How was the Caribou Antia kayak created? The anatomy of the design process
The Caribou Antia is the next generation of sit-on-top kayaks with unique characteristics. It officially premiered at The Paddle Sport Show 2023 in France.
Final design of the Caribou Antia kayak
Manufacturing technology used in the Caribou Antia design process
The kayak was designed specifically for rotomoulding technology, also known as rotational molding. This manufacturing process enables the creation of large, three-dimensional objects with complex shapes. In this process, polymer granules are placed into a mold, which is heated until the material begins to flow. The mold then rotates across three planes around two parallel axes. As a result of this movement, the polymer coats the inner surface of the mold, creating a uniform structure. This technology is widely used in the production of diverse goods – ranging from complex industrial shapes to consumer products – due to its ability to effectively and precisely form large and intricate parts.
When creating any product, it is crucial to consider multiple factors, such as practical application, functionality, manufacturability, image, and economic aspects. The balance of these elements in shaping the final form varies depending on factors like the industry, target audience, usage conditions, regulations, market positioning, access to technology, and budget.
For example:
-When designing a medical product, the primary drivers are standards and certification requirements, which dictate material selection and the consideration of ergonomic and functional aspects.
– In the case of designing a new line of living room furniture, the possibilities are much broader, and stylistic and usability aspects play a greater role in determining the final form of the product.
When designing the Antia, the primary criteria were increasing the boat’s stability and buoyancy within the capabilities of rotational molding technology, which imposed a number of constraints. The kayak’s hull had to be monolithic and meet the requirements of a two-part mold , all while accommodating the target dimensions (a 3-person kayak) and the specific type (sit-on-top). The latter is characterized by a closed hull, allowing the user to sit on the kayak rather than inside it. This solution ensures greater freedom of movement, easier boarding and disembarking, higher load capacity, and effective deck drainage.
Due to the center of gravity being positioned higher than in classic kayaks, the bottom geometry must be adapted to provide greater stability. These baseline assumptions define the project framework, within which we focus on:
– Production technology (rotational molding)
– Usability aspects (sit-on-top, 3-person capacity)
– Functional aspects (transport and storage, cargo hatches, adjustable seats, accessory mounts)
– Image aspects (sleek silhouette, modern and attractive styling)
– Economic aspects (price aligned with a specific market segment, appropriate profit margins)
It is worth noting that the economic aspect is already defined to some extent at the very beginning of the project by the choice of production technology, which facilitates the initial estimation of implementation costs.
With the project foundations and priority hierarchy established, we proceed to develop a personalized action plan tailored to our specific objectives. The first step is creating the new hull geometry, with the deck shape subsequently designed to complement the chosen underwater profile.
In traditional sit-on-top applications – predominantly found in fishing kayaks – the primary focus has been on stability, dictated by the static nature of the activity. In the case of the Antia, designed to fulfill the dual role of both a fishing kayak and a river touring kayak, it was necessary to combine stability with improved speed and maneuverability.
By conducting observations, testing various kayaks available on the market, and drawing on the expertise of experienced kayakers and boatbuilders, we formulated hypotheses and sought solutions that would guarantee an optimal balance between stability and agility. The goal was to create a kayak that meets diverse expectations – performing equally well during calm fishing and dynamic river paddling.
Rhino 3D preview: Three different hull geometry concepts
Ultimately, from a pool of concept models, we selected three distinct bottom geometries, each offering unique nautical properties. These differences stem primarily from the hull’s cross-section. In short, the closer the cross-section resembles a rectangle, the more stable – but less maneuverable – the kayak becomes. Conversely, the more the cross-section resembles a circle, the less stable it is, but the greater its maneuverability. We therefore offer different options, allowing kayakers to tailor their on-water experience to their specific preferences, depending on whether they prioritize stability or agility.
Cross-sections of three hull geometry concepts
1:10 scale hull models were 3D printed and tested on the water. Where resources permit, it is also possible to conduct virtual testing using specialized software that simulates the behavior of objects with specific physical properties under defined conditions and forces. Such simulations enable more detailed analysis, though they typically entail higher costs. This type of research is of paramount importance in the design of high-performance sports boats. The final decision regarding the method of verification depends on the project’s complexity and the required level of analytical detail.
For the Antia, scale model tests proved sufficient to make a definitive choice, allowing us to effectively determine the next design steps while considering budget constraints.
* Prototyping
At 2s.design, we operate an extensive in-house 3D printing facility that allows for the immediate verification of product geometry and functionality.
This capability enables us to rapidly adapt and optimize our designs, ensuring we deliver the highest quality results.
3D prints used for initial on-water tests
Preparing a new product design for mass production
Once the hull geometry was finalized, we moved on to designing the deck for the Antia. In line with the key objectives, the kayak needed to accommodate three adults, offer ample cargo space, and include additional utilities such as a phone shelf, a water bottle holder, and mounting points for accessories useful for anglers and paddlers (e.g., rod holders, cameras, GPS units). Furthermore, with storage and transport in mind, the deck geometry was designed to allow for stacking (nesting) multiple kayaks. This addresses a major pain point for rental shops regarding logistics and ease of cleaning.
