Customization of a Composite

Speedboard

Fairchild Wheeler Inter-District Magnet

L. Fatsy

Abstract. Downhill longboarding is the control and orientation of a rider down a constant
decline, aiming to increase speed while maintaining safety. This sport has advanced with the
manufacturing technologies of the decks, in the form of composite speedboards - A high strength
to low weight board utilizing properties of multiple different structural materials and fabrics.
The process of applying fabrics to boards require specialized materials and presses, mainly
Carbon fiber and a Ribbed press, to ensure complete structural integrity and strength. The
combination of materials with a highly accurate press will create a uniform bond between
stratum; This will create a higher resilience to compression and damage, leading to better
endurance in an entirely damaging sport. The finished product will be a high strength board that
has a lower weight than a maple wood replica, with the addition of being highly variable to suit
the rider's needs.

Table of Contents
age
P
(i) Abstract.......2
(I) Introduction....5
(II) Literature Review..7
(III) Methods...13
(IV) Proposed Results.15
(V) Conclusion....17
(VI) Reference cited....18

Table of Figures.
Page
Figure 1. Toothless Longboard Press...7
Figure 2. Ribbed/Solid Wood Press.8
Figure 3. Homemade Pressed Board Example....9
Figure 4. Complex Mold Example.10
Figure 5. Concave Variation..16

Introduction. Downhill skateboarding is a sport that is based around the natural geocentric force
of gravity, and utilizing the slope of an open road and the aerodynamics of the specific stance the
rider takes to reach near terminal velocity, while lacking any protective structure surrounding
you, as safely as possible. Downhill skateboarding is limited by the riders comfort and the
reference/contact points of the board. This function of the board is only accessible through the
method of creation - or when the plies of material are pressed together to form a specific shape.
Presses are a method of applying a constant force to separate segments of material, around a
specific shape (Cebulski, 05/05/10). Once pressing is complete, and the bonding agent is cured
and properly adhering the plies of material together, the final shape of the board is demonstrated.
There is currently no way of creating a new reference/contact point directly into the board
without expensive aftermarket applications. With the addition of open customization through the
removal and reinstallation of separate pieces contributes to make this a difficult task, both to
research and implement, as this is the first of its kind. The process of building a downhill
speedboard requires building materials, board design, and a board press or mold (Roarrocket,
03/16/15).

The strength and rigidity of any and all compositions or structures is the choice of
material, The majority of applications tend to attempt maximum strength to minimum weight,
most commonly using aluminum alloys or specific fabrics (Consortium, 2006). In the production
of a Downhill skateboard, the most versatile materials are carbon fiber and fiberglass(Yan
Poirier, 11/18/13). Both are fabric materials, that are adhered to wood or another support
structure with high strength resin (jestah, 12/06/06). When adhering to wood, it is most often
applied during the pressing process between plies of wood (TeacherOfTheWays, 01/04/09), or
atop the top or bottom of the board. Customization of the board allows each individual rider to
utilize their own preference, due to every aspect that is able to be changed in a board. There are
differences in the concave - the U shaped bend in the wood parallel to the direction of the
board, this simple shaping gives the rider leverage and traction to properly control the board.
Wheel flares exist above the location of the wheel, to allow for extended clearance, to prevent
wheel bite or contact between the rotating wheels and stationary (in relation to the wheels)
deck. This allows the rider to run larger wheels, and has an increase of concave in that area. W
is another board shape term that describes the uncanny resemblance to a letter, the shape is an
extended hump along the middle of the board. Drops are the lowering of the foot platform from
the trucks, lowering the center of gravity from a rider, and enabling pockets to fit your foot into.
Bringing this all together with the process of 3d printing will enable the production of a
completely customizable board, with the benefits of weight saving fabric materials, and a large
palette of concave additions to choose from.

Literature Review. The sport of Downhill Skateboarding/Longboarding is a gravity driven

boardsport, utilizing paved mountain roads or hills to accelerate to a top speed which is
determined by the aerodynamic stance the rider takes. This sport is incredibly unique in the way
that there is no one proper way to Downhill skateboard, so the rider themselves must define how
they want to participate in this sport. One of the ways is with board design. The complete
customization of a speedboard is only attainable through aftermarket applications, homemade
presses, or expensive custom orders. The production of a composite speedboard within itself if a
daunting and difficult task, With the addition of open customization through the removal and
reinstallation of separate pieces contributes to make this a difficult task, both to research and
implement, as this is the first of its kind. The process of building a downhill speedboard requires
building materials, board design, and
a board press or mold.

