Three brothers from Scotland are taking on a monumental challenge that shows how 3D printing is not just for the workshop but for the open ocean! Ewan, Jamie, and Lachlan Maclean are currently nearing the end of their 9,000-mile (approximately 14500km) journey to row across the Pacific Ocean on a carbon fiber boat. The boat itself is outfitted with more than 40 customized parts made using a Formlabs Form 4 3D printer. Their current target is to set a world record for the fastest unsupported three-man Pacific crossing while simultaneously attempting to raise £1 million for clean water projects in Madagascar.
The boat is named Emily-Rose, and it was designed with additive manufacturing at its core. Co-designed with the Ocean Rowing Company, the team utilized Formula One-grade carbon fiber for the shell of the boat. The Macleans produced 3D printed parts, including performance-critical ergonomic rowing seats that were created using 3D body scans of each rower. Additionally, sleeping platforms and weather-resistant mounts for the boat’s navigation and communications systems were also 3D printed. Ewan Maclean noted that, “Ocean rowing is a sport of marginal gains. If we can make the rowing position slightly more efficient or keep equipment more stable, it saves us time and energy every single day.”
A 3D mockup design of the boat to be used. (Credit: Maclean Foundation)
The team used Formlabs’ latest engineering resins to create parts that would have the strength of traditional production materials. Many of the last adjustments made to the boat were thanks to the adaptability of additive manufacturing. They were able to design a gimbal for their Jetboil stove and a UV and salt-resistant fixture for their satellite dish. These pieces are designed to survive prolonged exposure to the sun, mechanical stress, and saltwater. Ewan had said that, “Ocean conditions are one of the harshest environments for any material. The fact we can print, fit and rely on these parts at sea is a big shift in how we think about outfitting boats.“
The use of desktop-scale 3D printing meant that the brothers could iterate designs in real time. Instead of outsourcing, they were able to control the entire process from design to installation. This helped ensure that each part was custom-fitted to both the boat and crew. Ultimately, the flexibility allowed for the brothers to respond quickly to new ideas, test prototypes, and refine parts of the boat without significant delay.
The Maclean Brothers who helped create the Maclean Foundation. (Credit: Maclean Foundation)
While the boat serves as a showcase for additive manufacturing, the purpose behind the Maclean brothers’ journey is humanitarian. Through their foundation, the Maclean Foundation, they are working with partners in Madagascar to provide long-term safe water access. In the Ambohimanarina municipality, only 14% of residents currently have clean drinking water. The funds raised from this project will help build boreholes and water systems that can change that reality. The Macleans previously set a record for the Atlantic crossing in 2020, completing it in 35 days. This Pacific mission is longer and more demanding, but also a test case for how 3D printing can deliver reliable, high-performance parts for extreme environments.
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*All Photo Credits: Maclean Brothers / Maclean Foundation