Concept ID Sketch
Kayaks manufactured using rotomoulding technology often struggle with maintaining hull rigidity – a problem not encountered in laminate kayaks. The plastic shell, particularly in higher temperatures, is prone to deformation, which negatively impacts not only its appearance but, above all, its nautical properties. To prevent this, the design process must incorporate ribbing, convex surfaces, and other geometric solutions to increase structural stiffness in key areas.
The 2s.design studio specializes in industrial design, introducing an innovative approach to transforming ideas into reality.
The Antia’s hull, exceeding 5 meters in length to accommodate the required load capacity, presented a challenge in terms of structural rigidity. The integration of aluminum profiles into the deck proved to be an effective solution. These profiles not only effectively stiffen the entire structure but also serve as universal mounting rails. They allow for the attachment of seats with sliding adjustment, accessory mounts, and transport straps. Additionally, they protect the deck edges when storing kayaks on racks and can be easily replaced in case of damage. This solution delivers multidimensional benefits, combining structural reinforcement with practical mounting capabilities and protection.
Caribou Antia Cross-Section
With all key design criteria in mind and a full awareness of the resulting constraints and possibilities, we proceeded to model the preliminary deck geometry. The goal of this stage is to create a model that will serve as the basis for a 1:1 scale mock-up and necessary testing. During this process, we incorporate the primary lines that define the deck’s form and styling. In the case of the Antia, these lines correspond to the gunwales and the contours of the cargo hatches.
Key character lines defining product perception
Ensuring a harmonious composition of these key shapes is crucial, as the entire structure and styling directly depend on them. All remaining details and aesthetic elements are derived directly from these primary forms. Exploring a wide spectrum of possibilities and selecting the optimal geometry at this stage accelerates the subsequent design process and helps avoid time-consuming and costly revisions.
1:18 scale 3D print for preliminary geometry verification
Design validation and full-scale prototyping
The Styrofoam mock-up, machined using a 5-axis CNC mill, precisely replicates every designed shape, enabling accurate testing of the developed solutions. This model allows us not only to better understand and evaluate the aesthetic aspects but also to practically verify whether the functional assumptions are effective or require modification. It serves as a tangible, ‘hands-on’ validation of the design’s efficiency.
Video showing the milling of the 1:1 scale prototype
Despite adverse weather conditions, we successfully launched the mock-up to test its nautical properties and deck ergonomics. Additionally, we conducted trials with a group of athletes with disabilities to evaluate the kayak’s potential suitability for users with mobility impairments.
On-water testing of the CNC-milled Styrofoam prototype
The tests confirmed that the designed form performs according to assumptions, requiring only minor modifications to the hull geometry (a minimal increase in stability) and the proportions of deck elements (adjusting the center of gravity for a 3-person load). Furthermore, trials involving users with disabilities demonstrated that the proposed design meets their needs significantly better than traditional solutions. The high stability, spacious flat deck, and low gunwales significantly facilitate boarding and disembarking, ensuring both safety and user comfort.
Final Design
Based on the conclusions from the tests, we proceeded to model the detailed geometry of the Antia. During this process, we focus on refining all details, such as the precise shape and placement of pockets and handles, water drainage grooves, the shape and positioning of anti-slip mats, the layout of threaded inserts, the hatch sealing and locking systems, as well as the seat construction and other components.
Our work focuses on refining and expanding the CAD model with increasingly complex and fine details, while considering interdependencies and meeting the requirements of usability, economic, technological, and stylistic aspects. We ensure that every added detail harmonizes with the whole, balancing functional needs with manufacturing constraints and cost efficiency.
Final CAD model of the finished product
With a complete CAD model validated for demolding – accounting for fillet radii adapted to milling tools and ensuring surface continuity – we proceed to production preparation. This step bridges the gap between digital design and physical manufacturing.
Rotational molding tools are fabricated from large aluminum castings, which are subsequently CNC machined to achieve the required surface finish. The molds must be equipped with a custom frame to allow for suspension within the oven, and they also feature a series of sockets and technical ports.
Antia kayak production molds designed by 2s.design
In accordance with client guidelines and production machine specifications, we proceed to design the mold geometry, which will be manufactured by an external contractor. This stage involves translating the product design into a negative space that meets all mechanical constraints of the manufacturing equipment.
It is worth noting that mold production is a time-consuming process – primarily due to the extensive CNC machining required – and typically has a lead time of 2 to 4 months. This timeline is a critical factor in the overall project schedule.
The Caribou Antia production mold before being loaded into the oven.
The final stage of preparing the kayak for market involved outfitting it with accessories and developing the branding. We designed all complementary elements, including deck mats and seats, to fully tailor the product to the expectations of future satisfied customers. This holistic approach ensures that the functional hardware and visual identity work together seamlessly.