreglass and carbon to add strength and stiffness, but otherwise, this is similar to what I think you are suggesting.

Macroscien
QLD, 6806 posts
18 Oct 2012 10:29PM
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FormulaNova said...


If you are talking about PET in the above example, with just normal foam, I don't think it would be stiff enough.


That is why the board must be pressurized to get right stiffness.
The main technological problem is to create bridges made of carbon reinforced plastic connecting both sides of the board.
This way only you may have 5 cm thick board with adequate stiffness. Eventually even foam inside become redundant. If your car could drive few tone on inflated tires board could support rider 100 kg , without problem.
So technological problem is only to create a bit complicated structure that is in bedded into external walls and join with internal walls.
There are some thicker parts to support mast, straps and fin bod and PET board is ready.
I hope that pressurized board could remain pumped all the life and we don't need to use pump every time like kiters do, unless even better material come and we will be able to roll down the board after deflating.

JonesySail
QLD, 1082 posts
19 Oct 2012 12:07AM
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Blimey 5 pages! think its gone off track some...
Think what Macro started off saying us that $2500+ is pretty steep for a new board....tend to agree, but what he also is missing is how most retail business works in the world, there are layers of distribution, each having their own costs/margins/taxs that get passed on... if you work it backwards a board ex factory probably is only $500 or less...still I would think $1500 for mass produced and $2k custom is about right, unless factory's start retailing direct.

*Side note, BEST kites did exactly that when they launched years ago, smashed the market, 2 kites for the price of one deals!, even 3!...but once they got their foot in the door, they went back to tradtional distribution systems and prices to match...issue is no one really wants to deal with the end customer!...thats what stores are for!

Rather than OEM, as previously stated your better off getting 100+ people that all want the same board/model, work with a dealer to do a pre pay deposit bulk order, then you will get your price break, !

Everytime I walk into a Wind/Kite/Sup shop i cant fathom how they make a living, so many models choices...stock holdings, cash flow nighmare.

Here is my recent example of why we need stores/retailers...

I needed a new boom, so today I went in checked their 'special price' boom didnt like it, didn't like what else that was on offer, then spotted the boom of my dreams in the corner on its lonesome....just crying out for me, decent fair price, deal done.

Then for more service, they are happily shipping a 2nd Hand sail I sold on SB for me my customer in NSW, and will do for the next sail also....so then when cashed up I will get a new sail from them!

The 2nd Hand wave board I have just purchased from SB is also getting shipped via a shop in VIC, I'm sure those funds will get directed back in to the store, 2 x happy bargain hunters = 2 new store product sales.

The SUP i purchased this year, I did so after test riding several models FOC from local store.
The Kite I purchased last year was the same, several demo's/sizes before I was happy, then purchased from the store that I demo'd from.

I couldnt have done any of the above without my local store/s.

Personally , I cant wait to see the 'Macrosciencewindsurfer deluxe edition V3' sometime soon...he may be on to something with at least one of those fancy high tech thingy fibre gel pva air inplate super laminate cyber cell concepts....I bet 1$ one day there will be a different way to build boards,
let me know when its here,.....

FormulaNova
WA, 14560 posts
19 Oct 2012 5:41AM
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Macroscien said...
FormulaNova said...


If you are talking about PET in the above example, with just normal foam, I don't think it would be stiff enough.


That is why the board must be pressurized to get right stiffness.
The main technological problem is to create bridges made of carbon reinforced plastic connecting both sides of the board.
This way only you may have 5 cm thick board with adequate stiffness. Eventually even foam inside become redundant. If your car could drive few tone on inflated tires board could support rider 100 kg , without problem.
So technological problem is only to create a bit complicated structure that is in bedded into external walls and join with internal walls.
There are some thicker parts to support mast, straps and fin bod and PET board is ready.
I hope that pressurized board could remain pumped all the life and we don't need to use pump every time like kiters do, unless even better material come and we will be able to roll down the board after deflating.




Without really wanting to make this go on and on, Macro, I think you need to get some understanding of material science. You may have missed the fact that the inflated tyres on your car are not stiff and are actually really heavy.

If you don't understand how a current board is made, how can you understand the requirements for board construction?

