Aerospace Mold Making Course
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Mold Basics
- Introduction to Molds
- Composite Manufacturing Processes
- Basic Rules to Follow
- Mold Terminology
- Summary of Mold Basics
Mold Construction Methods
- “Off-The-Shelf” Molds: Flat Plates & Extrusions
- Single-Use Molds
- Moldless Construction
- Molds Made From Existing Parts (“Splash Molds”)
- CNC Machined Molds ("Direct-to-Mold")
- CNC Machined Patterns
- 3D Printed Patterns and Molds
- Large Scale Additive Manufacturing (LSAM)
- Summary of Mold Construction Methods
Mold Materials
- Overview of Foam Materials
- Rigid Foam and Tooling Board
- Casting Foam
- Tooling Paste
- 3D Printed Plastics
- MDF and Engineered Wood
- Gel Coat
- Fiber-Reinforced Composites
- Aluminum & Steel
- Other Materials
- Summary of Mold Materials
Mold Design
- Establishing Mold Requirements
- Design Requirement - Cost
- Design Requirement - Quantity of Parts
- Design Requirement - Lead Time
- Matching the Mold to the Process
- Female vs Male vs Closed Mold
- Matching the Mold to the Materials
- Demolding Considerations
- Edge Features
- Summary of Mold Design + Design Example
CNC Machined Molds and Patterns
- Overview of CNC Machining
- CNC Machines
- Cutting Tools, Machining Parameters, and Formulas
- CAM, Toolpaths, and CNC Control Software
- Stock
- Work Holding
- Work holding - Double Sided Tape
- Work Holding - Clamps
- Work Holding - Fasteners
- Work Holding - Vacuum Table
- Finishing Work
- Mold Release
- CNC Mold Machining Process Guide
- Summary of CNC Machined Molds and Patterns
Making a Composite Mold from a Pattern
- Construction Process Overview
- Demolding Strategies
- Inspection, Defects, and Repairs
- Finishing Work
- Summary
Advanced Molds and Patterns
- Multi-Section Patterns
- Multi-Section Molds
- Closed Molds
- Advanced CAM and Machining Strategies
- High Temperature Molds
- Summary of Advanced Molds and Patterns
Appendix
- Terminology
- Purchase Guide (Updated 05/14/2024)
- Mold Release Process Guide (Updated 05/14/2024)
- Epoxy Gel Coat Mold Process Guide (Updated 05/31/2023)
- Splash Mold Process Guide (Updated 05/31/2023)
- Fusion 360 CNC Machining CAM - Revised Sump Mold (F3D File)
- DarkAero Aluminum Mold Support Structure Plans (Updated 06/30/2023)

Design Requirement - Cost

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