3D-Printed Water-Jet Propelled Surfboard
Designed and built a modular, water-jet-propelled surfboard around a mostly 3D-printed propulsion unit (FDM/PLA). Integrated a waterproof electronics bay, a modular battery system, a high-power brushless motor and a water-cooled ESC, with jet geometry iterated in CAD. A hands-on additive-manufacturing and rapid-prototyping project.
This project is a modular, water-jet-propelled surfboard drive system designed and built around a mostly 3D-printed propulsion unit. The goal was to create a compact and integrated jet drive that can be installed inside the surfboard hull while remaining modular, serviceable, and easy to iterate on.
The complete drive module is integrated into the board housing and includes:
- a water-jet unit
- two large batteries
- a high-power brushless motor (TFL / SSS 56123 500KV)
- a water-cooled ESC (HV OPTO 16S 400A)
- control electronics and safety systems
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One of the main flaws in this version was the sealing / gasket design. After some time in the water, water entered the battery housing because the rear part of the board was partially submerged while standing on it. This exposed the sealing design to longer underwater loading than expected and caused leakage into the battery compartment.
Future iterations will focus on improving sealing and waterproofing first, followed by efficiency, durability, and overall drivetrain refinement. Possible upgrades include a redesigned gasket / sealing interface, impeller and nozzle optimization, improved material selection for long-term use, and further weight reduction in the housing and internal structure.