Do everyone else a favor, and try some of your theories out instead of spouting new ones! We all have ideas, but without understanding the requirements you are just blowing hot air.

longwinded
WA, 344 posts
19 Oct 2012 12:07PM
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Macroscien said...
FormulaNova said...
I am not sure you could do too much better.


Could be made much easier, faster and extremely cheaper.
Like Pepsicola plastic bottle. One mould , blow up to the shape, fill with super strong but cheap foam, pump some pressure and board done. This technology could provide board at $50 max and you still not be able to brake it. Read the space in 5 years and we will see who was right.
BTW I wonder if somebody did already poly carbon ( pepsi bottle) sheet reinforced with carbon nano tubes (not one of us but in right laboratory)?
For me such material looks indestructible in our conditions.



We wont need to wait 5 years. All production boards in the 80's were made this way.

Mobydisc
NSW, 9028 posts
19 Oct 2012 4:39PM
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Yeah most boards were made out of plastic in the 80s and some of the 90s. Either blow moulded polyethelene (I think) or rotomoulded. I miss those boards as they were so tough.

When I got back into windsurfing in 2007 it was so surprising to find out almost all boards were made in one Thai factory owned by Cobra. I remembered Cobra as one brand amongst many in the early 80s. They had their epoxy boards. Somehow they've worked out a way to out compete all the windsurf board factories in Europe, America and Australia. No more Mistrals or F2s made in Germany.

As I mentioned before it would be great if there was a modern equivalent of the Bomboras from the early to mid 90s. Modern fast shapes built to take into account their weight and flex. Tough boards that don't crack if you drop them. Also selling for about half the cost of lighter boards.

On the other hand if you take into account inflation and the rising costs of living, $2500 or so for a top of the line board works out quite well to the equivalent boards of 15 or 25 years ago. So the real cost of boards has gone down over time.





dan berry
WA, 2562 posts
19 Oct 2012 6:05PM
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This thread started with an obvious complete lack of knowledge in board construction and is now at a point where we are being "educated" on how it could be done better. Macro, if you want a blown plastic board go ****ing buy a second hand on from the 80s ( you'll pick on up for about $2 on eBay) waaaaaaaaaaay cheaper than the $ 500 your talking about.

dan berry
WA, 2562 posts
19 Oct 2012 6:07PM
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Actually I'll buy one for you if you just shut up

kato
VIC, 3391 posts
20 Oct 2012 12:21AM
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I saw a Bombora 260??? (Long skinny one) last weekend and i know why we don,t still use them and build them that way. THEY WERE CRAP!. This one had 1000mm worth of neg tail rocker which would change as you steped on it. The nose rocker did the same. But!!! it was still bullet proof CRAP.

I like a board that is well designed and built and the shapper deserves to MAKE a living. The quickest way to kill any industry is to choose stuff on price alone, have a look, Macro at what goes into making your board and the time to do it.

Come on down and I,ll teach you how to shape, then have a look at how much you collect for your job.

Better still just buy a well built second hand board

This page has gone on for long enough

Mobydisc
NSW, 9028 posts
20 Oct 2012 7:03AM
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The Bombora 260 is crap. I have one under the house and it's unsailable due to being bent out of shape. However the 270 which was released about a year later was better built. I sold mine in 2008 and it still was in good condition.

So not all Bomboras are crap.

jermaldan
VIC, 1572 posts
20 Oct 2012 9:53AM
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BIC Techno E-Large was plastic foam. Had one and it was bomb-proof, but heavy! Didn't go half bad either.

I do think that we have moved on from this though.

Chris 249
NSW, 3309 posts
22 Oct 2012 12:12PM
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Macro, the idea is bizarre and shows a basic lack of understanding of the forces and physics involved.

So you are simply going to get some "pepsi bottle plastic" and fill it with "super strong but cheap foam", are you?

For a start, those simple plastics are neither light or rigid. Secondly, do you really think that there is "super strong but cheap" foam around that you could find but that the current industry is too stupid to use?

If you showed some respect, you would actually have checked the cost and materials characteristics of foam and found that there is no such miracle product. THAT is why the industry don't use it, not because they are too stupid to think of looking and just needed the great Macro to tell them they should look!

