YouTuber Emily The Engineer has explored the limits of 3D printing and constructed a life-size, buoyant Benchy boat. The project impressively demonstrates the possibilities and challenges of large-format 3D printing.
Benchy, a popular 3D printing test model, served as the starting point for the ambitious endeavour. Emily modified the file to create a real boat. She used several 3D printers to produce the individual segments. The parts were printed with five wall thicknesses to ensure watertightness.
Various techniques were used for the assembly. The main bonding method was chemical bonding with 3D printer glue. In addition, Emily used a soldering iron to weld plastic parts together. Epoxy resin was used to seal the outer seams.
The stability of the boat proved to be a challenge. Emily experimented with PVC pipes as stabilisers, but this proved to be counterproductive. She eventually developed a system of 3D-printed clips that attached pontoons closer to the hull.
Emily installed a trolling motor for propulsion. To increase safety, she integrated an emergency stop switch from an old treadmill. A 3D-printed battery holder prevents the battery from slipping.
The project revealed some of the weaknesses of 3D printing in large format. Exposure to sunlight and heat led to problems with the electrical connections. The limited battery capacity restricted the range.
Despite these challenges, Emily managed to cover a considerable distance with the boat.
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