Design
What Happens When a Computer Programmer Decides to Build a Cheap Surfboard?
Posted by Sean Fallon at 9:20 AM on May 23, 2008
Not surprisingly, you get the nerdiest surfboard ever. The "Shredder" surfboard was designed by a computer programmer named Mike Sheldrake after he decided to replace his old board. Since he did not possess the skills necessary to make a board the traditional way, he decided to use 3-D modelling software to design a snap-together deck built out of 400 pieces of computer cut corrugated cardboard then shellac it with fiberglass and epoxy resin. Thanks to a mathematically sound triangular pattern, force is evenly dispersed throughout the board—making it incredibly strong.
Sheldrake has already sold one of his creations to a pro surfer and he plans on improving his technique to develop boards that are stronger, lighter and more flexible. To that end, he hopes to have a product site launched in the near future where customers can custom design their own boards. And, since they are made from inexpensive materials, it should make a day of surfing at the beach a lot more affordable. [Popsci]

Comments (AU Comments · US Comments)
There are currently no AU comments for this post.
Snowlovers
Posted 3:05 AM 27/5/08
OK, now they need to make one out of FedEx boxes.
Snowlovers
skierpage
Posted 2:35 PM 24/5/08
@GadgetPlay: You can buy starchitect Frank Gehry's corrugated cardboard furniture. I recall "rougher" prototypes of sofas with cushions made of corrugated cardboard; comfortable but not so durable.
skierpage
macminime
Posted 12:24 PM 24/5/08
does anyone know if the 3G version will incorporate GPS?
i've heard rumors, but it sounds like the usual shellac that gets passed around just before a developers conference.
macminime
SharkByte
Posted 5:01 AM 24/5/08
i'd like to know how secure the fins are held into the body. if they're not, one good bottom turn or kickout and you're takin a header...
SharkByte
Geisrud
Posted 4:18 AM 24/5/08
@Pope John Peeps II: Look up "sway load" - should offer some insight into your question.
Geisrud
ninjamurf
Posted 3:41 AM 24/5/08
"Thanks to a mathematically sound triangular pattern"
It looks more hexagonal (honeycomb) than triangular? Although technically a hexagon can be divided into 6 triangles it seems odd to call this design "triangular" rather than "hexagonal" or "honeycomb"?
Useless sidenote for the day: Triangles and hexagons are the only polygons besides quadrilaterals that will tessellate (or tile) a plane.
ninjamurf
robinandtami
Posted 3:37 AM 24/5/08
Is it me, or does the underside of that board look an awful lot like really tasty fish scales?
robinandtami
MarlboroTestMonkey7
Posted 2:02 AM 24/5/08
Distribute as open source and we all be more happy.
MarlboroTestMonkey7
Lazarus511
Posted 12:54 AM 24/5/08
It's like, what if Keanu from Point Break, and Keanu from The Matrix, where like the same guy! Wooooooooo!
But seriously though. That looks awesome.
Lazarus511
Kuato
Posted 12:53 AM 24/5/08
I wonder which "3-D modeling software" he used? I use both UG and CATIA, maybe I can get a copy of the model...
But then I'd have to build an accruate sim, 'cause going outside with all that icky UV...
/shudder
Kuato
kazmodo
Posted 12:37 AM 24/5/08
@sharkilepsy, hey don't nit pick or I am gonna give you a "shellacking" like you never had.
Oh, also the act of applying shellac is "to shellac"... sort of like painting something with... paint...
1. shel·lacked also shel·lacked, shel·lack·ing also shel·lack·ing, shel·lacs also shel·lacks To coat or finish with shellac.
2. Slang
a. To strike repeatedly and severely; batter.
b. To defeat decisively.
kazmodo
Kaiser-Machead
Posted 12:34 AM 24/5/08
@nunzio910: I'm pretty sure there are no adult great whales that come in at even less than 10-13 tons =P
Kaiser-Machead
Thud
Posted 12:18 AM 24/5/08
Damn... Pretty. Wish I was a surfer.
Maybe I should just buy one and use it as a wall sconce. It just looks... *cool* with the light coming through it...
Thud
sofa2000
Posted 12:04 AM 24/5/08
weight, impact strength, and price?