Furthermore, if knew anything about the production of such boards you would know that high-pressure moulding of large objects requires extremely expensive moulds and complicated machinery - equipment that cannot be easily paid for if boards are to be sold cheaply. Getting plastic and foam to easily flow from end to end in a board mould is not a trivial problem, as you would know if you did some homework.

The most basic physics - if you knew it - would indicate that the stiffness of the foam is not the major thing in creating fast boards because most of the foam is too close to the neutral axis. The skin rigidity is what it critical, and pepsi bottles are not rigid. That is why old-style boards are so floppy.

Your attitude towards shapers and materials scientists is extremely arrogant. Your comment about an inflatable board doesn't just show that you completely fail to understand the issues, it also shows that you don't look at things around you. Go and feel the tyre of a racing bicycle - even at 150 psi pressure and in an object with as little volume as a tyre, the skin is so soft that you can easily flex it with your hand. A 150 PSI tyre is much softer than even the softest old board. And yet you want this to be rigid enough to perform AND to somehow handle the stresses, strains and point loadings!

It's one thing to have no idea, it is much worse to be so arrogant as to assume that you know more than all the current people involved in the game.

Chris 249
NSW, 3309 posts
22 Oct 2012 12:21PM
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On a more positive note....

Have we really "moved on" from the heavy but tough plastic boards? Compared to other more popular consumer/sporting goods, aren't modern windsurfers quite light and pretty fragile for their size?

As a comparison, the vast majority of sailing dinghies, kayaks and bicycles are built from fibreglass, polyethylene and similar plastics, or alloy. Those sports are much more popular than windsurfing and have either declined much less or grown much more, so there's no evidence that windsurfing is doing it better.

choco
SA, 4028 posts
22 Oct 2012 12:49PM
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New materials are being made all the time,
A team of scientists from California has created the lightest material in the world, which consists of 99.99 per cent air and is only a hundredth of the weight of styrofoam. The scientists poured a liquid mixture of several materials, including polymers and ceramics, into a microlattice and exposed it to ultraviolet light to harden it.




dan berry
WA, 2562 posts
22 Oct 2012 12:09PM
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OH GOD!!!!!!! Pleeeeeease make it stoppppp!!!!!

Macroscien
QLD, 6806 posts
22 Oct 2012 2:36PM
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Chris 249 said...
Macro, the idea is bizarre and shows a basic lack of understanding of the forces and physics involved.

So you are simply going to get some "pepsi bottle plastic" and fill it with "super strong but cheap foam", are you?

For a start, those simple plastics are neither light or rigid. Secondly, do you really think that there is "super strong but cheap" foam around that you could find but that the current industry is too stupid to use?

If you showed some respect, you would actually have checked the cost and materials characteristics of foam and found that there is no such miracle product. THAT is why the industry don't use it, not because they are too stupid to think of looking and just needed the great Macro to tell them they should look!

Furthermore, if knew anything about the production of such boards you would know that high-pressure moulding of large objects requires extremely expensive moulds and complicated machinery - equipment that cannot be easily paid for if boards are to be sold cheaply. Getting plastic and foam to easily flow from end to end in a board mould is not a trivial problem, as you would know if you did some homework.

The most basic physics - if you knew it - would indicate that the stiffness of the foam is not the major thing in creating fast boards because most of the foam is too close to the neutral axis. The skin rigidity is what it critical, and pepsi bottles are not rigid. That is why old-style boards are so floppy.

Your attitude towards shapers and materials scientists is extremely arrogant. Your comment about an inflatable board doesn't just show that you completely fail to understand the issues, it also shows that you don't look at things around you. Go and feel the tyre of a racing bicycle - even at 150 psi pressure and in an object with as little volume as a tyre, the skin is so soft that you can easily flex it with your hand. A 150 PSI tyre is much softer than even the softest old board. And yet you want this to be rigid enough to perform AND to somehow handle the stresses, strains and point loadings!

It's one thing to have no idea, it is much worse to be so arrogant as to assume that you know more than all the current people involved in the game.

Before such prosaic critics are posted better to know some facts:

Tensile strength of material:

Epoxy adhesive 12-30MPa

Polyester Resin -50MPa

Polycarbonate (your ordinary pepsi bottle !) 75 Mpa

So polycarbonate or your plastic bottle material is actually much stronger then epoxy or polyester resin.

