Bring Your Surfboard : Product development of a surfboard accessory suited for Thule ReVert

Sammanfattning

This master’s thesis in Mechanical Engineering, Sustainable Design and Innovation was conducted in collaboration with Thule Sweden AB. The project’s purpose was to evaluate and develop an accessory for the vertical, hitch-mounted bike rack Thule ReVert, to enable safe and secure transportation of various surfboard types. While the outdoor recreational market is growing, existing surfboard transportation solutions are almost exclusively limited to roof-mounted systems or specialized RV and van racks. This limitation creates a market gap for a hitch-mounted platform suited for regular passenger vehicles. Utilizing the Double Diamond framework, this project progressed through four iterative phases: Discover, Define, Develop and Deliver. With comprehensive market research and a competitive analysis, a functional analysis and requirement specifications were established. From this data, four distinct concepts were generated and tested using rapid prototyping, and then evaluated using a scoring matrix. The winning concept utilizes a ratcheting telescopic mechanism inspired by existing Thule design language to secure the surfboard tightly without the need for standalone straps. The structural integrity of the concept was evaluated via analytical calculations of multiple load cases, approximated beam theory and Finite Element Analysis (FEA). The analyses verified that the assembly securely tolerates the dynamic loading conditions and aerodynamic crosswinds. The project culminated in a prototype fabrication of an industrial-grade prototype for real-world mounting and validation. The resulting accessory offers a user-friendly and safe solution that naturally expands the versatility of the Thule ReVert.