A longboard is the product of

subsequent revisions to a standard
skateboard deck. They both are

constructed of multiple plys of, most commonly, maple wood. The process of constructing any
skateboard begins with a wood rspress. (TeacherOfTheWays, 2009) A press consists of two hard
shaped objects and a mechanism to apply a constant pressure upon both faces or hard pressing
objects.(Cebulski, 2010) This specific method uses a wooden spine, parallel to the board, with
multiple smaller bands perpendicular to the board. The spine and bands are milled or cut to the
shape of the concave to incorporate any or all features. as shown in the first photo. Presses come
in many shapes and sizes, and the first press presented was created to build a board that has a
large amount of flex, as the press will create and arc with the plies of wood. A similar method is
the ribbed press, or solid wood press (Rsnider, 2015) that fills the gaps between the bands
presented in the first photo. The toothless longboard press is much easier to produce, due to the
limited amount of material and low cost of production and manufacturing. Although, this process
allows for inconsistencies with the shape of the board post-press, and with the glueing pressure,
which can lead to delamination (Glen E. Sabin, May 17. 1993), which is the separation of the
layers of a composite structure due to failure in the binding material, or imperfection of the
layered material. These imperfections lead to the layers splitting from one another, negating the
structural integrity of the entire board.
The Second process, a ribbed/solid
press, does not leave gaps between the
perpendicular bands of wood, which
does not inhibit the the structural
integrity of the board due to the gaps
and inconsistency in

pressure.(Roarrocket, 2015) A mold is similar to a press, as it created the shape and contour of a
board, and requires a applied force to bind the wood together for the glue to harden, though a
mold is most commonly comprised of two single pieces of material, either cncd wood or
fiberglass. (Chainmailkid, 2015)

Carbon fiber and fiberglass are two materials most often used within board building, as they both
obtain a necessary feature; A high strength to weight ratio. The standard application of carbon
fiber for longboards is the use of a single sheet of carbon fiber, either unidirectional,
bidirectional, or tri-directional, that is either sandwiched between plies of wood or other
composites (Yan Poirier, 2013) or applied to the very bottom of the wooden deck (jestah, 2015)
due to carbon fiber and fiberglasss shared property; a high strength to weight ratio. The most
common application of carbon fiber and fiberglass in longboarding is the use of a single sheet of
fabric, composed of the material. (Consortium, 2006) Fiberglass is most often a standard sheet,
with varying thickness, though it does not change in composition. Carbon fiber is similar, though
has a key difference with the direction of the fibers. They are laid either unidirectionally, at 180
degrees from the direction of the board. Bidirectionally, at 180 and 90 degrees from the direction
of the board. And lastly,
tri-directionally, at 180, 90, and
45 degrees from the direction of
the board. (Prophet13, 2011) The
cloth in both cases is either
sandwiched between plies of

wood or other composite materials (Yan Poirier, 2013) or applied to the very bottom of the
wooden deck to offer a limited, but necessary amount of rigidity to suit the rider's preference.

The initial design of the board itself heavily influences the type of riding that is wished to be
achieved and overall comfort of the rider. A simple design (arcane, 2008) requires minimal effort
and lowers the expense of materials and man hours, by only including non-complex concave.
Though subsequently produces a lower quality board. The use of more complex shapes allows
the user to fine tune the board to the rider's own preferences, such as the use of drops, flares,
and W concave ( kdomitter, 2013) along with other modifications. The more additions and
modifications you include, the harder it will be to create, due to the increase of components you
need to include in the mold/press, resulting in
an increase of material use, and man hours
spent. By incorporating 3d printing, any shape
at all is possible, but comes at a cost; low
strength. As the material is a brittle plastic.
(tjo626262, 2013) With the inclusion of 3D
printed segments laiden with fiber threads,
(Ethan Steel, 2015 , Personal communication)
produced by a MarkForged 3D printer, the
necessity of a complex mold is nullified due to
the lack of a need to include aforementioned
modifications and additions to the mold/press.

