Pickleball Paddles
Pickleball Paddles
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As an avid fan of pickleball, I wanted custom paddles within regulation to improve my game.
Design
Design
The design for these paddles was driven by my preference for playing with a paddle with a larger-than-average handle length and a long and narrow face design compared to a short and wider face design.
I created a CAD model in Fusion 360 using regulation dimensions and my previous paddle as a guide.
I decided to extend the wood tang into the handle's body to increase the rigidity of the face where the ball would be hitting.
Additionally, I created a radius where the face becomes the tang to help minimize stress concentrations
Manufacture
Manufacture
To manufacture the paddles, I employed different techniques for the paddle face and handles.
For the paddle face and tang, I chose to use a 1/2" thick piece of 3-ply plywood as it would provide the right weight to the paddle.
Using a Lugana CNC router, a 1/8" endmill, and CAM that I created in Fusion CAM, I machined the paddle profile.
The remaining tabs and burrs were removed with a belt sander.
The paddle faces were sanded with an orbital sander grits 80-3200 to prep for finishing coats of stain and lacquer.
The handles were 3-D printed on a Markforged Mark Two using Onyx filament containing Nylon and chopped carbon.
This printer was chosen because it was the most accessible printer that produced parts to the tightest tolerance.
This would allow the handle to fit perfectly over the tang and blend seamlessly into the curved features during final assembly.
Once the paddle is assembled using epoxy, screws are added to further secure the handle to the wood.
The handle is then wrapped in grip tape and is ready to be used on the court.Â
Final Product
Final Product
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