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Picture of Fusion Board - 3D Printed Electric Skateboard
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This Instructable is an overview of the build process for the Fusion E-Board that I designed and built whilst working at 3D Hubs. The project was commissioned to promote the new HP Multi-Jet Fusion technology offered by 3D Hubs, and to show off multiple 3D printing technologies and how they can be effectively combined.

I designed and built an electric motorised longboard, which can be used for short to moderate journeys or combined with public transport to offer a much wider traveling range. It has a high top speed, is very manoeuvrable and is easily carried when not in use.

Step 1: Design Process

Picture of Design Process
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I started the project by identifying the main standard components of the longboard; trucks, deck and wheels. These were off the shelf parts so I used these as the starting point of the design. The first stage was to design the drivetrain, this includes the motor mounts, gearing setup and included some modifications to the trucks. The size and position of the motor mounts would dictate the size and location of the enclosures so it was important that this was completed first. I calculated the desired top speed and torque requirements which then enabled me to select the motors and battery for the board. The gearing ratio was also calculated and the pulley sizes were selected, along with the drive belt length. This enabled me to work out the correct size of the motor mounts which ensured a well tensioned belt.

The next stage was to design the battery and speed controller (ESC) enclosures. The selected deck is predominantly comprised of bamboo so is quite flexible, bending substantially in the middle. This has advantages of being comfortable to ride, as it absorbs the bumps in the road, and doesn't transfer them to the rider. However this also means that a split enclosure is needed to house the battery and electronics, as a full length enclosure wouldn't be able to flex with the board and would make contact with the ground during operation. The electronic speed controllers (ESC) were placed closest to the motors due to electrical constraints. Because the motors are attached via the trucks the position changes during turns, so the enclosure had to be designed to allow for clearance of the motors.

The battery system was placed at the other end of the deck and housed the electronics related to power. This included the battery pack, comprised of 20 Lithium ion 18650 cells, the battery management system, on/off switch and charging socket.

I used Autodesk Fusion360 for the entire design process, this software enabled me to quickly model components inside of the main assembly which speeded up the development time considerably. I also used the simulation features in Fusion360 to ensure the parts would be strong enough, especially the motor mounts. This enabled me to actually reduce the size of the mounts as I could verify the strength and deflection requirements and remove material whilst still maintaining an appropriate safety factor. After the design process was complete it was very easy to export the individual parts for 3D printing.

김동건11 months ago

I love it. I want to build this, so can i get the 3D model of this skateboard like the parts that you built with 3d printer? Thanks

seamster1 year ago

The board looks so good!! Love the clean design and layout of all the add-ons! : )

If you wanted to include links to the various purchased parts, as well as upload the files for the printed parts, I know people would really appreciate it. This is something I would love to recreate at some point. Very very nicely done!

exactly this, without still files, as cool as this project is, it's just a fancy advertisement. if you add files and try to share with the community, that's a bigger thing.

Amazing looking build! I also live in the netherlands and have an eskate :)