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The production of a mold is simplified for the most part, though with specific features (i.e.
flares) the mold would still have to incorporate them, as they are not features primarily found
within the standing platform, they are incorporated into the press itself, due to it being a shape
not able to be applied post production. There are many styles and preferences to be had with
board shape and design, as a thinner longboard is much more nimble, so acute turning and
control is improved, though at a consequence. A shear force, such as a maneuver called a slide,
which is turning perpendicularly to the direction of travel to slow down the rider in preparation
for a corner or for safety. (kdomitter, 2013) A wider board allows for more complete control at
faster speeds, because the foot has a wider platform to interact with, there being more surface
area for reference points. Much like a wheeled vehicle, the longer the wheelbase, the more stable
it is at speed, and the inverse is true as well. The shorter the wheelbase, a tighter turning radius is
achieved. Durability is the amount of wear an object can endure without suffering mechanical or
structural failure. Within downhill longboarding, mistakes are made, and imperfect situations
happen, leaving the rider in an imperative situation with the chance of suffering bodily harm due
to the lack of a surrounding safety structure and the high speed that is met. Not only is bodily
harm a result, but damage to the board and attached components is caused. A lighter weight
board with complex construction tend to delaminate more readily, as the materials separate when
great force is exerted between the layers. (i.e. board hitting wall) A lighter board does have less
inertia, and less momentum that carries it, but the structure retains strength most commonly in
specific directions, perpendicular to the board itself, or a downward force. The inclusion of a
protective metal housing, or ply of aluminum that extends a few millimeters out from the wood
to give a protective buffer. (Yakuza, 2008)

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The creation of a dedicated speedboard is a difficult and daunting task, as the structure and
shape is nearly limitless, but each and every variation lead to different uses and benefits, along
with drawbacks. Using 3D printed segments, reinforced with composite materials allows an
easier construction of the board, but decreases the overall strength and durability. The mere
method of pressing can lead to lack of structural integrity, or process used, or a simple crash.
Producing the strongest, most reliable, and most customizable board is difficult.

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Methods. Phase one:

Press construction
Cut 1 in. x 2 in. x 8 ft. into 8 1 foot segments
Mark shape of concave onto 36 wood pieces
Different shape for each - different concave
Cut each shape with tablesaw along lines
Apply glue on both long sides of 34 segments, and glue on the innermost side of
the outermost segments
Re adjust to ensure each segment is even
Using clamps, press together segments
Once dry, remove from clamps, sand excess glue
Repeat for upper portion of press, the exact opposite dimensions (convex instead
of concave)
Screw 2 x 4 x 36 beams atop and the top face of press, and below the bottom
face.
Attach parallel to direction of board if it were in the press
Drill 1 screw each foot on each beam
Phase two:
Building board
Fit 9 plies of maple into press
Apply liberal amount of wood glue evenly along each side of ply, except
the outermost sides. (top and bottom)

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 Attach clamps to both sides of press, 1 foot from edge

Clamp down until wood glue begins to drip from between plies
Allow time to cure ~12-36 hours
Take out pressed board from press, ensure it is correct shape
Input 3D model file into CNC machine, place uncut board into CNC machine, and
run. Cut away excess wood, and cut out mounting area for 3D printed segments
Sand rough edges
Cut out mounting holes
3D printed segments
Create 3D models of concave segments
Upload file to Markforged printer, print
Sand excess material

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Proposed Results. Developing and creating a layered structure first requires a semi-encasing
framework to define the intended final shape, and to ensure a faultless bond between each strata.
(Rsnider, 07/16/10) A longboard, composite, semi-composite, or wood are no different. Each of
the three are assembled using separate plies of material, and bonded with resin, or wood glue.
(Prophet13, 2011) Resin is primarily used for adjoining two separate types of materials together
in a way in which the subsequent object acts and distributes forces as if it were a single piece of
material - creating an incredibly strong bond where other methods of bonding are not plausible
due to strength limitations, such as physical means; nails, screws, and joints. Wood glue is most
often used when wood is bonded to wood, as the title implies, as the texture of wood on a
molecular level rarely differs from one another to the point that it negates adhesion. Resin will be
used to bind the polyamide thermoplastic and carbon/fiberglass used in the 3D printed segments
to create the custom designed concave and rigid substructure. (Ethan Steel, 2015 , Pers. comm.)
Wood glue will be used to adhere the plies of maple wood together to form the general backbone
of the board, the protective outer structure, and where the 3D printed segments are inlaid. Wood
glue would be used opposed to resin due to wood's natural porousness and uneven grain
structure, this specific glue expands, filling the gaps between grain, and the natural permeable
fibrous structure. This physically bonds each stratum of wood to the point that the glued area has
more strength than the wood itself. A powerful, constant compressive force ensures that minute
pockets of air do not become trapped in the bonding material (i.e resin or wood glue) and expels
excess bonding material along with any encased bubbles.(Greenamtern, 2006) Air pockets
between each stratum causes lessened strength of the overall board, and allows fractures to begin
and propagate from that point. Air pockets cause the board to be more easily destroyed. A Solid

