Tag Archive: kayak design

Wavewalk S4 mold completed

The S4 mold got coated with Teflon, and our mold makers are done with its final inspection.
It’s on the way to its new home at the production facility where our kayaks and boats are made.
Developing and producing such a large size cast aluminum tooling is a complicated and lengthy process, and it was carried out pretty much on schedule.
We are planning to produce the first S4 units next week.


The top part of the S4 mold. The golden-brown glossy material is the Teflon coat.


The purpose of coating the inside of a mold with Teflon is to prevent the Polyethylene from sticking to the mold after it’s cooled down.
If the Polyethylene sticks to the mold, the production team can have a hard time taking the molded boat out.


The mold’s top part viewed from another angle.


Close up of the bottom part of the Wavewalk S4 mold


The bottom part of the tooling suspended from a crane


Rear view of the bottom part (upside down) – The bottom half of the rear carry handles can be seen


The Wavewalk S4 cast aluminum tooling waiting to be picked up

More pictures of the S4 cast aluminum mold – bottom part

Our mold makers just finished casting the bottom part of the final mold for the S4 – the actual aluminum mold, and they sent us a couple of pictures.

While this may not look very impressive to most people, we are very impressed with it, and to us it is a most beautiful object  🙂

Anyways, this is a good opportunity for those who are interested in the design of the S4 to have a look at how it’s made.

The next steps in the S4 tooling include polishing the mold, building a steel frame, and coating the inside with Teflon.




First glimpse at the actual S4 mold

This morning our mold makers sent us these photos of the top part of the cast aluminum rotational mold for the Wavewalk® Series 4 (S4).

Next part they’ll cast in aluminum is the bottom of the mold.

After that, the two parts will be polished and finished, and mounted in a steel frame that will enable attaching the mold to the rotational molding machine.

The last step before the mold is ready for boat production is coating its inside with Teflon.


Front view of the top part of the S4 cast aluminum mold



Rear view



The first image (front view) shows a slight difference in the parting line between the top and the bottom of the mold, compared to our initial design. This change will enable our rotational molders to place the W logo higher than we’ve shown in the preliminary images and video that we produced. We’re happy about this opportunity to make our logo more visible.


W logo in new, higher location


Overall, we’re on schedule for starting production in April.

Wavewalk S4 pattern pretty much done

This morning the mold makers sent us a batch of new photos. This time it’s the top part of the S4 wooden pattern.

Some of the areas that have fine details in them were done with a plastic material, in order to achieve the highest precision.

As seen here, this wooden pattern is almost ready to serve as a mold for making the S4 in fiber-reinforced plastic (FRP), such as fiberglass, carbon fiber, Kevlar, etc. But in order to produce a cast aluminum rotational mold for the actual product, the mold-makers first need to use this wooden pattern to produce a set of two second generation molds called ‘sand mold’.


In the actual Polyethylene boat, the flat surface on top of the cockpit is cut away with a computerized router, thus enabling access inside through the opening, and attaching the two MDO saddle brackets and the saddle itself.

Stand up casting platform with integrated anti-skid surface. The slots are vertical structures that support the platform’s center.

Front tip and integrated carry handles. Good view of the slanted sides of the cockpit, designed to offer passengers comfortable paddling.

Front view.

Rear view with integrated carry handles and integrated stand for mounting plate for motor, rod rack, etc.

Side view.

Close-up on the slide-in mount for a vertical plate that can serve either to attach a motor, or to install a rod rack. If it serves to mount a motor, the vertical plate should be bolted to the cockpit’s rear end.