Fiberglass Boogie Board

 In this project we have decided to a make Boogie board so that we can learn the intricate process of making 3D objects out of composites. We chose Fiberglass for its various properties that are relevant for a boogie board such as high tensile strength and dimensional Stability. Using a shopbot we cut the foam in the shape of a boogie board then created mold for it where the boogie board foam would fit perfectly inside taking into consideration that the fiberglass layers will also add some thickness to the boogieboard. The shopbot malfunctioned and made this cavity in the middle of the boogie board so we mixed foam residue and epoxy resin then filled the cavity with it. Since the shopbot we had available to us was too small to make the full size in one go we cut half of it then the other half. Then we drilled some holes, added small cylindrical wood in between attaching the two pieces firmly together with some heat gun glue and finishing it off with the green tape. After that we applied the matrix to our cut fiberglass fabric layers, we gently wrapped them around the boogie board foam, added paper spray removal and enclosed it using with the mold and tape the mold firmly for extra pressure. Then we put in inside the vaccum bag sealed it off and left it overnight. Once the composite was cured, we cut off the sides, sanded it down, spray painted it and cleared coated it.