It all started with a text from my sister: “Hey, I have this idea for my paddleboard.” I could not help but be intrigued.
She had been paddleboarding for a while now, exploring lakes and rivers, and there was one thing she always wished she had — a cup holder.
But not just any cup holder. She needed something that could survive the demands of paddleboarding: waterproof, sturdy, and secure enough to be tied down with a bungee cord.
Her idea sounded simple, but, like all custom projects, there was a good chance the execution would get tricky. She had some basic dimensions and a rough idea of what she wanted. That is when she turned to me.
As a mechanical engineer, I am always excited by the opportunity to bring concepts to life, especially when it involves something as tangible and practical as a paddleboard accessory. I happily took on the challenge and dove into the design process.
Scoping the Project: From Vision to Blueprint
The first step in any project is scoping it out — getting into the nitty-gritty details of what the customer needs.
In this case, my sister was my “customer,” and the scoping process felt more like a brainstorming session over coffee than a formal meeting. She wanted the cup holder to fit various sizes of water bottles and tumblers, withstand splashes and submersion, and be easy to attach or detach from the paddleboard.
We hashed out the essential specifications:
- The dimensions of the cup holder
- The material that could survive exposure to water and sun
- The method of attachment.
Most importantly, we discussed how many she would need. Since this was a one-off project for personal use, we did not need to mass-produce the holders.
After gathering all the requirements, I had a clear vision of what the cup holder would look like and how it would function. It was time to start designing.
Turning an Idea into Reality: Design and Engineering in SOLIDWORKS
When it comes to turning a concept into reality, CAD (computer-aided design) modeling is my go-to tool. I fired up SOLIDWORKS and began playing around with different design ideas for the cup holder.
The basic structure needed to accommodate different cup sizes while being both lightweight and robust. I also incorporated slots for bungee cords, so the holder could be securely fastened to the paddleboard without wobbling or coming loose.
SOLIDWORKS allows me to visualize every angle of a design, ensuring that all components are functional and practical before ever building a physical model.
Once the design was finalized, the next step was figuring out how to manufacture it.
Navigating the Manufacturing Process: Choosing the Right Path
Here’s where things got interesting. Designing the cup holder was one thing, but making it was an entirely different challenge.
For large production runs, machining or injection molding might be the way to go. But since this was a small project, with just a few cup holders to make, I had to find a more cost-effective solution. That is when I realized that 3D printing would be the ideal approach.
With 3D printing, I could produce a low-volume batch without the expensive setup costs associated with other manufacturing methods. However, choosing the right type of 3D printing and material was crucial. I needed something durable, waterproof, and capable of withstanding wear and tear.
To make sure I was heading in the right direction, I reached out to the team at A3D Manufacturing.
Partnering with A3D: Leveraging Expertise in 3D Printing
A3D Manufacturing has a wealth of experience in advanced manufacturing, and they were the perfect partner for this project. I walked them through my design and explained what I was aiming for: a cup holder that could endure the elements and look good doing it.
After reviewing my CAD model, they recommended using their HP Multi Jet Fusion (MJF) 3D printer with PA12 material.
PA12, a type of nylon, is known for its durability, impact resistance, and waterproof qualities (with the right finish), making it the perfect choice for outdoor applications like paddleboarding.
A3D Manufacturing’s HP MJF printer offered high precision and accuracy, ensuring the final product would match my design specifications down to the millimeter.
Once we settled on the material and the printing method, we moved forward with the next steps: finishing and coating.
Adding the Final Touch: Red, White, and Blue Cerakote Finish
While functionality was my main priority, I wanted to make the 3D printed cup holder visually appealing as well. My sister and I agreed it needed to have a custom touch — something that made it stand out on the water.
That is when we decided on a patriotic theme: red, white, and blue.
A3D Manufacturing recommended applying a Cerakote finish, a durable ceramic-based coating that provides both aesthetic appeal and added protection. Cerakote is used in various industries, from firearms to automotive parts, because of its toughness and resistance to environmental factors like moisture and UV light.
For this project, the Cerakote finish would not only give the cup holder a bold, American flag-inspired look but also enhance its durability.
With the design finalized, the manufacturing method chosen, and the finish selected, it was time to see it all come together.
The Final Product: Testing the Paddleboard Cup Holder
A few days later, the prints were done and shipped out. I was excited to see the final product in person. When the package arrived, I quickly unboxed the cup holders and was immediately impressed by the quality of the prints. The Cerakote finish looked fantastic, and the dimensions were spot on.
But the real test was still ahead — would it perform as expected on the water?
Before hitting the lake, I decided to test it at home. I grabbed a few different-sized water bottles and tumblers to see how they fit in the holder. Everything fit perfectly. The bungee slots were snug, and the holder was stable, even when I gave it a good shake.
Next, I packed my paddleboard and headed to the nearest lake for the ultimate test.
Performance on the Water: Success!
Out on the water, the cup holder exceeded my expectations. The bungee cords held it securely in place, even through choppy waters and sharp turns. I was able to keep my water bottle within arm’s reach, and it stayed put, no matter how rough the conditions got.
The Cerakote finish also held up well, resisting scratches and wear from exposure to the sun and water. My sister was thrilled with how it turned out — her paddleboard looked great, and now she had a functional, sturdy cup holder that added to the experience.
What I Learned About the Importance of Collaboration and Iteration
This project was not just a one-off exercise in custom manufacturing; it was also a valuable learning experience.
First, it reminded me of the importance of collaboration. Partnering with A3D Manufacturing helped me bring the design to life in ways I would not have been able to achieve on my own. Their expertise in 3D printing and material selection was crucial in turning the cup holder from a concept into a functional product.
Second, it reinforced the importance of iteration in design and engineering. Every step of the process — from scoping the project to testing the final product — required adjustments and fine-tuning. Without careful planning, this project could have run into several hurdles.
By taking the time to ensure each stage was executed properly, we were able to achieve a successful outcome.
My Takeaways for Future Custom Projects
So, what is next? After seeing how well this project went, I am excited to explore more custom designs.
Whether it is for paddleboards, other outdoor gear, or even something entirely different, the possibilities with 3D printing and advanced manufacturing are endless.
If there is one key takeaway from this project, it is that custom designs do not have to be complicated or expensive. With the right tools, partners, and mindset, you can turn almost any idea into reality — whether it is a cup holder for a paddleboard or something more complex.
The key is to focus on understanding the needs of the project, exploring different manufacturing options, and collaborating with experts who can help guide you through the process.
If I decide to take this design to a full consumer product mass production I can explore the injection molding route. Until I have hundreds or maybe thousands to sell, the 3D printer will be perfect.
This experience opened my eyes to the broader potential of custom part design and manufacturing, and I am already thinking about the next project my sister — or any future customer — might bring to me.
The Bigger Picture: Where Custom Manufacturing Is Headed
As I reflect on this project, it is hard not to think about the future of manufacturing. The world of 3D printing is expanding rapidly. What was once a niche technology used for prototyping has now become a viable option for producing functional, durable products.
For businesses and individuals alike, this opens new opportunities to create highly customized, one-of-a-kind products without the need for traditional mass-production methods.
In the end, whether you are designing a custom part for personal use or for a larger commercial application, the principles remain the same: start with a clear understanding of what you need, collaborate with experts, and be open to refining your ideas along the way.
That is how you turn great ideas into reality — one project at a time.
Stay tuned for updates on how the cup holders perform over time and what new ideas we come up with next!
Contact us to explore how partnering with Hawk Ridge Systems and A3D Manufacturing can help you turn your own custom project ideas into reality.
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