What give the board the real strength is embedded glass or carbon nano tube fibre.
Glass fibre -1500 MPa
Carbon fibre -1600 MPa
so resultant composite may reach tensile strength up to 1200 MPa

You claim that polycarbonate could not be used for board production is simply untrue. For nowadays practical reason is much easier to apply resin that form composite material based on other "plastics" .

Technology of other "plastics" is not yet on "home garage DIY" level.

By comparison you will not be able to create simple " stupid" Pepsi bottle in your garage but you still could do the best windsurfing board if you are lucky.






evlPanda
NSW, 9202 posts
22 Oct 2012 3:38PM
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(.).)

Macroscien
QLD, 6806 posts
22 Oct 2012 2:48PM
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choco said...
New materials are being made all the time,
A team of scientists from California has created the lightest material in the world, which consists of 99.99 per cent air and is only a hundredth of the weight of styrofoam. The scientists poured a liquid mixture of several materials, including polymers and ceramics, into a microlattice and exposed it to ultraviolet light to harden it.






That is correct. You referencing to so called airgel, aerogel or even aeropraphite.

If w cubic meter of water weight 1,000kg the same volume of that gel may weight - even less then 1 kg at their extreame!

Obviously we don't want that !!! We don't want the board lighter then air that will fly like a balloon

Carantoc
WA, 6591 posts
22 Oct 2012 1:11PM
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Macroscien said...Before such prosaic critics are posted better to know some facts:

Tensile strength of material:

Epoxy adhesive 12-30MPa

Polyester Resin -50MPa

Polycarbonate (your ordinary pepsi bottle !) 75 Mpa

So polycarbonate or your plastic bottle material is actually much stronger then epoxy or polyester resin.

What give the board the real strength is embedded glass or carbon nano tube fibre.
Glass fibre -1500 MPa
Carbon fibre -1600 MPa
so resultant composite may reach tensile strength up to 1200 MPa

You claim that polycarbonate could not be used for board production is simply untrue. For nowadays practical reason is much easier to apply resin that form composite material based on other "plastics" .

Technology of other "plastics" is not yet on "home garage DIY" level.

By comparison you will not be able to create simple " stupid" Pepsi bottle in your garage but you still could do the best windsurfing board if you are lucky.




I was going to point out that 'stronger' and 'tensile strength' are not the same thing, boards used to be made from blow molded poly and they were crap, boards are not made from 'nano tubes', and this started off about making cheaper boards not using the latest materials from NASA which are made in 1 cm3 lots with a budget meausred in US billion $.

But then I realised so many people have already pointed this out yet the dribble continues to run, and thus I would only be demonstrating my own stupidity in continuing to page 6.

Macroscien
QLD, 6806 posts
22 Oct 2012 4:00PM
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Carantoc said...
I would only be demonstrating my own stupidity

Just mark a space and read in 10 years time.
I am not going to win this discussion for following reasons:
Primo. That is fight one against all
Secundo. Facts against emotion.

You are all still comparing old moulded boards in 80's to modern layered composites, forgetting that moulding or even 3D printing technology changed a bit over last 30 years.
If you take a best board today for destructive test to measure breaking forces -
there is nothing unique or exceptional.
Take a board, support on two beams 2.0 m apart and press in the middle.
Few hundreds kilo (I guess and board will break in half).
Replicate that "unique" structure with other materials at same weight - say -6.0kg but build by engineers not " shapers" and the board with same outline made of X material and Y internal structure could be 10 x resistant to breaking , stiffer, etc what ether you like.
Read the space in 10 years from now and pick-up the winner in this discussion.
I bet my $1 that you will be able to make your own 3D design board on the web, order and have your own board 3D printed and mailed to you like T-shirt today.

Mark _australia
WA, 22301 posts
22 Oct 2012 2:03PM
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Macro, FFS.

What is a soft drink bottle made from?
Last time I looked it was HDPE, not polycarbonate.


Secondly, you can look at carbon nanotubes all you like but I don't think a new product like that, used in a totally new way, moulding with LDPE or HDPE or bloody melted candles for that matter, is so NEW that will not achieve your $500 board.

