Preparing the Fiberglass Mold

Before the shell can be fabricated, the mold has to be produced. Based on Solidworks drawings, the cross-sections of shell were printed in 1:1 ratio on A0 size paper. The 2D profiles were transferred to plywood and cut according to its shape. Each ribs were then attached to the base profile using brackets.
After printing using plotter the paper was cut according to its profile

The 2D shape of profile are pasted to plywood

Ribs profile are cut according to its shape using jigsaw

The ribs were placed at equal distance from each other

Ribs being installed to top mold

Bottom Mold

The ribs will be soon filled with PU foam and before fiberglass hand lay up can be done.

Hock Shen preparing the PU chemical mixture


Ribs ready to be filled with PU foam

Filling the PU Foam

Vanilla Ice cream?
Pu foam are left to solidify

Trimming the excess Pu foam

Upon filling with PU Foam the mold was later trimmed and one layer of glass fiber was added to give the mold surface better strength.

Top Mold
Bottom Mold

Chopped strands Glass fiber layers were then applied onto the mold to produce the shell.