Escuela Superior Politécnica del litoral

Facultad de ingeniería Mecánica y ciencias de la producción

Materials Selection

Homework 1

Group 3

Product Development for a Windsurf Mast

 Activity 1: Concept development

In windsurfing the mast, its like the skeleton of the setup, it must resist the resistance force of the
wind at high speeds. Commonly the windsurf masts are made of carbon fiber given that they must be
stiff and light, this bring us to the main characteristics that must be considered for the design.

• Resistant to salinity
• Resistant to humidity
• Flexible
• Not buckling
• Rigidity
• Amount of carbon
• Low density
• Reasonable cost
• Easy maintenance
• Ergonomic model
• Easy to transport
 Recyclable
 Shock resistant
 Flat surface

 Activity 2: Feasibility study

Searching online the main brands of windsurf masts that appears are Loft sails and Unifiber, they sell
masts made of carbon fiber glass and classified by the percentage of carbon content. Though they are
one of the main brands in the field. They are limited to sales in the US. To compete in the market the
product must have technical advantages over the competition.

 Activity 3: Material selection and design

Given the main characteristics the mast must have, the main one is the ability to bend when force is
applied, and it must be light. The principal candidate for the material is carbon fiber, the content of
carbon in the compound affects the result, as said by professional windsurfers the carbon content is
reflected in the weight and response of the mast. For example, in a mast with 100% carbon content
the response is higher than a 75% or 50% carbon content, it also is lighter.
Another material that can be use is a high density polyethylene HDPE, this have less density than
carbon fiber. The weigh would decrease considerably, it can be recyclable, and is resistant chemical
too, ideal for salinity of sea.
Other materials that can be used in windsurf masts is fiberglass, which can be a little more economical
than carbon fiber. It also provides greater flexibility but less hardness than carbon fiber. Other
differences between these materials are: carbon fiber is more resistant than glass fiber, glass fiber
weighs more than carbon fiber. In some cases, masts can be made from a combination of both
materials.

 Activity 4: Planning and scheduling

Gantt chart for the product development

Month 1 2 3 4 5 6 7 8
Purchasing raw material
Prototype production
Tests
Modification
Large scale production
Development

 Activity 5: Researching the market

Prototyping the product is essential to its development, there must be test made to ensure the quality
and limits of the mast. During this period the modifications are made, there should be tests of the
combinations of carbon content in different amounts and finding the best combination for a given
application.

 Activity 6: Large scale production and launching

During this stage the consumer’s feedback is important, the information gathered from the people
using the product helps to its improvement. Also, is important to design the process of scale
production with the most efficiency.

 Activity 7: Product life cycle

The carbon fiber will get in foil, after having a mold, it is put in layers together with the resin, until to
get the dimension given in the design process. After the fabrication the mast is ensembled in the
windsurf and will be used for a long time until the mast shows signal of deformation.

 Activity 8: Recycling and obsolescence

Carbon fiber is recyclable so after the life period of the windsurf mast the carbon fiber can be reused,
pulling away the resin and the carbon fiber immersing the piece in alcohol. Extract both products by
decanting