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)

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