Making a large composite mold of complex shape. Part 2: Covering the plug.
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- Опубликовано: 2 янв 2025
- This is the second part of a short video series on making a large composite mold. We show how an XPS core can be covered with abachi veneer and prepared for finishing. Abachi veneer can be grinded easily and smoothens the surface considerably. Hence, less effort is needed at filling. This is a large advantage over covering only with glass fabrics. See last part for information on how to shape the core: • Making a large composi...
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Next and last part on mold-making is ready and online:
ruclips.net/video/ubFT8IJA_TE/видео.html
Where do you get the vacuum bags to do such a large project
truly amazing job! beautiful.
Thinner fiberglass tends to drape better, though this is *very* interesting.
Yeah, I think both have good and down sides. Thin glas fiber is great until you sand through ;-) When the core is not resistant to putty, things get really complicated ...
Beautiful! 👍🙂
Did you use polystyrene or polyurethane, and how did you avoid reaction between resin and foam
We used extruded polystyrene and epoxy resin. Epoxy does not dissolve the foam, in contrast to polyester resin.
how do you know how much smaller to make the foam plug in order to make the actual mould the correct size?
In case a tight fit for such a large part is truly important, you can estimate the tickness of the layup and covering and consider it during desing of the templates. Anyway, this method will provide parts that differ maybe 1 mm at 2000 to 3000 mm total size. That should be fine enough for most applicatrions. Even CNS-machined parts have to be egalized after machning and differ surely 0.1 or 0.2 mm …
Andres Great work! What program did you use to make the drawings for the quarter inch plywood guides? What drawing does one need? Please comment on this part of the build. Thank You!
Yeah, exactly. I'm trying to figure out how to make those by sampling planes from a mesh of my object, but the thickness of the plywood guide has to be taken into account so as the cut pieces will conform to each other perfectly as Andres has done. Andres, please advise.
What kind of foam is that that can handle fiberglass resin?
It is XPS foam. You sould use epoxy resin and not polyester. Epoxy will not dissolve XPS, while polyester will.
Wow incredible how much work goes into this. I've been watching your last video and plan to build an RV on a truck similar to this using XPS and fiberglass. Just a boring old box of course but lightweight.
If it's not for boating or aeroplanes, the process should be much easier, right?
Boxes are much easier than curved surfaces. Also, if you need only one copy, you might consider to make the RV directly from the plug. This means that you shape the XPS plug as needed and laminte your RV on top of it. The foam can be dissolved with acetone afterwards, and the surface is filled with putty. That's good enough for an RV on a truck. Pieces for airplanes need to be much lighter and should have a perfect surface. Filling with putty should be reduced to a minimum. That's why it's better to use molds.
Thanks! My current plan is to just build with XPS insulation foam and leave it as insulation and structural part of the wall. Just hand layup from both sides. From what I've learned so far this should be a relatively straightforward and easy process, but what is somewhat worrying me is that I can only find very few projects doing this.
It seems to me that for tiny houses this construction method would be one of the best and easiest ways to make curved and organic shapes and be creative.
Do you think I'm missing something? I'm going to do some experiments of course.
Your idea sounds fine to me: using XPS as a core material and insulation is a good idea. Not because it hasn't be done means it's not good. Just make sure that it is fully enclosed in glass fibers. This will prevent problems with delamination and humidity buildup. Make also the outer laminate strong enough to prevent damage from outside. The layers inside can be much lighter without losing stability.
Are those purple pins you are using? Please explain. Thank You!
That's just a sort of needles to fix the wood while working. Nothing special about them...
Nice work! How much vacuum can you pull over the XPS plug without making it collapse?
I usually use as much as needed to properly press the veneer. Maybe 0.3 bar. However, the used XPS, Styrodur CS 3035. is not too soft and withstands stronger vacuums for sure. The data sheet says it withstands 1.3 bar, so that full vacuum would still be fine.
Nice tutorials
hi friend...where you buy these polyurethan sheets ? its to expansive ...here in israel. your advice! thank you
It's not polyurethan, it's extruded polystyrene (XPS). Polyurethan does not melt and crumbs. I bought the material online in Germany. Not cheap, but still ok. It's possible to use less material by making frames that are barely large enough for the pieces.
Love the video! Have you ever considered using 3D Printed Molds?
Thanks! I've heard of people using printed molds/plugs. Printed parts tend to have a structured surface. Never done it myself, but should be fine as long as the surface quality is sufficient. Smaller molds/plugs can also be CNC. Machining/printing large molds will be quite expensive.
@@andreschavarria1450 If you're ever interested in using 3D printed molds for future composite projects definitely reach out!
@@robpaddock134 Printing this size would be expensive, you would need an industrial-size printer which is pretty much not sustainable for the average garage. If it was everyone would be doing it. Do you have a website to see samples of your composite moulds? I have yet to see anything feasible for making one-offs. Like I said if it was that accessible everyone would be doing it as just to not work with harmful chemicals all day. Please show me your website, surely if you work with such equipment you'd have a website and samples of your moulds? Please share?
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Is this a fairing for Velomobiles ?
No, it's a plug of a cabin for an airplane. It's going to be a flying wing, and hence, the shape is somewhat unusual. A plug of fairing for a velomobile coud be made excatly the same way.
The next part is online:
ruclips.net/video/YkFQqXs6-ac/видео.html
Please give thumbs up if you like the series ;-)
where is the rest of the video?
We are still working on the plug: The last weeks we shot several times filler and sanded the surface smooth. This week we will shoot clear coat and start probably in the weeked with mold making (parting surfaces). The next video will come when we have enough video material and the plug is ready. It's a sort of live documentary and we can't go faster than it happens ;-)
Sweet!
What are you busy building
Yeah, its a lot of work, but the plug will be used for a clear canopy, which has to be crystal clear. The next part is online...
nice video