Since I have started publishing works in carbon fiber, and since a very good utility of a CNC is machined molds and models for parts carbon fiber (as I demonstrated with the bicycle seat) I’ll show you how to make the hull of an RC sailboat. I built this boat before this machine, and really the reason for making a CNC was able to create models of ships.
So in this post, I will describe the process of manufacturing the hull of a sailboat. You will see that it is easier than it looks:
First you have to have the plans or have generated 3D hull we manufacture. Personally, I found the plans for Luna Rossa, a type Copa America 2000 sailboat.
From here I have generated 3d Catia, and prepared to make the model on my own (I had no CNC at the time)
As I said, did not have CNC, but there is a technique to generate this surface with just a printer, a saw and some sandpaper. It comes to divide the area into sections:
I use polyurethane foam, selling insulating applications, it is 3 cm thick. Once printed all sections are glued together and sanded carefully until the desired surface.
Obviously, I already prepared a base to go sticking all sections, with a wood perpendicular to the base as a guide, so that all sections were in the correct position.
After sanding the surface, have to make rigid, for which just a few layers of glass fiber and epoxy resin, it will be made. It is important to use Epoxy resin, not polyester, because I would run out of polyurethane foam. This resin attacking the polyurethane foam
This would be the result:
Once the resin hardened, we have the surface ready for sanding and putty over in order to have a model with a polished mirror surface.
Having no CNC, could make the mistake of not sand well, and eat more than one portion of another, which would be a serious problem, so I had to make sure the entire surface symmetry. For this I manufactured a gauge:
I can not list here the huge amount of hours of sanding and putty to get a model in good condition. but the result was pretty good.
I was missing one thing only, eyelashes to output fiber, and clearly define the cut line with the bow.
Many hours of sanding and putty, and finally the models were ready to apply mold release and start making the molds!
The manufacturing process of the mold is substantially the same as with the saddle post.
First release agent. Very important. After a first layer of Gel Coat.
Just before you start cure, I apply layers of fiberglass with polyester (cheaper since have to use large amounts)
must take into account the thickness to be achieved, because the mold must be rigid.
Here are the ready, perfect molds. No defects and quite rigid.
The next step is now to apply mold release, and carbon fiber sheet.
The application of carbon fiber, is performed in the same way as with the seat: Pre impregnate cloth, applying on the mold, laminating many layers as may be necessary, and then Peel Ply retainer blanket and vacuum bag. So get a hull for a sailboat that will be followed to end. Here are some pictures of the finished sailboat and sailing:
A very good result, the ship sails perfectly. Of course, mount is a different job. If anyone is curious about how to make a boat like that contact me.