Electric Hydrofoil

Objective

I was always fascinated by the art of hydro foiling, ever since I've seen videos of people gliding effortlessly through the water, I've wanted to build one. This winter break I spent countless hours designing, laminating, and prototyping a custom e-foil. Introduced in 2015 by Lift, e-foiling as a watersport hobby has grown slowly, with the main constraint consisting of the immense cost, upwards of $10,000. I wanted to replicate and improve on previous DIY designs for a fraction of the cost, furthering the hobby and simplifying electronics and designs to produce a cheaper alternative.

Process

Being my first time working with a resin-based hand lamination, I utilized online resources to learn the intricacies of each process and the possible weakpoints for failure analysis. I decided on unidirectional carbon fiber fabric laminated onto a 3d printed assembly and 6oz fiberglass for the eps foam board. The process consisted of lots of sanding, shaping, and waiting for epoxy to cure but in the end, turned out fairly uniform and plenty strong for the application. By creating a modular system of attachment, various-sized wings, and configurations could be utilized to increase stability or performance.

As for the electronics, I constructed a lightweight, high-efficiency battery and utilized a 6384 outrunner motor rated for its waterproof features and high torque profile with a VESC to have precise control over throttle calibration. A lightweight design was crucial for this build not only reduces weight, but also increases maneuverability and performance.

Result

Testing to come soon! Still too cold 🥶