Using a CNC Router to Machine Aerospace Grade Mold Patterns (part 2) 

You've got this 100% right. Very impressed by your talent guys. Wish you a lot of success.

Wow, very impressive. I am looking forward to your subsequent videos and the finished airplane.

I really enjoy this. Thank you very much.

The array of talent is very impressive, i wish you all the best & can’t wait to see the final product? Good luck!

Finally part 2! Thanks fellas

You are now my most favourite youtube channel. Thank you Sir.

Very informative. Lots of thinking goes into those parts.

Wow, I built my own router and what I learned with months of experience, you taught in a 12 minute video. Lots of good info

There is a bike I've wanted to design for so long and this helps my knowledge grow how to make molds and plugs. ty

So well explained. Thanks.

Great video! I learned a lot. I have a CNC router I'm still working on. It's great to see how tooling board can be cut and layered to save on costs.

@11:30 Tidbits like this are what make RU-vid great for this sort of platform. You learn these sort of things by very costly experience otherwise.

If you ever find yourself wondering what topic you should cover in your next video, I'd like to suggest that you take us much deeper into the details of your manufacturing process. I'm particularly interested in the processes through which you proceed from CAD drawing -> plug -> mold -> part. I should confess that my interest is purely driven by idle curiosity, so I can't reasonably ask you to devote much time to a task that will not move your project forward. But hey, keeping us viewers entertained/educated is perhaps not a total waste of time. Of course, I understand that you may not want to reveal proprietary manufacturing processes, but I probably wouldn't understand those anyway. So the "kindergarten" version of carbon fiber manufacturing will be more than enough to keep me awed and confused (a chronic condition I'm afraid). In any case, I enjoy your videos, and I'm grateful that you take the time to make them!

Does alabaster (gypsum) have significantly higher thermal expansion coefficient?

Awesome video. Could you post a link where I can purchase this tooling board?

Really enjoyed this video, learned a lot from it. Giving me damn ideas now, and that always gets expensive! But glad I watched!

what densities of tooling board are used, when vendor? what resin is used for infusion? vendor?

Thanks for sharing your valuable info!!

Is higher density foam like extruded polystyrene a good alternative?

Hi guys! Which material do you use on foam which is gray?

When you do multisection plug make two holes on the datum bottom face of the plug at the ends of the plug. Place all those holes in one line on all sections of the plug and when you will assemble the plug use those holes and dowel pins inserted in those holes to align the sections. It is the proper way to alight the sections of the plug rather than using the sections split faces. You also can use those holes to control the length of the plug, not only straightness, just maintain a little gap between the plug sections to be able to adjust the plugs positions.

You got a great logo man.

Nice analogy on Gordon Ramsey! Have you guys looked at those Kuka robot arm types of machines? I know they are much higher priced than the router, but you could probably machine a whole plug without needing to separate it into parts?

beautifully explained. how do you overcome the Z axis limitations (8"-tool)? do you split the plug drawing into sections and fix them together later on?

Hello ! Very informative video. Thank you. What is the cost of tooling board ? And with one have you here in this video ? Thank you, George

I am going to start wearing my hat like that. Turned up and just a little to the side. Not perfectly straight. That's because they are crazy. Crazy good!

I just watched both parts. Wow so informative. Good timing too as I am about to order a similar router. Was considering the 5'x10' Avid Pro but space is tight so maybe I can get by with 4'x8'. However will mostly cut thin sheet aluminum for an airplane that was plans built but i own the rights and will be kitting it. When you ordered your machine, did you have them add the extra crossbars or did you just order from 8020 yourself. Also it looks like you have more welded cross braces on the leg kit. Can you confirm? I already have my electronics (clearpath Servos) and an ATC S30 spindle since I will need the auto tool changing. Also have same Series 3 Tormach as you. Very inspiring to see you pull this all off with the same tools I have. I shoudl be able to make a low Tech Ultralight if your able to make this high tech aircraft. So inspired by your work and been following. Only disagreement is I am a Solidworks guy from so long ago I can't make the switch to Onshape. :) Oh one last question I am also getting the 8" risers, but was going to get the 12" Z axis as I may need the extra height for a rotary axis I will make to cut the fishmouth in 4130 and 6061 tubing. Did you ever consider the 12" Z axis to be able to go below the table, or off the side if needed? My rotary may end up beside the machine installed always with the longer boom option.

Just saw watched the Garmin Osh Kosh video with the Patey brothers, one thing they mentioned that suck out to me and reminded me of your build is how carbon fiber breaks down under the UV from the sunlight. How do you plan to prevent that? Further they said that the heat from the sun causes the carbon fiber to get “soft” and lose its rigidity, going on to say that some manufactures limit dark colors on their carbon products. How do you plan to handle that as well? Especially because I don’t think your design has a metal frame to pull strength from.

Are there any other RU-vid channels like this documenting the development process for their product on the CNC floor?

Do you have a vlog on how you made one actual PLUG!?

Is there a video explaining the process of pulling a mold from the plug? How is this done?

For tooling material - Necuron :)

You could 3D print a flimsy shape that would't be smooth anyway, then add a CF layer and weld in a tube skeleton, then finish it as a plug. Say you were to make a plug of the entire fuselage, that would be very heavy to deal with. Hint hint single piece fuselage is a good thing.

were is the link for part 1

900th like was from me. Just that you know.

I take it aluminum is too expensive for what you need to do? I can see small parts using aluminum but those plugs look really big.

Goodbye clay mold new technologies are faster accurate and reliable, good job guys nice 👍

Where do you get your tooling board from?

pls whats the name of that tooling board???

Lights-out machining with a budget machine. Brave...

Climb milling vs conventional milling, has to be programmed

-and now I want to build a plane.

yall hiring?

การบินที่ง่ายก็คือทำให้ข้อมูลการบินเหมือนรถยนต์ที่วิ่งบนถนนเราไปสถานที่ต่างๆถูกต้องเพราะเราอ่านป้ายจราจร

Walgreens sells frozen pizzas?

A frozen pizza from Walgreens... 🤔

7:58 to much work and waste time. Just use 4-5 axis CNC machine to make the entire positive for mold.