kayak design

Zusam­men mit unse­rem lang­jäh­ri­gen Part­ner Lett­mann sind wir stolz auf das Ergeb­nis des 2018 auf der Mes­se Boot vor­ge­stell­ten Mantas.

The new cree­ker from the tra­di­tio­nal Moer­ser brand is dou­bly con­vin­cing. Becau­se both per­for­mance and kay­ak design impress.

  • Pro­jekt: Kajak-Optimierung
  • Kun­de: Lett­mann GmbH
  • Leis­tun­gen: CAD-Optimierung, Visualisierung
  • Web­sei­te:
  • Jahr: 2018

Competence through many years of experience

In this pro­ject we were invol­ved in the design of the upper ship, the CAD imple­men­ta­ti­on and the tool construction.

kayak design

The­re is litt­le room for maneu­ver on the under­si­de of white­wa­ter kay­aks due to hydro­dy­na­mic requi­re­ments.
On the other hand, we were able to pro­vi­de the upstream side with the unmist­aka­ble, modern inter­pre­ta­ti­on of the Lett­mann look.
Im Ver­gleich zur Gra­na­te wirkt der Man­ta schär­fer gezeich­net. Die typi­schen Schwün­ge, Ecken und Kan­ten sind prä­zi­se her­aus­ge­ar­bei­tet und las­sen kei­nen Zwei­fel an der Schnel­lig­keit und Zuver­läs­sig­keit des Pad­del­boo­tes. Stu­fen und Hin­der­nis­se im Was­ser sind somit kein Pro­blem.
The wide stern gua­ran­tees a quick and safe ascent. Rear spoi­lers ensu­re excel­lent acceleration.

Sketch eines Manta Kajaks von Büro für Industrial Design in Deutschland
CAD Konstruktion eines Manta Kajaks von Büro für Industrial Design in Deutschland

Rapid development - exact CAD implementation

Com­pared to other boats, we were able to signi­fi­cant­ly speed up pro­duct deve­lo­p­ment using CAD imple­men­ta­ti­on. While the boats used to be san­ded manu­al­ly from foam blocks over weeks, today it is fas­ter and, abo­ve all, more pre­cise to crea­te the data on the com­pu­ter. Errors that are only detec­ted while the pro­cess is run­ning can also be quick­ly rec­ti­fied in this way.
This saves ner­ves, time and money.

Support from AZ

We also sup­port­ed the Lett­man com­pa­ny with our in-depth know­ledge and the deli­very of 3D mil­ling data during the sub­se­quent tool design.

The boats are made of poly­ethy­le­ne using a rota­tio­nal sin­te­ring pro­cess. A PE pow­der is fil­led into the molds. The­se two-part or multi-part molds are even­ly hea­ted in lar­ge fur­naces and rota­te around them­sel­ves on two axes. The mel­ting mate­ri­al forms a uni­form wall around the tool molds. After coo­ling, the boats can be demold­ed and finis­hed.
Thanks to the pressure-free pro­cess, the pro­ducts are vir­tual­ly stress-free and the­r­e­fo­re extre­me­ly tole­rant of shock and pres­su­re. This makes the boats safe and durable.

Com­pared to lami­na­ted tool molds, which are only made for small quan­ti­ties or first pro­to­ty­pes, alu­mi­num molds are more expen­si­ve to pro­du­ce, but their dura­bi­li­ty is many times lon­ger. In addi­ti­on, they signi­fi­cant­ly impro­ve the qua­li­ty of the boats. The molds cool down more even­ly and thus gua­ran­tee a con­trol­led coo­ling pro­cess of the pla­s­tic. The result is lower defor­ma­ti­on rates and increased pro­duct quality.

Two types of mold crea­ti­on had to be weig­hed against each other: CNC mil­ling or cas­ting.
Cast molds have poorer sur­face qua­li­ties during pro­duc­tion. Howe­ver, the sur­face has a major influence on the hand­ling and the appearance of the boats - a strong argu­ment for CNC-milled shapes. In addi­ti­on, alt­hough a manu­al­ly gene­ra­ted model of the boat was available, an addi­tio­nal model based on the digi­tal data would have had to be gene­ra­ted for the sake of accu­ra­cy. Thanks to the CAD con­s­truc­tion, this step could be skip­ped becau­se the data for the nega­ti­ve molds could easi­ly be gene­ra­ted digitally.

The tool hal­ves were mil­led from solid alu­mi­num blocks by an Ita­li­an part­ner. An enorm­ous amount of mate­ri­al and cos­ts, which, howe­ver, pays off in later pro­duc­tion. Thanks to the pre­cise shapes, the Man­ta can be mass-produced in lar­ge num­bers in Lettmann's in-house pro­duc­tion facility.

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