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Wood press is the ideal method of pressing, as it enables constant contact between the outermost
wood ply and press. This produces an exact copy of the shape of the press. This design also
requires fewer clamps or weights, as the force of compression is evenly distributed over and
throughout each half of the press, from nose to tail. The total cost of the Solid Wood press press
is much greater than that of a Dimm or Ribbed press as it is made of much more material, as well
as requires more time to construct. (Chainmaillekid, 2013) Nevertheless the Dimm and Ribbed
press do not create an exact shape, or expels trapped air and excess binding material.
(TeacherOfTheWays,2009) A higher quality press creates a board with a more defined shape,
increased strength, and increased resilience to
abuse.

Concavity is the shape of the board throughout the length, from nose to tail. It curves
inward, from the sides to the centerline of the board. This most often defines the limitations of
riding that can be done, as more features are added, the rider has more comfort with their stance,
leading to increased leverage over the wheels and physical control of the board. A simple
concave is predominantly 9/16 of an inch in depth, from the center of the board to the edges.
Such concave allows the the press to be manufactured at a lower cost, without sacrificing the
structural integrity or strength as well as
allows the 3D rendered model, necessary
for the CNC milling, to be made without
fault or hindrance. Looking directly at the
nose of the board, at eye level, shows the

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radial concave as a vague U shape, this shape creates a an incredibly strong resistance to
torsional flex and bending, as well as laterally. These physical stresses are commonly
encountered during quick maneuvering through a corner, where the rider's center of gravity
suddenly shifts, transferring the force throughout the deck to the trucks, thus enabling turning.
Without the physical duality of resistance, the board would not be able to appropriately or
efficiently transfer the force of the rider's movement to the trucks, negating any directional
control. Prior to the pressing process, a bonding agent is applied between each stratum, to bond
and create a solid object. The physical application of wood glue or resin diminishes air bubbles if
spread prior to pressing. The glue or resin should be spread evenly throughout the surface of the
ply, from edge to edge. Once a ply is placed upon it, there is no gap for the glue or resin to flow
into, thus creating no environment for air bubbles to be trapped and formed.

A total cost completely depends on the chosen materials and tools used to process and
create the press and board. Without access to the necessary knowledge of the availability of such
materials and tools, a cost is purely speculation To begin production and manufacturing of a
composite speedboard the ideas, board design, and press design must be finalized and developed.
The first physical means of production is the press, which must be constructed to form the shape
and strength. Subsequently, board materials must be acquired, prepared, and pressed to form the
rough shape with correct concave. Thereafter, the final shape must be cut from the blank,
forming the backbone of the board. The 3D segments must then be printed, correctly measured,
altered if need be, and then inlaid into the backbone. After the components are bought, or
created, the blank longboard has to be cnc-cut to allow the 3D segments to be inlayed,

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The potential limitations to the production of a composite speedboard would be cost of

total materials and time spent creating the board and press, and due diligence, or lack thereof.
Without following the gantt chart closely, the board may be created too hastily for it to function
properly. If the cost is entirely out of pocket, the acquisition of materials may be delayed, or
alternative methods or materials must be used to compensate for lack of appropriate funds. Due
to lack of proper CAD software knowledge, and available training in CAD programs and their
implementation into the physical printer, the production of the 3D segments may be limited.

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Conclusion. Downhill longboarding, as a sport is mostly held back by the cost of producing
quality boards, as they truly enable the rider to utilize their skills. An under defined board will
not allow the rider to lock themselves into the deck, removing their concentration from riding
down a hill to ensuring they remain standing on the board, controlling it. The production of a
deck would have lower costs compared to a fully composite fabric board, but with similar
strength and rigidity properties. This combination of a wooden backbone, or more essentially a
standard wooden deck, with inlaid 3D printed composite interlocking and secured segments
would achieve the required strength, rigidity, and customizability that this sport is lacking. A
well produced deck, using the a uniform compression press, will hold a defined shape through
more abuse, as the press creates complete adhesion between each strata. Every inch of surface
area of one ply, is entirely attached to the surface area of the next - creating no cavities lat
degrade the board.

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