3D CAD Design ( Computer Aided Design )
Unlike many of our competitors CORE Paddles has full 3D CAD engineering capabilites in house. We design, develop, test and build tooling entirely in house. By bringing the CAD modeling in house we cut down on the possibility of any translation errors between the designer and the CAD technician. This also allows us to infinitely adjust and test every model until it is perfect. Without the financial constraints of working with external design consultants we are able to focus on the paddle: not the costs associated with designing it.
This has numerous benefits not the least of which is the ability to sweat over the most minor of design features. Every curve, every surface, every interface is designed, tested and re-designed to be tested again. This process is continuous during the entire design cycle of every paddle.
We use Rhino 3D and Solidworks for all surfacing and tool design / development. Mecsoft software is used to generate all CAM data for tooling. This combination of software allows us to design pretty much anything imaginable. It takes years to master but once the skill set is there the ability to conceptualize, design, validate and manufacture is beyond compare. To our knowledge CORE is only company to bring every aspect of the design, validation and tooling development in house.
FEA ( Finite Element Analysis )
Finite Element Analysis is the ability to test a design to failure within the 3D CAD environment on the computer. It provides invaluable data in regards to how specific shapes transmit energy across thier surfaces and is used to pinpoint areas where stress within the part can lead to failure. Once an initial design is completed we test it by loading the component and running it through a series of stress cycles. The software completes the calculations and a visual reprsentation of the stress is displayed on the model. This visual outline shows the designer where stress within the part is accumulating ( red shows failure ). By visualizing this we can change the design to better distribute these stress' within the part. A major benefit of this technology is that you can physically see how the shape of a model affects strength. Minute changes can make major differences in the strength and by continuously modifying the model we are able to both increase strength ( by adding material where it is needed ) and reduce weight ( by removing material from where is isn't needed ).
In the photos below you can see that stress distribution within the production model CORE Tour blade stays well below the 75th persentile under a full load equal to 200% of what the paddle will see in general use. This gives the blade roughly a 250% safety margin in general use. Well beyond the strength of any other blade on the market. Note the complete lack of red / orange coloring on the displaced blade. This shows a near perfect energy transmission across the face of the part.
FEA showing stress distribution within CORE Tour blade at 200% load.
Not only is FEA great for visualizing strength it is an amazing tool for validating the actual performance of the final part. Items such as section flow visualization and displacement under load can also be defined in the computer. We can see how water flows over any given section of the blade and then modify the blade as needed. We can also see how stiff a blade will be when a specific load is applied. These help us perfect not just the strength but also the feel of the final product.
FEA showing displacement of blade tip under 200% load.
FEA essentially allows us to perfect the design(s) befor we commit to cutting tooling. It is really an incredible tool as it allowed us to perfect the blades to the point where each physical test proto required ZERO shape changes befor commiting to production. Most companies go through 2-3 physical models to perfect the design. We nailed them the first time out.
CAM ( Computer Aided Machining )
Computer aided machining is the term given to the transfer of the 3D CAD data created above into a physical part. It is essentially the cutting of the material to make either the CAD components themselves or the tooling required to mold them. Special software is used to translate the 3D CAD data into a set of tool paths that drive a CAM machining center. These codes ( G-code ) are then loaded into a CNC Mill and a block of material is cut to the exact profile of the piece. To our knowledge CORE is the only company that has dedicated CNC equipment in house.
All of this adds up to one simple thing: CORE can make better paddles, and bring them to market faster than our competition.
