Brief Description: O2 Center Console - 1st mold design unsatisfactory
This first mold attempt involved a 1 piece mold so that the console could be produced without a seam.
The part can be produced as desired in this 1 piece mold. A key feature were the2 ports included in the mold to allow compressed air to be used to aid in mold and part separation.
However, the part produced was structually problematic. I had envisioned bonding on a flat bottom plate to complete the piece but when faced with the task, I couldn't come up with a good solution that wouldn't add a lot of weight and complexity. Without a bottom plate, the console had to be layed up pretty thick and internal support would have to added to be structurally sound.
I should have known better since I've fooled around with composite RC plane fuselages when I was a kid. They were all constructed in two halves and bonded together. At that time, the builder was usually given the task of joining the two sides and I had done it a few time. This thing looks and feels like an RC fuselage and I should have taken that approach from the beginning.
Since I took on the project to learn more about composites and specifically mold making. The quality of the plug, mold and product all turned out quite well but it was time to get some more experience.
