3D Printed Boat

The PRINTcess

Project Navigation

Cost:

$7.5k

Time:

6 Months
Watch the PRINTcess Build

Project Overview

The #3DBenchy model has become something of a legend in the 3D printing world—it’s a fun test print, a standard for tuning settings, and a symbol of what’s possible with this technology. Somewhere along the way, I (and many others) started to wonder: could this iconic model be scaled to a full-size, functional boat?

That’s where the PRINTcess project began. About 2.5 years ago, I started working on the first piece of the puzzle: a large-format 3D printer with a 1 m3 build volume. It took several iterations before this printer could extrude enough material to print the boat in a reasonable amount of time. My current version is able to print 200 lbs per day using an MDPE10 extruder and quick rack-and-pinion actuators. The 600 lb hull was printed in 3 separate pieces, measuring 3.3 ft wide and 10 ft long in total.

With its exaggerated, Steamboat Willie-esque proportions, Benchy was always going to make for a cartoonish, larger-than-life vessel. Early on, I decided to embrace the novelty, leaning into the fun rather than aiming for practicality. The most challenging obstacle was bringing to life the oversized cabin, which is what keeps the smaller model from floating upright.

Learn how I tackled these challenges and 3D printed the iconic Benchy model at full scale with the PRINTcess project.

Demonstrating the true scale of Dr. D-Flo's 3D Printed boat by placing it next the original Benchy model

Specifications

Life-Size 3D Printed Boat Benchy with smokestack sailing
Dimensions: 10' Length x 3'4" Width x 8'1" Height
The PRINTcess is a 45:1 scale version of the Benchy model.
Draft: 14" (w/ 2 people)
This vessel sits shallow in the water, making it suitable for calm lakes and shallow waters.
Weight: 1200 lbs
This wieght includes a 400 lb concrete keel that runs along the bottom of the hull.
Material: Recycled PETG
While PETG isn’t the ideal hull material due to its flexibility, requiring added thickness for the desired stiffness, it’s a step towards more sustainable manufacturing. Made from recycled PETG, this hull showcases how repurposed materials can be used in large-scale 3D printing projects
Propulsion: 2 Hp Electric Trolling Motor
This motor provides enough thrust for leisure rides, allowing the boat to glide smoothly without excessive noise or emissions.
Power: 2x 12V 100Ah Mini LiFePO4 Lithium Battery and 200W of Solar Panels
This setup extends battery life on the water, providing an extra 25% of range every 4 hours in the sun.

Cost and Bill of Materials

The affiliate links may be present below.

The most common question about this project was how much did it cost? More specifically: is 3D printing a boat cheaper than buying one? Well, you can purchase a barebones 10 ft Jon boat for $800 from a Bass Pro Shops (does not include motor/batteries). Let’s break down the cost of my hull as that is the most direct comparison:

The total cost of the hull was $2,107—about 2.5 times more expensive than a comparable commercial boat. This estimate doesn’t include labor or the operational costs of my large-format 3D printer.

The simple takeaway? 3D printing a boat is far more costly than buying one off the shelf. But there’s more to it: commercial boat manufacturers benefit from significant economies of scale. For a Jon boat manufacturer, producing a single new plastic boat would cost millions in molds and tooling setup, but those costs are spread over hundreds or thousands of boats. 3D printing offers a unique approach without the upfront tooling costs, making it ideal for one-off creations like the PRINTcess.

But that only includes the hull. So, how much does the cabin cost?

License: This project is licensed under BY-NC-SA 4.0. Users are allowed to adapt and remix the work but all contributions must be distributed under the same license as the original (e.g., noncommerical). The base 3D model cannot be redistributed, but modifications that unlock new features or significantly improve the base function of the printer can be shared. For any questions on this license please contact Dr. D-Flo.

3D Model


While it’s unlikely anyone will attempt this project exactly as I’ve laid it out—due to the need for a large-format 3D printer—I’ve uploaded the CAD model to share in the open-source spirit.


  Open-Source Content

Dr. D-Flo’s #1 priority is ensuring uninterrupted access to his digital fabrication content for everyone. Information and project files are free without any intrusive advertisements. The goal of this website and YouTube channel is to inspire more makers, DIYers, machinists, fabricators, and engineers as we need physical solutions for many of the problems facing our society.

If you find yourself in a position to contribute, we would greatly appreciate your support through becoming a YouTube channel member, a one-time donation, or purchasing your tools through Dr. D-Flo’s Amazon store.

Discussion and Feedback

Do you need more help? The best way to get your questions answered by Dr. D-Flo and other DIYers is to post a question on the forum. Click here for the forum topic specific to this project.

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