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.
Shapeoko CNC Prototyping
Lacking ownership of any existing molds, I began to adapt 3D models of our paddle boards into scaled thermoform molds.
Learning CAM for Fusion 360 on the fly, I cut over 25 scale models with various forms and toolpaths.
Developing a Toolpath
Successive Iterations
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.
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.
Transportation Considerations
After confirming and attempting to source a mold, it became clear that 12 feet of layered plywood would present transportation challenges.
With that in mind, we next sought ways to increase the mold’s portability.
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.
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.
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.
Foam Core
With a foam core, we knew preemptively that our molds risked deformation. However, given the low yield and cheap cost, we could intentionally destroy the mold through use.
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.
