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  1. #16
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  2. #17
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    Quote Originally Posted by XstreamVking View Post
    Built a lot of molds? This skips a tedious step. That is all. You produce an actual prototype (hull) out of this foam mold. The foam mold is not meant to pull numerous boats out of.
    I'm quite familiar with the traditional mold building process so Noli needs explain the comment that they will skip the "plug" stage.

    There is no technical reason they can't create the actual mold from the finished, sanded putty by laying down a top coat then carve away the foam from the back side and build up with a superstructure to support the mold. No need to produce a prototype if your CAD modeling is based on years of experience and proven mathematics.
    Mark

  3. #18
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    Also, if you were going to use the plug method wouldn't it make much more sense, and save a butt load of time to create the plug from foam then build a traditional mold from it?
    Mark

  4. #19
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    traditionally, a model of the object that you're building is built to the exact size of the finished object by using clay (for example). The object is then coated with a hardener and buffed to a good shine, then a mold release agent is applied, so that the female mold, when laid up on top of the plug, can be easily removed.

    What do we traditionally do with that plug that we spent hundred of man-hours on, and material?

    The answer is we throw it away.

    After we build the female mold, we throw away the plug in the traditional method

    What if instead of designing the actual model using clay, we build the model inside a computer where we can see the 3-dimensional character of the object? Inside the computer model we can zoom in, turn upside down, and we can even stress the model to see where it would fatigue without even spending a cent on the clay model, which btw the clay model cannot perform stress functions.

    check out this model as depicted by CAD software
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    The two objects are symmetrical. The line of symmetry is the red arrow. The object on the right is what we build in the traditional method where we take a block of foam and chip away till we get the desired object, called the plug

    Now look at the left object. it is the same object as on the right, as a matter of fact we can fold this image along the line of symmetry and the two objects would fit on top of each other. Instead of chipping away on a block of say foam, why not gouge out the center of the foam to produce the same object but it's mold shape instead of the plug shape. That is exactly what the CNC machine is doing, it is gouging out the shape that we want, and when completed we have a female mold bypassing the plug-build step. The CNC machine only knows about the surface layout in 2D. And because of this the CNC can gouge out the surface of the mold shape from the foam

  5. #20
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    Quote Originally Posted by mjw930 View Post
    Also, if you were going to use the plug method wouldn't it make much more sense, and save a butt load of time to create the plug from foam then build a traditional mold from it?
    .


    If we were to build a plug for this model
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    first we would need a ton of foam, foam will not create sharp edges, and we would use hundreds of man-hours in time, all for what? We do this just so that we can see the real life object. This would increase the cost and the time all of which will proly be just thrown out after we build the female mold.

    Some would also say, ok, we won't build the actual size, why not just build the model in 1/5 scale. If we did that then we wouldn't have the real size model anyway, so why not just model the object inside CAD?

  6. #21
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    Noli,

    I understand the process, I was responding to a comment that they would make a plug from this form then make the mold. I think the part that's missing for some is how they take this finished form, which is hollowed out of a large block of foam and produce the final mold. By final I mean the structurally reinforced "mold" that they can resuse hundreds of times.

    If there was a picture of a completed mold using this process it would clear up some of the confusion. In particular what the "underside" of the mold looks like.
    Mark

  7. #22
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    .

    no plug will be made from this female mold

    this completed female mold will get a hardened surface then boats will be laid up from it

    What that hardened surface is, and what materials goes into the hardened surface has never been shared publicly...I don't think I'll ever find out





    .

  8. #23
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    Quote Originally Posted by mjw930 View Post

    If there was a picture of a completed mold using this process it would clear up some of the confusion. In particular what the "underside" of the mold looks like.
    .




    The completed mold. Plug build is bypassed. metal braces surround the foam's underside.

    This is DW's newest model, the 36 RT. The first hull was delivered to Perf Boat Center. The DW crew is currently laying up the second hull.


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    .

  9. #24
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    How many parts can be pulled from these reinforced "foam" molds? Traditionally, the 1st part pulled (the master) from the mold was reserved for more molds to be made in the future. I had no idea you could pull very many parts from a cnc'd foam mold. New tech is wonderful.

  10. #25
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    .

    I'm sure we'll be able to find out the final number of boats that were built from this mold

    But remember that DW is always trying to make the product better. I bet just after 5 or 6 pulls, Sr will have new ideas about the changes to the original hull design to make the boat run better. He does this with his race boats.

    Are we going to see a new mold incorporating all of the new enhancements that came about as a result of seeing the performance of hull version #1? If DW does this, he would only have to rebuild the two sponson molds (if the changes were to the sponsons) as this mold come in 3 pieces. If the enhancements were for just the tunnel, then only the tunnel mold would be altered.


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  12. #26
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    Quote Originally Posted by XstreamVking View Post
    How many parts can be pulled from these reinforced "foam" molds? Traditionally, the 1st part pulled (the master) from the mold was reserved for more molds to be made in the future. I had no idea you could pull very many parts from a cnc'd foam mold. New tech is wonderful.
    From what's been described the foam will be 2 layers removed from the actual female mold. They coated the foam with putty that hardened then CNC'd that to make the final surface which will then be coated with a another material that will be the base gel coat is sprayed onto when they are building a hull. It looks like they then reinforce the foam to create a superstructure. Technically the number of hulls they can pop from one of these molds is no different than a traditional finished mold.

    The modular construction for the bigger boats is a game changer, very cool stuff.
    Mark

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  14. #27
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    most overnite successes usually take at least 10 years


    Certified turd polisher,

  15. #28
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    Yellow Fin 21

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    I just invested in my Hybrid Flats boat! lol

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  17. #29
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    Click image for larger version. 

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  19. #30
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    The mold is getting very close...


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