2Foil | 'A new way to produce eFoilboards'

This new eFoil design utilizes twin-sheet thermoforming to make the product cost-effective. Twin-sheet thermoforming is a production process that involves two plastic sheets being heated and then formed into a desired hollow shape. This process is faster and less labor-intensive than producing carbon boards. Plastic is more elastic and better able to withstand impact compared to carbon, but has limitations under heavy loads. To increase strength and stiffness, the board has ribs and a metal construction connected to the mast, and is filled with 2-component PU foam for buoyancy. This design offers improved cost-effectiveness, industrial production, impact resistance, and durability, making it more sustainable than current carbon boards laminated with epoxy.

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Analyse

During the analysis phase, I mainly conducted desk research and created a set of requirements based on all the information and conversations with stakeholders.

Ideate

In the ideation phase, I generated numerous ideas and made decisions using various methods.

Concept

During the concept phase, I developed the ideas further to determine their feasibility. I then used different methods to make further decisions.

Materialisation

In the materialization phase, I produced many prototypes and researched various production techniques, including visiting many different manufacturers.