- at 1 to 2 lbs per cubic ft, an EPS (stryrofoam) blank might weigh 2 -4 lbs before it is glassed with epoxy and fiberglass; probably less than a cardboard blank.
-what keeps your knee or heel from denting all of those 2" gaps? I think it needs a deck skin and fin reinforcements, that or an absurd amount of fiberglass.
- that EPS blank can be milled to the final shape in half an hour on a shaping machine, much less time than it takes to cut, glue, and assemble 400 pieces of cardboard.
detailed build process :)
[www.swaylocks.com]
sofa2000
lpranal
Posted 11:58 PM 23/5/08
Wonder why he went with cardboard instead of corrugated PVC...
lpranal
Metropolis
Posted 11:52 PM 23/5/08
That's fucking awesome.
Metropolis
dhaberer
Posted 11:43 PM 23/5/08
funny, i was just thinking this morning about how surfboard should make the move from fiberglass to fiber carbon (though a quick search shows someone already thought of that). just happened to be on my mind as i'm getting a new board this weekend.
dhaberer
greimel
Posted 11:39 PM 23/5/08
This looks cool, but it's no new technology or anything - honeycomb core composites have been around for years. It would be cool to see the core made out of PP. That's make it very cheap and (almost) completely transparent.
@Pope John Peeps II
The cardboard acts like the vertical component of an I-beam. It will be very strong when loads are applied to the top and bottom. Forces applied to the sides or ends could potentially collapse the honeycomb, so could a force in one direction on the top and a force in the opposite direction on the bottom.
greimel
sharkilepsy
Posted 11:37 PM 23/5/08
"shellac it with fiberglass and epoxy resin."
shellac is a material not a verb. you can't "shellac" anything with fiberglass...bra
sharkilepsy
y_chromosome
Posted 10:35 PM 23/5/08
As a packaging designer who has everything to do this at his fingertips, I shamefacedly admit that I have never thought about this.
But it does start me thinking about ways to build that kayak I've been wanting...
y_chromosome
nunzio910
Posted 5:11 PM 23/5/08
Yea, looks pretty sweet..especially if you are a two ton great white. Does that look like a fishing lure to anyone?
nunzio910
sonburn
Posted 4:37 PM 23/5/08
@DeanOfAllTrades: thanks. I knew that... but good sharing.
sonburn
poppageorgio
Posted 3:51 PM 23/5/08
With the demise of ClarkFoam, there is pretty much only one manufacture of surfboard blanks, causing drastically inflated prices of boards in the past year. As far as rigidity goes, it doesn't take much to snap a current board in half. I would think torsion would be a huge factor though. As far as riding one, surfboards are like sports cars - the lighter you can build them, the more maneuverable they will be. I can't wait to see how this plays out. Its hard being a geek and a surfer. Surfing lifestyle is always leery of innovation.\
poppageorgio
valarmorghulis
Posted 3:00 PM 23/5/08
@Pope John Peeps II: i'm pretty much talking about side to side. you put torque on it and it should snap pretty quick.
but to anser your question, yes, a physicist would be able to explain this.
valarmorghulis
Pope John Peeps II
Posted 2:42 PM 23/5/08
Wait, wouldn't the force only be distributed evenly along certain axes???
I mean, say if you twisted that board, surely there are some directions in which it does not distribute force....
You can make a bed out of cardboard, but if you kicked it from the side it would still collapse.
Can a physicist explain this?
Pope John Peeps II
DeanOfAllTrades
Posted 2:00 PM 23/5/08
@sonburn:@giyad: Fiberglass in surfboards is not the same as fiberglass insulation in your home. Well it is but it isn't. Think of boats and cars. These are long strands woven into sheets and held together with resin. Fiberglass insulation is the small itchy scratchy stuff that you are thinking of.
DeanOfAllTrades
SpudMills
Posted 1:30 PM 23/5/08
Nerd don't surf.
SpudMills
nate4096
Posted 1:29 PM 23/5/08
@GadgetPlay: from the article: "Clear Seas: This surfboard's frame is cut from 16.6 square feet of cardboard and covered in transparent fiberglass."
nate4096
GadgetPlay
Posted 1:06 PM 23/5/08
@HDC: "hopefully he can make them transparent like that so you can see underneath."
No problem! He'll just use some of that new transparent cardboard thats all the rage these days.
