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the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634676084058-K1VFMF2E78VWDI5KNQN3/1810_+_Ref_1012-12.png Form After assessing our needs, we researched thermoform mold constructions. Though overlooked, we found wood molds could yield cheap manufacturing costs + could be reinforced with fiberglass matte within the factory. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1663737110989-I7YU48OIF1NNXN087K6Q/PauHana_Big+EZ_VFT_all_2048x.jpg Form https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1663737115960-YJEVN20AAY6W2W3PY9EY/PauHana_Endurance_VFT_all_2048x.jpg Form https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1663737120183-1MULTJ8FT829XDK3M0XG/PauHana_Navio_VFT_all_2048x.jpg Form https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634677549618-QD89M1XM6L3FPX00J0S7/IMG_0282b.jpg Form - Thermoform Testing After building a vacuum forming table from a space heater and a wooden box, we began to test the fidelity and alignment of our mold forms. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634677554098-UT18GRI1HMKRGK7RSWE2/Screenshot_6b.jpg Form - Logging Results Though notation took precedent on this project early on, the potential for years of iterative development in tooling called for a single document to compare findings. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634679529497-DDQZO2RYIGGZGQZX7QN1/_DSF3345.JPG Form - Full Scale Testing Our next step was to bring a mold to completion and test it at full scale. In order to clear up any confusion, a line-by-line order of operations was formulated and passed to our factories to ensure the mold met our specified glassing process. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634678287978-X9M2CEBPP778OD1E4BWK/1901_BigEZ+Bottom_Plug+Render_0127.jpg Form - Lattice Frame By considering a latticework interior, we hoped to cut down on transport weight. However, the sheer number of parts to cut would drastically increase the machining time. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634678292721-F6ZQF1YF54GKJYRAIGOT/1810_3D+PrintA_Ref_1012-44.jpg Form - Segmented Mold By breaking apart the mold into four, we hoped to tap into a much larger market of smaller-sized CNCs or even 3D printers. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634678351514-OEPIQ693QEZVFGDAWO81/IMG_0417.JPEG Form - Inverse Thinking By mold-making through Glas Fiber Reinforced Concrete, we risked a heavier mold that was cheaper and close enough to our thermoform factory to negate transport issues. https://images.squarespace-cdn.com/content/v1/556e12f9e4b027319153fb42/1634679384453-KR7JW82ZRU8Y2H2YK7QV/IMG_3338.JPEG Form - Foam Core With a foam core, we knew preemptively that our molds risked deformation. 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