Episode 2: From the 3D mold to the final fiberglass mold

Once we have the 3D printed molds, we need to convert them into resistant and reusable molds, capable of withstanding the lamination and infusion process. We do this by coating them with fiberglass and polyester resin.

The process has several steps that ensure a clean and functional finish:

1️⃣ Filing the printed pieces → we eliminate imperfections and marks from the 3D print.

2️⃣ Surface finishing → we polish thoroughly to achieve a completely smooth and uniform surface.

3️⃣ Waxing → several layers of mold release wax are applied, which will create a barrier and allow the mold to be removed later.

4️⃣ Application of the gel-coat → a surface layer that provides hardness, chemical resistance and a professional texture. It is the visible side of the mold.

5️⃣ Lamination with fiberglass and polyester resin → we place layers of fiberglass impregnated in resin on the 3D mold, until we achieve the desired thickness and rigidity.

The result is a robust and polished mold, ready to receive the carbon fiber and withstand the entire manufacturing process of the tail.

➡️ In the next episode, you will see how we laminate the tail with carbon fiber on these definitive molds.