DarkAero Mold Making Course Now Available – https://darkaero.com/courses/mold-making
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(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:
https://www.darkaero.com
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https://www.linkedin.com/company/darkaero-inc
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การบินที่ง่ายก็คือทำให้ข้อมูลการบินเหมือนรถยนต์ที่วิ่งบนถนนเราไปสถานที่ต่างๆถูกต้องเพราะเราอ่านป้ายจราจร
Awesome video. Could you post a link where I can purchase this tooling board?
Is higher density foam like extruded polystyrene a good alternative?
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.
For tooling material – Necuron 🙂
what densities of tooling board are used, when vendor? what resin is used for infusion? vendor?
pls whats the name of that 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!
were is the link for part 1
were is the link for part 1, found it https://www.youtube.com/watch?v=zlgq6REw1S4
Hi guys! Which material do you use on foam which is gray?
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
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!
You are now my most favourite youtube channel. Thank you Sir.
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.
Wow, very impressive. I am looking forward to your subsequent videos and the finished airplane.
900th like was from me. Just that you know.
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.
Walgreens sells frozen pizzas?
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
7:58 to much work and waste time. Just use 4-5 axis CNC machine to make the entire positive for mold.
Thanks for sharing your valuable info!!
-and now I want to build a plane.
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
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?
Climb milling vs conventional milling, has to be programmed
We used to use a technique like this in the 70's where we would stack hand cut plywood to make a smooth curvature. Ribs over profile pieces can also be done I suppose. CnC routers made a huge difference in accuracy though! https://rqriley.com/fiberglass-over-foam/