Goal:
Design and optimize the foam plug (2 halves, left and right side) for the main Aerobody mold, as shown in figure 1, then break it up into machinable parts that can fit within our foam blocks (size of 95.9”x23.9”x3.9”), as shown in figure 2.
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Mold Process:
Once the foam plug is machined and assembled, then we’ll a fiberglass wet layup to create a strong and reusable female mold of the car, shown in figure 3. Once we the female fiberglass mold is complete then we do a carbon fiber infusion
Features That Should Be Included:
All cut up pieces of foam must fit within the blocks of foam with no negative draft angles
The nose, side and tail must be able to easily attached and removed from another
Fiberglass mold should end up with a flange on the right plane of the plug and on the top plane of the plug
Ideas On How To Optimize For Cost:
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Surface Modelling 101: Surface Modelling 101
Aero Model:
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Optimised model: