3d-print your own hydrofoil wings and save hunderes of dollars $$$

I recommend using a big nozzle. A .2mm or .6mm layer height won't affect the finish. When it's covered by fiberglass. Don’t use more than 10% infill. The 3d printed core provides basically no strength. I used 600gsm unidirectional and 450gsm biaxial per side . Plus one layer of 160gsm twill(fiberglass). You want the majority of fiber along the length of the wing.

I recommend using a vacuum bag but you can definitely just hand laminate it. You can of course use carbon fiber (which is stiffer and slightly lighter) but I didn't think the higher price was worth the potential benefits when I made mine.

The 1100 has been optimized to make the lamination process easier. (See instructions)

The wing utilizes a 23015 NACA profile..

I also have a 1400cm2 pump/ high efficiency wing

If you are planning to do a vacuum layup you should check out my vacuum pressure regulator. If you are looking for custom fin boxes (parametric) say less.

There is now a pdf with dimensions of the fuselage

Instructions

You should sand the core to get good adhesion with between the core and skin. 60-120 grit is fine.

The 1100 has some design features that simplifies the fabrication process.

1. These three holes gets filled with epoxy. (this will allow you to tighten the screws properly and countersink the holes).  You will later drill new (smaller) holes for your hardware.

2. This sacrificial wall will allow you to easily glass over the entire top surface without getting epoxy in the       fuselage cut-out. 

3. After glassing you can simply cut through the fiberglass/carbon and the outermost wall. I recommend dremel or multitool, its difficult but possible to cut trough it with a box knife.

Lastly you will need to remove these caps, you can use a chisel, grind or whatever. you just want to avoid damaging any surface that could lead to epoxy seeping into the hollow wing.

All wings are designed with 45mm hole spacing, but can be changed in fusion.

I recomend following this video for fitting your fuselage. 

And this one for glassing your wings