A composite enclosure for an Insta360 camera, designed to fit around a hydrofoil and observe cavitation and underwater flow. I developed the shape and adapted the fabrication process through equipment and material setbacks.
35 knots is the stated design target, not a verified test result.
What — The problem
At Navier, I designed a fairing to mount an Insta360 camera around a hydrofoil. The goal was to observe cavitation at the propeller and hydrofoil, as well as vortices in the surrounding water, to inform efficiency improvements.
How — My contribution
- Developed the shape using CAD and 3D sculpting, with compatibility for different Insta360 camera models.
- Used 3D-printed and clay forms to shape the fiberglass composite exterior, and vacuum-bagged the layup.
- Created a separate mold for the camera insert and bonded the two composite components into one fairing.
- Compared production and composite methods, then used epoxy filler and sanding to create a smooth exterior.
Why — Result and learning
I produced a bonded composite camera fairing with a smooth exterior, camera insert and protective interface. The project developed my mechanical design and composite fabrication skills, particularly adapting a manufacturing process when equipment or materials caused problems.
The camera imagery illustrates the underwater observation task. The design target was up to 35 knots; no verified operating speed or measured efficiency improvement is claimed.
Troubleshooting and design constraints
- Repaired malfunctioning 3D printers so I could produce the forms needed for fabrication.
- Restarted the forming process when the clay proved too sticky to work with.
- Accommodated multiple camera models within the enclosure.
- Added a rubber seal at the inner interface to protect the carbon-fiber hydrofoil.
I painted the fairing orange for visibility if it detached and incorporated buoyancy into its sealed portions so it could float. These features addressed recovery as well as fit and fabrication.
Skills demonstrated: Mechanical design, composite fabrication, manufacturing iteration and troubleshooting.
Fabrication, camera fit and observation