For a 10mil investment you MAY make a superior board with a faster process and cheaper materials but then you need to sell a load of boards to pay off that investment. Windsurfing is small, so in reality if your carbon nanotube infused moulded polycarbonate thing works you'd be better off moulding aircraft parts or bikes.

And whilst I typed this I see you are back to getting non-windsurfing materials people to design it. It has been done, Nomex and aluminium honeycombs have been around for ages. It is superior, but it costs too much, the process of laminating it into a sandwich structure is different and more labour intensive. Currently we have a perfect blend of lightness vs strength with relatively easy manufacture as PVC foams are easy to vacuum onto a styro core.
If you want a 4kg board with 10x the strength you go for it. It will be a $10K board.

Short version:
You can make a $500 board and it will be sh!t
You can make a much better board and it will cost too much.
Analogy: There is a reason we have an established method of construction and it is the same reason your house is not made of paper, and neither is it made from gold, platinum or carbon nanotubes.

Carantoc
WA, 6591 posts
22 Oct 2012 3:41PM
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Macroscien said...
Carantoc said...
I would only be demonstrating my own stupidity

Just mark a space and read in 10 years time.
I am not going to win this discussion for following reasons:
Primo. That is fight one against all
Secundo. Facts against emotion.



Thirdly-o : You don't win discussions, you win arguments and discuss discussions

and finally : because Macroscien is talking jibberish out of his arse. What is your discussion ? It was originally that boards cost $300 to make and we are being ripped off paying $2500 - but then when that didn't go your way (due to your own admission that you understand neither the materials, processes nor labour resources used in the construction of a board today, or in fact the history of baord construction) it turned into jibbish comments about the instability of a single hydrofoils, the availability of unemployed NASA female engineers, the tensile strength of blow molded coke bottles and various other totally random and ill-conceived dribbles.

This thread can be won by nobody because it makes no sense.

The kettle remains goldfish.

Macroscien
QLD, 6806 posts
22 Oct 2012 5:49PM
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Mark _australia said...
Macro, FFS.

What is a soft drink bottle made from?
Last time I looked it was HDPE, not polycarbonate.


Secondly, you can look at carbon nanotubes all you like but I don't think a new product like that, used in a totally new way, moulding with LDPE or HDPE or bloody melted candles for that matter, is so NEW that will not achieve your $500 board.

For a 10mil investment you MAY make a superior board with a faster process and cheaper materials but then you need to sell a load of boards to pay off that investment. Windsurfing is small, so in reality if your carbon nanotube infused moulded polycarbonate thing works you'd be better off moulding aircraft parts or bikes.

And whilst I typed this I see you are back to getting non-windsurfing materials people to design it. It has been done, Nomex and aluminium honeycombs have been around for ages. It is superior, but it costs too much, the process of laminating it into a sandwich structure is different and more labour intensive. Currently we have a perfect blend of lightness vs strength with relatively easy manufacture as PVC foams are easy to vacuum onto a styro core.
If you want a 4kg board with 10x the strength you go for it. It will be a $10K board.

Short version:
You can make a $500 board and it will be sh!t
You can make a much better board and it will cost too much.
Analogy: There is a reason we have an established method of construction and it is the same reason your house is not made of paper, and neither is it made from gold, platinum or carbon nanotubes.

There is one very interesting technological problem yet to be solved. I agree this is not for SB to resolve as NASA I am afraid is not ready either.

You have Mark two parallel surfaces made of composite (say poly carbon infused with nano tubes) - is extremal strong for linear breaking breaking - at least 3 times stronger then structural steel, but very fragile for lateral forces.
That is why my new structure comprise from two surfaces at distance , then connected by perpendicular bridges made or carbon nano tube again to keep surfaces at same distance , then gas at very high pressure (ie hellium) try to force the surfaces apart). Such a structure should be now very resistant to lateral forces .
You could build everything from that - from air plane and rockets, buildings to windsurfing boards.
I am not saying that is too expensive to build our boards because such technology doesn't exist beside my concept yet. But what eventually come to commercial reality materials and manufacturing could be very cheap.



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"SB Community OEM board ?" started by Macroscien