--------------------------------------------------------------
On a more realistic note, about 40 years ago I read about a way to make furniture by cutting cardboard into shapes and laminating layers together with varnish, and shaping, sanding and painting. I think I like this better, but it's the same idea.
GadgetPlay
bigpolla
Posted 12:40 PM 23/5/08
wow, cool idea
i say whats gonna happen is that hes about to launch the site and some douche company is gonna offer him a few grand, he'll take it, and then the company will make millions off it.
bigpolla
cchromy
Posted 12:01 PM 23/5/08
Genius can't wait to get my own
cchromy
billcanada
Posted 11:51 AM 23/5/08
Even sharks will be more attracted by that.
billcanada
jrghoull
Posted 11:49 AM 23/5/08
i'm more into boogie boarding then surfing...still though...if its not too much money...who knows...
jrghoull
myotheralt
Posted 11:41 AM 23/5/08
@RiceBandit: hows that? only three are made, and one gets turned into a time machine then run over by a train?
myotheralt
Vonn64
Posted 11:30 AM 23/5/08
@HDC: Picture this: you wipe out and.. wait.. Where's my board?
Next thing you know it shatters your jaw/nose because you couldnt see where it was coming from either.
Vonn64
sonburn
Posted 11:27 AM 23/5/08
@giyad: um... fiberglass is already used in the production of traditional boards... won't be any more uncomfortable than other fiberglass coated boards dating all the way back to 1946 when the first one was made.
sonburn
superbalde
Posted 11:26 AM 23/5/08
@geedots: $500-$600 is crazy pricey for a shortboard. You must not be buying local or only thinking of big name guys like Rusty and Merrick or thinking of some high-tech stuff like the firewires, avisos, or XTR/EPS boards. Course it also depends on where you live. I'm in San Diego so there's a ton of local shapers here.
superbalde
HDC
Posted 11:25 AM 23/5/08
Hopefully he can make them transparent like that so you can see underneath. Glass bottom surfing! Good for seeing the Great White coming at you from below.
HDC
surfer88
Posted 11:00 AM 23/5/08
I read about this the other day. I'd love to try one out and see how it feels in comparison to my foam boards. Thanks for showing the surf community some love today Giz!
surfer88
geedots
Posted 10:57 AM 23/5/08
@doofusgumby:
I hope you're right. I wonder how much longer we're going to feel the effects of Clark shutting down. Until new boards go below $500-600, I'm buying used.
geedots
giyad
Posted 10:43 AM 23/5/08
fibreglass doesn't sound too good on your skin...
giyad
phijef
Posted 10:42 AM 23/5/08
great way to recycle cardboard. Sweet board. Wished I surfed!
phijef
rdldr1
Posted 10:31 AM 23/5/08
Looks like a Jewish surfboard to me...
rdldr1
doofusgumby
Posted 10:16 AM 23/5/08
with the impending demise of styrofoam, he might be ahead of the curve on this.
doofusgumby
discounteggroll
Posted 10:05 AM 23/5/08
let's get the TMNT/Shredder reference resolved aready...
"rafaello tried it, and came out parmesan"
NEXT!
discounteggroll
baldingnerd
Posted 10:03 AM 23/5/08
pretty shnazzy
baldingnerd
RiceBandit
Posted 10:00 AM 23/5/08
This will forever be known as the De Lorean of surf boards.
RiceBandit
j4sk868
Posted 9:49 AM 23/5/08
Looks like the soles of my Vans.
j4sk868
Delaportas
Posted 9:46 AM 23/5/08
That board looks pretty sweet. The scary part is the guy hopes to make a kit that you put together yourself. That could be bad news for people who don't like to read directions.
...goes and throws out hardened pile of fiberglass resin and cardboard
Delaportas
djtooshay
Posted 9:46 AM 23/5/08
@shenanigans61: Neither am I, and I agree 100%.
djtooshay
chaoslink
Posted 9:37 AM 23/5/08
"And, since they are made from inexpensive materials, it should make a day of surfing at the beach a lot more affordable."
... after he recoups R&D costs and if he doesn't mark them as "high performance" boards and if they can be produced at the same rate (and with the same amount of labor) as traditional boards...
chaoslink
shenanigans61
Posted 9:30 AM 23/5/08
I'm no surfer, but that's pretty sweet.
shenanigans61