The recent challenge brought to the shop was to 3D print a discontinued pivot drive for a NuCanoe fishing kayak. Our client, Traquan, obtained a CAD STEP file from NuCanoe so we had a framework to start with. However, the model imported as zero-thickness surfaces, and for 3D printing, we need a solid with defined wall thickness. After standard solidifying methods in Fusion 360 failed, we found the solution using Blender.

Part 2 of the challenge was the size. We split the model into 4 sections to fit the build plates, designing dovetail joints directly in the slicer so the parts could be reassembled without sacrificing structural integrity. The parts were bonded using a combination of industrial and marine adhesives.

We chose PETG for its superior tensile strength, UV resistance, and ability to withstand elevated outdoor temperatures. Here's the assembled part: