Vacuum-formed Skateboards
I made multiple custom-designed skateboards by vacuum-forming thin sheets of maple veneer on top of a hand-carved foam mold.
Project Summary
I started the project by deciding on the size and contours of the skateboard deck itself, and then began shaving down a piece of insulation foam to make the board's contours, as shown in the photo below. The skateboard has the usual curves at the front and back, as well as a slight bevel on the sides. I then put a thin layer of Titebond on each veneer, stacking a total of seven on top of the original mold. I then placed the maple veneer sheets, all sitting on top of the foam, into the vacuum bag to be molded for 24 hours.
With the seven layers of wood all warped into the desired shape, I cut out the shape of the board, a fish in this case, using a jigsaw. After sanding, painting, and sealing the deck, I installed trucks and wheels that matched with the colors of the deck. Finally, I laser cut a piece of grip tape in the shape of fish scales and adhered it to the top of the board.
Skills & Tools
- Woodworking
- Graphic design & laser cutting
- Power tools
Progress and Final Product
The photos above show top, bottom, and side views of the skateboard, as well as the pink foam mold used during vacuum-forming.
Future Improvements
- More consistent contours by machining the foam with a CNC machine, rather than molding by hand
- Experimenting with more differing shapes and contours
- Custom-pouring skateboard wheels in 3D printed molds for more unique wheels