We want to share with you this project that we are working on. It will entail some molding – oh no the dreaded pop-out! Those folks are so ignorant, molding is not the devil, it’s a tool and for the purposes of this project we are going to need TONS of parts that are exactly duplicated which is one of the forte of molding! The derogatory pop-out term, you’ll just have to unlearn. We’re sorry that there are so many sad and sorry folks that seek their own self-interest through misleading ambiguity in this sport, just how it is. Thankfully it’s still possible to bring factual information to folks. Anyway, after we talked about the potential for shaping or creating with that 3D printing concept, in particular the core of a wakesurf board, we thought we’d try that using existing techniques. So this post will introduce a build to create a carbon fiber honeycomb cored wakesurf board.
You’re no doubt familiar with a honeycomb shape, it’s a repitition of a hexagonal and we all learned about them, probably in the second grade, looking at bee hives. Now we won’t challenge your belief system, bees make individual cells that are always a hexagon and each cell is always the same size within that hive. Whether you believe in divine inspiration or years of evolution, we don’t really care. What bees do, is make those little hexagons all over, they aren’t sequential. You never see 3,127 bees waiting for their turn to make a cell, they can be built in a random order, because each one is exactly the same and with the six sides, they will always fit together PERFECTLY, so long as they are made with the same orientation. That is to say not on a diagonal, but say with one flat side on the bottom. With that orientation and with the uniform size, the busy busy bees can randomly build cells and eventually they will form the hive with a complete honeycomb. AND all 3,128 bees can be busily making their individual cells simultaneously. Some here, some there, and eventually it will all get filled in.
Cool, huh? Nature is very inspiring. Ok, so lets take a moment and look at the basic building block of the honeycomb. Now, it really isn’t the hexagon, at least not from a molding or construction standpoint used by builders, it’s one half of that. It’s four lines, but it is an open shape. Here is an amazing rendering of that!
See?! We told you it was amazing.
We want to take a moment and editorialize here. The concept of a basic building block that can be used in repetition is important for this project. It’s also important in trick naming. There are these groups that attempt to devalue other folks tricks, for their own self-interest. Proposing that certain tricks NOT be recognized, but instead be considered combinations, which will devalue them. BUT more importantly, they don’t suggest that be used consistently, only the specific tricks they choose…yeah, that inconsistency creates favoritism and bias. Now, we are all in favor of a consistent naming process and if those groups applied their logic to ALL tricks, not just the ones they want to devalue, it would be fine, Everyone would have the same playing field, but…they don’t do that. They hand pick only certain tricks, really to create bias and favoritism. So one such trick would be the “Blender” diminish that into a combination of a surface reverse to a surface 360.
Those same folks never suggest that an air 180 be termed an air 180 into a switch revert backside surface 180. What’s the likelihood that trick is going to be called correctly? Not much, right? Also, that air 180 entry then will be duplicated in an air reverse, won’t it? Those folks don’t want that, it’s not about fairness or consistency in naming, it’s about creating bias and favoritism for specific riders. No doubt those are the same folks that say judging should be fully subjective because wakeboarding uses it! But they pick and choose what to use from other sports, trick names are littered all over wakeboarding and damn near every other sport. So you get it, ignore the application of trick names from a sport when it doesn’t suite their purposes, but cry we must be consistent with every other sport when it does suite their purposes. AND don’t even get us started on why there are any unique tricks at all in a fully subjective system that is supposedly based ONLY on the full run!!! But it isn’t is it? It’s based on the individual tricks involved, in fact if a rider doesn’t land a trick that supposedly isn’t scored?! WTH?! It’s subjective on the full run, but wink wink we recognize individual tricks, wink wink but we don’t score them, well sort of you can get a zero, but no positive values! Oh what a total crock of s*^! It’s all such a convoluted mess.
Ok, end of rant!
So we saw that basic building block (BBB) and can you see how we can make a hexagon from that? If we take another identical piece like the one above and then invert it, by flipping it upside down and backwards, we can affix it to the first building block to arrive at a hexagon’ish shape, like this:
Right? Can you see how we flipped the second iteration of the BBB? We’re sorry, it’s hand shaped so isn’t exactly a hexagon If it was molded it would be 100% accurate. Ok, ok, ok, we’ll stop that now. But you get the idea, with proper alignment and repitition, we can build a large honeycomb structure from a single BBB.
We didn’t carry it out too far, but this is what repeating all those little structures would look like sort of interlocked.
It’s possible then to create several long sections of the repeated BBB and then to glue those all up to make a honeycomb structure, just like the bees do! That’s exactly the process that’s used with many aluminum honeycomb panels.
Now, we’ll eventually create a mold that will allow us to create that hexagonal shape, but it’s not going to be today! The weather here is crazy cold, we woke up to 28 degrees with frozen garden hoses and windshields! So we’ll wait for warmer weather to do that. But we can sort of do a rudimentary shape using dowels to test the concept. It will consist of curves rather than straight sections, but we can replicate it and invert it to create a honeycomb of circles! This will be the basic shape of the sections:
We know!!! More amazing drawings! We sure hope we inspire folks to break out the crayons today and develop something meaningful!
Thanks so much for following along, we really appreciate it.