Continuing the development of the project we have been working with cnc’d foam molds in which to create fiberglass forms. There are 3 components to the fiberglass: the fiberglass mat (or cloth), resin, and hardner. The mat or cloth is the actually material. The resin is what wets the mat/cloth, giving its structural value. The hardner is added to the resin before applying to the cloth. The hardner, just like the name implies, hardens the resin. Once dry, the combination creates a very rigid material.
The steps are fairly straight forward. CNC a form out of the foam blocks. Preparation for the to lay the fiberglass on the foam mold has two parts: cover the mold with a material to keep the resin from eating the foam. Once dry, a release agent is applied to the entire surface, allowing the hardened fiberglass to be removed from the mold. Fiberglass mat/cloth is cut into shape and laid over the mold. The mixture of resin and hardner is mixed and applied to the fiberglass mat/cloth with a brush. Multiple layers are used to give the finished product its strength and rigidity.
Our studies revealed a few points that will be key in our final design. First, the fiberglass mat/cloth can be laid over very complex shapes with relative ease. Second, the mixture of resin to hardner is very key in the cure time and strength of the final product. Third, great care needs to be taken with the creation of the initial mold, as the final product amplifies any imperfections in the mold.
