Surfer Eddie Rosenberg got here to a life-changing realization in 2022 after a model new surfboard suffered from strain dings—a browsing time period referring to compacted foam attributable to the strain from toes or knees. Reflecting on his frustration on the dinged-up board, he realized how incongruous it was to a) be so hooked up to an object made of froth and fiberglass and b) to be introducing these synthetic and probably polluting supplies into the ocean, when browsing is admittedly about being at one with the water. As he says on his web site: “That query became an obsession with surfboard development—exploring new strategies to remove the poisonous styrene foams and carcinogenic resins that dominate the surf world.” Thus, FUNNER Surf Craft was born.
The Oregon-based surfboard startup seeks to introduce new strategies for producing surfboards that prioritize sustainability and efficiency: two issues that matter to the browsing neighborhood. Historically, surfboards are constructed from a foam core coated in fiberglass and resin layers. Not solely are these supplies derived from non-renewable assets, however the manufacturing course of, which includes sanding the resin and fiberglass coatings, generates particulate matter and dangerous VOCs.
Rosenberg’s purpose was, subsequently, to seek out extra sustainable processes and supplies for establishing a surfboard simply as sea-worthy as its foam counterpart. In only a few years since its founding, FUNNER Surf Craft has achieved this purpose, utilizing a mixture of progressive manufacturing strategies, like 3D printing and CNC machining, and sustainable supplies to make a collection of wave-friendly and inexpensive surfboards.
The important thing innovation developed by FUNNER Surf Craft is the Air Core, a hole body for the surfboard made utilizing FDM 3D printing and recycled PETG. To make the board, this Air Core is encapsulated with renewable Paulownia wooden decking, which is CNC machined to form and internally laminated with pure basalt material and a bio-based epoxy, eliminating the necessity for fiberglass from the board’s development. Lastly, the exterior wooden surfaces are infused with waterproof, plant-based oils with no VOCs.
Bringing 3D printing to browsing
After first listening to about FUNNER Surf Craft and its progressive Air Core method, we have been desperate to be taught extra. In any case, we all the time wish to hear in regards to the artistic ways in which additive manufacturing and sports activities intersect. Right here is our dialog with founder Eddie Rosenberg about his firm’s sustainable mission and the way 3D printing has come to play an integral function in his surfboard manufacturing:
VoxelMatters: In your journey, at what level did 3D printing turn out to be a transparent resolution for establishing surfboards?
Eddie Rosenberg: The surf {industry} has lengthy relied on poisonous supplies like polyurethane foam and polyester resin, leading to fragile boards with a heavy environmental influence. In search of a greater various, we turned to 3D printing. It allowed us to create hole Air Cores from recycled polymers, eliminating poisonous supplies whereas enhancing power, buoyancy and sustainability.
VM: And what benefits does 3D printing provide in comparison with conventional surfboard manufacturing strategies?
ER: Our 3D printed Air Cores ship a trifecta of advantages: efficiency, sustainability and manufacturing effectivity.
One of many largest environmental breakthroughs is eliminating conventional fiberglassing. Typical boards depend on petroleum-based fiberglass and resin for sturdiness and waterproofing—supplies that emit toxins, create hazardous waste, and require intensive labor.
By integrating 3D printing, we remove the necessity for fiberglass encapsulation. This reduces our environmental influence, simplifies manufacturing, and leads to stronger, extra sustainable, and less expensive boards.
VM: Do you 3D print in-house?
ER: All design and manufacturing occur in-house. This ensures tight high quality management, fosters steady innovation and reduces transportation emissions and waste— aligning with our dedication to sustainability.
VM: Have you ever encountered any challenges in utilizing 3D printing for this software?
ER: Completely. Early on, we realized that totally 3D printing a whole surfboard wasn’t sensible attributable to weight and print time. Conventional foam blanks are gentle, and whereas 3D printing affords precision and effectivity, printing an entire board, particularly one sturdy sufficient to remove fiberglassing, can be too heavy and gradual to fabricate.
Our resolution was the Air Core design—a fusion of 3D printing and CNC woodworking. Our 3D printed parabolic rail construction supplies sturdiness and precision, whereas CNC machined Paulownia wooden skins, bolstered with basalt, flax and bio-epoxy, create a high-strength, light-weight outer shell.
By merging additive and subtractive manufacturing, we’ve streamlined board-building, making it stronger, extra sustainable and extra environment friendly—with out compromising high quality.
VM: Do you employ 3D printing for the rest along with the Air Cores?
ER: Proper now, our major focus is Air Cores, however we’re actively exploring 3D printed fins, board racks and different equipment.
VM: How receptive has the surf world been to utilizing new manufacturing strategies like 3D printing?
ER: The surf neighborhood more and more embraces innovation, particularly when sustainability and efficiency go hand in hand.
One cause for this adoption is our proprietary algorithm, which makes it seamless for shapers to work with us. Beginning with industry-standard shaping applications like Shape3D, AKU Shaper and The Shaper Bay, we will immediately convert practically any board design into our development methodology. Shapers don’t have to be taught new software program or change their course of—they form, and we maintain the remainder.
By making it simple to combine our 3D printing expertise, we’re making certain that extra boards are inbuilt a approach that’s higher for surfers and the planet.
FUNNER Surf Craft and the way forward for surf
Finally, as the game of browsing rises in reputation, notably within the North West the place FUNNER Surf is predicated, the corporate appears well-positioned to assist surfers transition to extra sustainable choices with out sacrificing—and even enhancing—the standard of their trip.
