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

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

"Ocean rowing is a very interesting sport because it's relatively new. Few people have rowed across oceans, and there's a lot of room for innovation and many unsolved problems in this sport."

Engineer Ewan Maclean

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

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

Producing Custom End-Use Parts with Form 4

The Maclean brothers continuously documented ideas for improvements that could make their trans-Pacific journey safer and more comfortable. With years of 3D printing experience, Ewan paid particular attention to how equipment functioned and where every detail could be optimized.

"Ocean rowing is a sport where small improvements matter. In any aspect, even if it's less than a one percent improvement 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 custom end-use parts. Some parts, if manufactured by welding, would be heavier and difficult to achieve the ideal shape that conforms to the boat's curves.

Ewan had previously used Formlabs 3D printers, 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 start using. Once set up and the resin is loaded according to the steps, you can start printing immediately, which was very convenient for us."

Engineer Ewan Maclean

From Sketch and 3D Model to PreForm Print Preparation

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

1. Document problems and usage requirements that needed improvement during the voyage.
2. Sketch parts and confirm installation positions and geometric constraints.
3. Create 3D models that conform to the boat's or equipment's dimensions.
4. Import models into PreForm and complete print orientation and support settings.
5. Produce parts using Form 4 and physically confirm assembly.

"I just needed to import the files into PreForm and send them to the 3D printer, and it would produce parts that met our needs and assembled 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 exhibited excellent strength, sufficient for real-world applications."

Engineer Ewan Maclean

The Rose Emily's parts were made using three Formlabs resins: Tough 2000 Resin, Durable Resin, and Clear Resin, each addressing different needs such as structural strength, durability, flexibility, and mold making.

"The strength and detail presented by these parts are amazing. For this mission, 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' body types, 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 Mounts

Starlink equipment for satellite communication must be installed at specific locations and angles to ensure stable signal reception and prevent water accumulation. The mounts also need to withstand the impact of waves hitting the stern, as well as prolonged exposure to salt and UV radiation.

Jetboil Stove Gimbal

This temporary addition helps the Jetboil stove remain 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 custom 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 stuffy and cramped cabin.

Custom Ergonomic Seats

Long 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 lets go of their oar, the oar holder helps secure it, preventing interference with other rowers' movements and the limited operating space on board.

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

"You can take parts directly from the 3D printer and put them into real-world applications. One of the best ways to test the quality of parts is to put them through approximately 120 days of ocean travel in harsh environments of salt, weather, UV, and repeated use."

Engineer Ewan Maclean

Crossing the Pacific is not just a test of the Maclean brothers' physical and mental endurance, but also a practical test for the Rose Emily and its custom 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 custom end-use parts that meet specific geometric shapes, installation conditions, and ergonomic requirements.