The HollowBoard Template Maker (HBTM) is a specialized freeware application designed to automatically convert 3D digital surfboard models into printable blueprint templates for crafting hollow wooden surfboards.
The program bridges the gap between advanced computer-aided design (CAD) and traditional garage woodworking. It allows builders to create internal structures—like internal ribs, skeletal frames, and structural spines—with exact millimeter precision. Key Features of HBTM
Direct CAD Integration: The tool allows users to import .brd shape files generated from popular surfboard design software like AkuShaper.
Automatic Internal Calculation: Instead of manually figuring out complex internal slopes, HBTM automatically calculates the precise dimensions of individual cross-sections (ribs) based on your overall board profile.
Compensation Variables: Wood has thickness, which changes the required size of internal parts. HBTM lets you define parameters like skin thickness, spine thickness, and rail thickness. It automatically shrinks the interior skeletons so the outer wooden skins fit seamlessly.
Multiple Layout Formats: Generates ready-to-print PDFs. These can be output as 1:1 scale large-format blueprints for a commercial plotter, or tiled across multiple standard letter-sized sheets for home printers. The Precision Crafting Process
Building a precision hollow board using HBTM involves a streamlined, software-to-wood workflow:
[Design Board in AkuShaper] ➔ [Slice at Set Intervals] ➔ [Import into HBTM] ➔ [Adjust Material Thickness] ➔ [Export 1:1 PDF]
The CAD Slice Process: In AkuShaper, builders slice their digital surfboard model at uniform intervals (commonly every 200 mm) along the length of the board. Extra slices are added at the high-stress, high-curve areas of the nose and tail.
Thickness Calibration: After importing into HBTM, you enter the exact measurements of the timber you are using (e.g., a 6 mm wood skin or a 20 mm solid rail).
Template Export: The software exports a comprehensive PDF package containing the precise curves for the outline, profile, and internal framework ribs.
Physical Transfer: The 1:1 scale templates are printed, cut out, and adhered directly onto plywood or Baltic birch using spray adhesive. From there, you can track lines perfectly with a bandsaw or jigsaw. Rail Style Configurations
Different wooden building methods require distinct internal skeletal layouts. HBTM supports custom configurations based on your chosen construction technique:
Solid / Square Rails: Used when framing the rails out of solid wood perimeter bands. The software shapes the ends of the internal ribs with squared edges to cleanly butt against the inner framing rail.
Strip Planking (Bead and Cove): Used when the exterior curves of the board are tightly wrapped in thin wood strips. Selecting this mode instructs HBTM to round off the edges of the cross-sections, allowing the outer strips to transition smoothly over the frame without hard corners. Compatibility Note
HBTM is traditionally launched as a Java Web Start (.jnlp) utility. When running it on modern operating systems like macOS, it is common to hit security blocks because it is unrecognized freeware. To open it, you simply need to navigate to your system’s Security & Privacy settings right after downloading and click “Open Anyway”. If you want to start building, tell me: What surfboard design software you are currently using. The wood thickness you plan to use for your deck and rails.
If you need help troubleshooting the Java setup or finding a source to print a 1:1 scale blueprint. HollowBoard Template Maker – General Discussion
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