Scottish Crew Tests 3D-Printed Boat Parts in Pacific Crossing

Three brothers from Scotland are taking on a monumental challenge that shows how 3D printing is not just for the workshop but for the open ocean! Ewan, Jamie, and Lachlan Maclean are currently nearing the end of their 9,000-mile (approximately 14500km) journey to row across the Pacific Ocean on a carbon fiber boat. The boat itself is outfitted with more than 40 customized parts made using a Formlabs Form 4 3D printer. Their current target is to set a world record for the fastest unsupported three-man Pacific crossing while simultaneously attempting to raise £1 million for clean water projects in Madagascar.

The boat is named Emily-Rose, and it was designed with additive manufacturing at its core. Co-designed with the Ocean Rowing Company, the team utilized Formula One-grade carbon fiber for the shell of the boat. The Macleans produced 3D printed parts, including performance-critical ergonomic rowing seats that were created using 3D body scans of each rower. Additionally, sleeping platforms and weather-resistant mounts for the boat’s navigation and communications systems were also 3D printed. Ewan Maclean noted that, “Ocean rowing is a sport of marginal gains. If we can make the rowing position slightly more efficient or keep equipment more stable, it saves us time and energy every single day.”

A 3D mockup design of the boat to be used. (Credit: Maclean Foundation)

The team used Formlabs’ latest engineering resins to create parts that would have the strength of traditional production materials. Many of the last adjustments made to the boat were thanks to the adaptability of additive manufacturing. They were able to design a gimbal for their Jetboil stove and a UV and salt-resistant fixture for their satellite dish. These pieces are designed to survive prolonged exposure to the sun, mechanical stress, and saltwater. Ewan had said that, “Ocean conditions are one of the harshest environments for any material. The fact we can print, fit and rely on these parts at sea is a big shift in how we think about outfitting boats.“