Yamaha Superjet Wide Tray Inserts

This project involved end-to-end design and fabrication of custom wide tray inserts for a Yamaha Superjet. I developed the surface geometry in SOLIDWORKS using a single 3D sketch, then produced scaled prototypes on my Prusa FDM printer in multiple sections for fitment validation. After a couple of design iterations, I created 3D-printed tooling and an acrylic alignment jig to support proper orientation during composite layup. The tooling was prepared using filler primer, wax, and PVA prior to layup. I then laser cut 1708 biaxial fiberglass and performed a wet layup to manufacture the final parts, repeating the process for both sides. The completed trays were riveted to the jet ski, structurally reinforced with foam and additional fiberglass, and finished with Hydroturf (EVA Foam).