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Anchor points and connections for xfoil: 3D-printed hardware for tarps, ponchos, and more.

  • Apr 25
  • 3 min read

Those working with ultralight films like xfoil face the challenge of safely transferring forces into the material. Since tear resistance under point loads is rather low, mechanical solutions like eyelets are unsuitable. A stable solution is offered by combining full-surface bonding with 3D-printed reinforcements.


The mounting principle: gluing on the underside

A crucial factor for durability is positioning: the hardware is always glued to the underside of the film. When the guy line exerts tension, the component is pressed against the film. The film acts as a mechanical barrier, meaning the load is not solely dependent on the adhesive but is physically supported. This significantly reduces shear forces on the adhesive tape and prevents premature peeling.


Material choice: PETG / ASA

Among the available filaments , PETG and ASA are the most suitable materials for this purpose, with different thicknesses:

  • Cold resistance:

    Both PETG and ASA remain sufficiently tough at sub-zero temperatures and do not tend to fracture brittlely. ASA is slightly more dimensionally stable.

  • Toughness / Abrasion:

    PETG is sufficiently abrasion-resistant for moderate friction (e.g., cords).

    ASA is similarly tough, but overall somewhat more robust against continuous mechanical stress.

  • UV resistance:

    PETG is only conditionally UV-stable and can become brittle in the long term.

    ASA is significantly more UV-resistant and clearly superior for permanent outdoor applications.


Geometry: The 0.2 mm ramp

All components taper to a thickness of 0.2 mm at the edges. This flat geometry is necessary to ensure a seamless transition between the hardware and the film. Sharp edges would create stress concentrations where the film could buckle or tear under load.


The 4 hardware modules (OpenSCAD code)

Here are the code blocks for the individual components. The hole diameters are optimized to 1.5 mm to ensure a press fit for 2 mm linen.


1. Tension triangle (corners)

With rounded corners (radius 2 mm) to avoid notch effects on the film.


// xfoil_triangle.scad
size=30; tc=1.0; te=0.2; hd=1.5; r=2; $fn=60;
difference() {
    hull() {
        linear_extrude(te) offset(r) polygon([[r,r],[size-2.5*r,r],[r,size-2.5*r]]);
        translate([3,3,0]) linear_extrude(tc) offset(r) polygon([[r,r],[size-9-2.5*r,r],[r,size-9-2.5*r]]);
    }
    translate([8,8,-1]) cylinder(h=3, d=hd);
}

2. Surface lifter (round)

For guying points on the surface to create more space under the tarp.


// xfoil_circle_lifter.scad
d=30; tc=1.0; te=0.2; hd=1.5; $fn=100;
difference() {
    hull() { cylinder(te, d=d); cylinder(tc, d=d-10); }
    translate([0,0,-1]) cylinder(3, d=hd);
}

3. Locking toggle (Toggle)

Mechanical closure (T-shaped) for doors or poncho sides. The base is hole-free for maximum adhesive surface. You need to cut/punch a hole in the Xfoil at the desired location, insert the toggle from the back, and then glue the base in place. This ensures that the hardware is pressed against the foil when pulled, instead of just being held in place by the adhesive tape.


// xfoil_toggle_unten_schmal.scad
bd=30; th=8; tw=7; te=0.2; $fn=60;
hull() { 
    cylinder(te, d=bd-10);                      // Schmaler Teil unten
    translate([0,0,1-te]) cylinder(te, d=bd);    // Breite Fläche nach OBEN versetzt
}
cylinder(th, d=5);
translate([0,0,th-2]) rotate([0,90,0]) hull() {
    translate([0,0,-tw/2]) sphere(d=5);
    translate([0,0,tw/2]) sphere(d=5);
}

4. Mini anchor (counterpart)

Small adhesive dot (20 mm) with central hole for the rubber loop of the toggle.


// xfoil_mini_anchor.scad
d=20; tc=1.0; te=0.2; hd=1.5; $fn=80;
difference() {
    hull() { cylinder(te, d=d); cylinder(tc, d=d-6); }
    translate([0,0,-1]) cylinder(3, d=hd);
}



Manufacturing and assembly

Those without their own 3D printer can use the SCAD files to have the parts manufactured in a local makerspace or FabLab. The material costs for a set of hardware are minimal.


The bonding surfaces can be degreased with isopropanol before assembly. Information on choosing the right tape (e.g., filament tape or LSE-compatible industrial tapes) can be found in the detailed tape guide for xfoil projects .

 
 
 

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