Posts: 6766
Joined: 12/7/2001 From: Andover,
MN, USA Status: offline
Just curious, how would you join a two piece mold cut out of aluminum?
I have a quickie wing mold that Wayne Seiwert made for me, but I would really like to get one made out of aluminum, but the costs are very expensive. Not sure if you have any interest in laying up and selling wings after completion, but there would be a market for wings like this if done in the right airfoil.
yep. cnczone.com If you click on forums, then DIY cnc machines, then wood routers, cnc wood router project log, then last is "Quick build cnc router" this is my build log for my machine. Not sure, but should probably keep comments of building machine over there on cnczone.
DAVEN, To join a mold, cut out left and right, butt them together at the root. Im thinking that would work.. but then again Ive never done it. Yea, I would try it. You have a design in mind.
I still need to do a little testing and will need help from the list. but i will take a crack at it. Probably do it out of MDF first, then try aluminum. I am going to call my cnc buddy and see what I need to do to convert some SW files into g-code.
I think that we could do the whole process right here on this forum. I can take pictures and post results.
I just finished a test cut. I used some regular, floor underlayment particle board. I took the profile of an airfoil, converted the profile, then I set up my machine to cut into the board, index over .00629", cut the profile, step over, etc. I think the total step over was about 3/4", so it almost looks like a mold for some wheel pants. The airfoil was 5" long. just a simple naca 0009. I used a 1/4" ball nose carbide cutter.
My machine cut out this female mold spectacularly. The entry and exit was dead on. you cant tell by the picture, but it came out super smooth.
I think I will cut out the male part as a test, and use MDF.
Looks good. For sure I think your setup could make semi-decent plugs if you were prepared to surface coat & finish, at least 95% of the surface shape is there. Here is an mdf (female) mold I have seen for surface comparison. Havent seen the finished one yet. Also shows a bit of the tear out problem I was mentioning along the lamination when the surface angle is shallow relative to the glue joint line.
< Message edited by ptxman -- 3/31/2006 3:14:25 AM >
Posts: 154
Joined: 2/28/2005 From: burlington, IA, USA Status: offline
Ok here is a really crazy thought but here it goes anyway. If you are looking for a way to create a smooth finish could you spray the inside of the foam mold with a multi-layer of a dry wall material? Then run it through the router? I use this method to cover foam blanks for canopies to fill holes. (the following would not be part of your process) Then I create a plaster mold (the -). And then pour plaster for the positive. Your machine could make killer blanks for vacuum forming canopies as well.
I dont think I would like the dust, but Im sure it could be done. I was also thinking, in the back of my mind, I believe the auto industry uses some sort of modeling clay, and they use a 5 axis router to create prototypes. I would need to find a longer router bit, because you need clearance below the gantry to do any deep stuff like canopies and the like.
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RE: build composite aircraft - 
