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Friday, September 22, 2023
HomeCNC Router MachineUsing a CNC Router to Machine Aerospace Grade Mold Patterns (part 2)

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


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DarkAero Mold Making Course Now Available – https://darkaero.com/courses/mold-making

Join the DarkAero Community – https://www.youtube.com/darkaeroinc/join
(Exclusive members only content including photos, videos, live Q&A and more!)

Part 1: https://youtu.be/zlgq6REw1S4

DarkAero 1 – https://www.darkaero.com/aircraft
DarkAero Apparel – https://www.darkaero.com/shop

In this video we go over how we machined the mold patterns (also referred to as master molds or plugs) for the DarkAero 1 aircraft. We also talk about strategies for machining accurate multi-section plugs on your router.

Some of the key strategies for making a high quality, aerospace grade plug include selecting the right plug materials (tooling board), having a good method for securing them to your router table, and being strategic about how you program your tool paths.

If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage.

More information on DarkAero can be found on our website and other social media accounts:




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  1. การบินที่ง่ายก็คือทำให้ข้อมูลการบินเหมือนรถยนต์ที่วิ่งบนถนนเราไปสถานที่ต่างๆถูกต้องเพราะเราอ่านป้ายจราจร

  2. 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.

  3. 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!

  4. 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?

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