Want a composite pickleball paddle that crushes the competition for a few dollars? Of course you do! This paddle is based on a $90 paddle with some slight mods. The biggest in my opinion is no edge guard (layer seal) because it maximizes the contact surface. The paddle meets all regulations. At the time writing this it only has a little play time on it, but appears it will last.
-Perimeters = 3
-Standard 7 top and 5 bottom layers
I printed the handle on its side as shown in the picture. I wanted the top and bottom layers in the paddle surface to have the varying orientation through the thickness for strength. I was afraid to print it on end and have the paddle crack between layers at the highest stressed point. Some epoxy filled the rough bottom surface common to the supports nicely.
The body of the paddle is right at the extremes of my powder coated steel print bed. ABS may be tough if you don't have an enclosure to prevent warping. I used ABS for the hardness and strength. PETG may be a suitable alternative that will not warp. Suggest adding a few more layers to the top and bottom face for more strength. This also provides more material to work with when sanding smooth.
Step 1: Join the Handle to Body
Do a check fit first and sand a little if required. I used a 5 minute epoxy and some clamps.
Step 2: Sand the Paddle
I sanded the whole paddle with 220 grit paper with my small orbital sander.
Step 3: Fill Rough Areas and Sand Again
Step 4: Paint and Add Grip Tape
I used a matte black finish and some blue grip tape.