you'll need to use something strong. there's a lot of pressure on a boom head

Given the strength required, complexity of the few parts, and the fact there is every chance nobody has produced files for it - why? Many other boom heads will fit. Ones for a slightly larger dia tubing can be used with a plastic shim, and often this is preferable anyway as it improves articulation and eliminates tubing wear.

Back when almost everything had an Aeron head and tail say 5-10yrs ago it was very common to swap heads, and if it is that kind of age boom the spare parts will be very common as a result.

Thus, may be better to post a pic here and somebody will have fitted a different head to it, almost guaranteed.

Maui has been gone for ages

What is the diameter of the tubing at front end (clean, no plastic etc over) ?

The Aeron head I was referring to (Aeron, Severne, KA, Simmer, others) from say 5-10yrs ago, has a 87mm wide fitting and dia of about 30-31mm, as I said you can shim it though
I cna take more precise measurements of a spare one I have if u need

blank on purpose!

I bought a boom head from Maui Sails a year ago. Very fast delivery and also to reply my emails.

WillyWind said..
I bought a boom head from Maui Sails a year ago. Very fast delivery and also to reply my emails.

Hey Willy wind would you mind measuring how wide the boom head is where it attaches to the boom? I am hoping it's less than 90mm.

thanks Shannon.

The carbon-reinforced nylons I've tried 3D-printing for other applications are not particularly strong.
For example, the Markforged Carbon-Reinforced Onyx (nylon matrix) has only a tensile strength at break of 30 MPa, which is a very small fraction of what conventional carbon-reinforced epoxy laminates can take (around 600 MPa). You need to consider that most 3D-printing technologies use chopped fibres, as opposed to the continuous fabrics (multiaxial or unidirectional) used in vacuum infused composites.
There are some niche continuous-fibre 3D-printing technologies such as the one offered by Polymaker using also nylon as a matrix. The tensile strength goes up to 100 Mpa, and the reason why it is still a fraction of the strength (of traditional composites) is due to the relatively weak strength between the 'printed' nylon layers, compared to the chemically cross-linked epoxy matrix of conventional vacuum infused laminates. The performance comparison in shear strength is even worse.
Just my two cents from what I've experienced.

shannon19 said..

WillyWind said..
I bought a boom head from Maui Sails a year ago. Very fast delivery and also to reply my emails.

Hey Willy wind would you mind measuring how wide the boom head is where it attaches to the boom? I am hoping it's less than 90mm.

thanks Shannon.

Sin said..
The carbon-reinforced nylons I've tried 3D-printing for other applications are not particularly strong.
For example, the Markforged Carbon-Reinforced Onyx (nylon matrix) has only a tensile strength at break of 30 MPa, which is a very small fraction of what conventional carbon-reinforced epoxy laminates can take (around 600 MPa). You need to consider that most 3D-printing technologies use chopped fibres, as opposed to the continuous fabrics (multiaxial or unidirectional) used in vacuum infused composites.
There are some niche continuous-fibre 3D-printing technologies such as the one offered by Polymaker using also nylon as a matrix. The tensile strength goes up to 100 Mpa, and the reason why it is still a fraction of the strength (of traditional composites) is due to the relatively weak strength between the 'printed' nylon layers, compared to the chemically cross-linked epoxy matrix of conventional vacuum infused laminates. The performance comparison in shear strength is even worse.
Just my two cents from what I've experienced.

Imax1 said..
Also , injected plastic parts ( plastic boom head ) , have a kind of grain structure , ( molded under high pressure ) ,which makes the part strong . 3D printing just lays layer apon layer with the molten plastic sticking the layers together . Even with carbon you still wont get a good bond . Not near as strong . Some injected plastic parts have glass or carbon fibers in the plastic which is the strongest . This is expensive because it wears out the molding machine and tooling and has to be added to the price.
Its kind of like comparing the strength between the same steel manufactured in different ways . Cast ( 3D printed ) , rolled or extruded ( plastic block ) and forged ( injected plastic ) .
That's enough useless waffle from me.

Thanks guys. Sounds like it's not a good option either. I will figure something out I am sure.

Mark _australia said..
Buy a KA / Simmer / Severne one for the small boom.
The larger one looks like somebody wrapped it with extra to repair, is that the case?

Yeah I think you are right. I have ordered 2 from Maui sails. I think the 90mm gap will work on the inside. Fingers crossed I hear from them in the next couple of days.

thanks Shannon.

shannon19 said..
G'day all. I was just wondering if anyone might have cad files for 3D printing boom heads? I have a friend who is going to attempt to make one but if there is something to work off it might be handy.

I have 2 fiberspar booms that need the head replaced and i have been unable to find spare ones so 3D printing might be the easiest way to solve the problem.

Thanks Shannon.

Most generic boom heads will fit.
I fitted them to my Fibrespar boom easily.
2nd Wind in Perth have some, I know.

The Chinook Pro 1 head will probably fit the smaller boom. Their website says it is for a diameter of 33.5 +/- 1mm and the width is 88mm

chinooksailing.com/collections/boom-parts-accessories/products/pro-1-boom-head-complete-with-rdm-adapter

It looks like Maui sails might be dead. I ordered the 2 boom heads from them and heard nothing till I lodged a PayPal dispute. I then got an email just saying to wait a bit longer. No invoice or tracking details.they said they can't track packages once it leaves the us. My money was refunded via PayPal. Best to steer clear of them in future I reckon.

JakeNN said..

Agree with OP ... It's too hard to find a matching boomhead ...

Need to consider ..
Diameter which can change over straight section
Straight section on outside of boom
Straight section on inside of boom
Curve on 'straight' section of boom (not always straight)
Tolerances are super tight

Please buy a new boom.

And like the last thread where you said the above - it is not the case.
There is almost always something that will fit.

And over two weeks before you made this post, I measured one of mineand told him it would fit.
Then a couple days later, an ex-boom manufacturer said many generic heads will fit. Geez if you think its all too hard,I think he would know.

Dunno what you have against mix n match when people have little $$$$ - it works and asking here what else might fit is a very valid questions.
Save $1000 and recycle. Bring it on.