Pickleball Paddle v3.0

This is v3.0 of a paddle design that can be printed on a Prusa MK3/4; bed size (X×Y×Z, 250 × 210 × 210 mm).

Revisions:

• Removed the need for dowels and replaced them with a variation of a half-lap joint between the body and handle
• Body and Handle have a 0.3mm top and bottom layer; increased surface area for better adhesion with the Surface Faces. 
• Surface Faces have raised edges to help align onto the body; makes gluing much easier. 
• Paddle thickness: ~10.5 to 11mm

Suggested filament per part(s):

• TPU - Handle Grip, Handle Cap
• PP/PLA - Body, Handle
• PETG/PET/PLA - Surface
• PLA - Handle Peg (you can try PETG/PET, but it was much easier for me to just print this in PLA)

Other Materials Required:

• Glue/Expoxy
  • I used White Gorilla Glue and 3M Super77 Spray Adhesive 
• Clamps
• Spare wood/flat surfaces
• Low Expectations

Printing Notes:

• I printed with a 0.6mm nozzle and 0.3mm layers.
• Try printing the test pieces to check for proper fit.
  • Print the Body and Handle test pieces to ensure the joint fits properly. 
  • Print the Face test piece (after the Body has been printed) to check that the face will fit onto the Body properly.
• May need to adjust the Handle Cap height to fit flush against the Handle Grip; dependent on the material shrinkage.
   

Assembly Notes: 

• Print the body and handle first. Glue them together (I used White Gorilla Glue).
• Print two faces, and glue them to each side of the body (I sprayed the face and the body with 3M Super77 adhesive). Use clamps and flat panels to help surfaces dry flat.
• Use the Handle Pegs to help align the Handle Grip. I glued the grip and cap in place and then wrapped them.
   

Final Thoughts:

I printed the handle and body in PP in an enclosure and with Magigoo. The Faces were printed with CF PETG. 

My commercially available pickleball paddle weighs 240g. 

This version I printed and show in the pictures weighs ~260g.

So far the paddle survived one game of play. I cannot comment much on the expected longevity or durability, but it seems to hold up to light casual play.