Greetings all, my name is Tyler Erwin and I'm a fourth year Mechanical Engineering student at San Jose State University. In the following project, I utilized 3 different forms of digital fabrication to create my own Matkot Paddle using Fusion 360 for the first time. This paddle is utilized on the beach or an open area for a memorable time with friends. The idea of the game is to rally with friends and to prevent the ball from dropping!

Supplies

In order to create the paddle as closely as possible to the typical sizes, I needed a 24" x 24" x 3/8" piece of plywood to create the paddle itself. Additionally, I needed filament for our 3D printer to make the grips. Finally, I used spray paint to level out the indent the paddle had to create a cool embedded Autodesk Logo. I also required epoxy resin to adhesively attach my grip to the paddle.

Furthermore, with the filament I was looking to find a unique filament I hadn't tried before, which I found with Protopasta's HTPLA filament. This unique filament is a stronger form of PLA that was especially helpful when it comes to wanting a strong grip. In order to print this filament, I needed to use higher heat settings and truly test our new Ender 3 printer's capabilities.

Step 1: Inspiration

Matkot is a very popular game in Israel over the summer where two people attempt to rally as long as possible using their paddles. This game has seen numerous iterations which I was fortunate to see as a Santa Cruz resident. Annually you'll see families play this game on our beaches, so I wanted to create a set for myself! In the images provided above you can find some examples of Matkot I found on google and an image of the Santa Cruz Beach Boardwalk, a beach I frequently visit.

Step 2: Paddle Designing

In order to create the paddle, I needed a spherical service with a connected handle piece. To start, I created a 10 inch diameter face to represent the main contact point of the paddle. I then gave myself a 6.5 inch handle length to allow the user plenty of space to hold the paddle. With the intention of rallying, it must be easy for the user to quickly adjust their positioning. With a longer handle, this intention is possible. I rounded the handle rather than keep it flat in order to create some versatility to the grip to allow the user to adjust quickly. The paddle transitions smoothly from the handle to the main contact piece as well.

Next, I utilized Fusion 360's "insert svg" to add the Autodesk Logo into the project. This was important to import into the sketch for the laser engraving. For visual purposes when I started the project, I made it a decal to showcase to my University's Makerspace how I intended to have the paddle look.

Step 3: Paddle Digital Fabrication

In order to digitally fabricate my paddle, I utilized a water jet and laser cutter. I required the water jet to cut through wood as thick as I chose because the laser cutter would've created a major burn (as you can see with the test paddle). I placed blue tape over the wood in order to easily spray paint into the logo and sand down the product. The blue tape would have no effect on the fabrication either. When using modeling software, I was accustomed to exporting .stl files. However, this was my first time using the .dxf file exportation to create the sketch the software required to produce the paddle. First, I cut the paddle out of my plywood slab using the water jet, then laser engraved the Autodesk Logo onto the paddle.

Step 4: Paddle Spray Painting

In order to fill the laser engraving to maintain a smooth surface, I coated the paddle with spray paint to fill the indent. I chose my school colors of blue and yellow to provide some school spirit to my paddle. I utilized the blue masking tape on the paddle to fill in the logo, then used paper to cover the rest of the paddle. I then let the paint sit for roughly 6 hours before drying. I sanded down the paddle to prevent any uneven layers to emerge.

Step 5: Grip Design

For the grips, I wanted to minimize the costs for filament and reduce the amount required as much as possible. I only ended up using less than $10 worth of filament to create my part despite using stronger HTPLA. I included the ASME font logo to my part using the same "insert svg" command. This time I was able to extrude cut with this feature rather than utilizing it for the sketch.

Additionally, to make sure the part matched the dimensions of the paddle, I actually learned how to transfer the sketch from the paddle to a separate part. This feature within Fusion 360 was helpful tremendously to ensuring my part came out proportional to my previous model.

After a test fitting, I decided to increase the thickness of my grip to give the user a larger surface to hold onto.

Step 6: Grip Digital Fabrication

In order to print my grips, I exported my grips as .stl files into Cura to slice the parts. Our club recently purchased two Ender 3 printers and after constructing them my grips were the first parts they printed. I utilized the HTPLA for my grips which came out perfectly with no tolerance issue. I then used epoxy resin to mount my grips to the paddle and held them there for an hour. Each print took roughly two hours to print and I was able to get all my parts done in a day thanks to our club's new print farm!

Step 7: Final Product

Step 8: Video Demonstration

Step 9: Future Improvements

One of the areas I thought about improving the model was the grips. I'm intrigued with trying more surface modeling to create some grip indents to improve the handling of the paddle. I had some initial attempts, but I personally felt they didn't look great with the ASME logo. Further development of my skills with Fusion 360 will allow me to improve upon this design. Additionally, one of my fellow club members recommended I add copper inserts to the paddle, which I think will look intriguing for a design.