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Old Apr 03, 2012, 02:46 PM
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USA, FL, Bradenton
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Using CNC router table to cut out half of fuselage and wings

I wonder how the factory cuts the inside out in the fuselage in the nose.
I wonder if they use the CNC to cut that out too. I guess you could make
a mold for the half to sit down into to hold it still tape it down to that mold.
My CNC would have a vacuum table where I could drill holes through the
mold and then it could it too. Just tape it would be easy way to hold it in the
reverse mold.
Just wonder how the factory does it with these styrofoam planes
like the BlitzRCWorks Sky Surfer . How they build these.
Anyone been to a factory that makes planes like these.
I can see in this model there is a seam down the middle of the fuselage and looks like
it was made in two halfs and then glued together.
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Old Apr 03, 2012, 03:09 PM
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It's my impression that most ARF foamies like the Sky Surfer are made in large metal molds that get filled with molten foam. That way, hollow cavities like inside fuselages aren't a problem; there's just a male insert in the mold. Here's a picture I found with a quick Google search for "foam airplane mold".
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Old Apr 03, 2012, 03:57 PM
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Australia, QLD, Little Mountain
Joined Feb 2010
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This will give you an idea of how they do it.
http://www.madehow.com/Volume-1/Expa...oam-EPF.html#b

Actually that article is a bit of a mess. Just scroll down to Molding. The drawing near that shows a schematic layout.
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Last edited by Whiskers; Apr 03, 2012 at 04:06 PM.
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Old Apr 03, 2012, 05:40 PM
low tech high tech
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Southern Vermont
Joined Feb 2007
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Yes, besides limited undercut facility, CNC milling takes a long time by comparison, and produces a lot of waste. Only one part can be worked on per mill at a time. With a plane composed of 2 fuselage halves, 2 H stab halves, a wing, and a hatch, a set of molds can be filled all at once compared to each part being cut out on a mill. And several identical molds can be used depending on the production rate needed. Depending on how they are made, molds can be cheaper than multiple CNC mills.
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Old Apr 03, 2012, 07:46 PM
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USA, FL, Bradenton
Joined Oct 2007
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Interesting process and thanks for the link Whiskers

I wonder if they make the molds with a CNC machine. I wonder if they are
aluminum which would be easy to cut with CNC.
I thinking of setting up a shop to build planes with this process here in America
for a change. Ive been looking at large CNC tables with auto tool changers etc.
Even 3D 5 axis CNC if needed.
I bet there is not a factory in America anymore doing RC products like this
anymore. I sure would be surprised if there are.
It would be my own company no other people to deal with. I would do it my way
I just want to do something diffrent here in America.
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Last edited by videorov; Apr 04, 2012 at 07:13 PM.
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Old Apr 04, 2012, 11:27 AM
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Joined Oct 2007
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metal molds

Quote:
Originally Posted by Rocketman1092 View Post
It's my impression that most ARF foamies like the Sky Surfer are made in large metal molds that get filled with molten foam. That way, hollow cavities like inside fuselages aren't a problem; there's just a male insert in the mold. Here's a picture I found with a quick Google search for "foam airplane mold".
I wonder if they are using CNC machines to make the molds or maybe even
stamp the molds out.

If you find anymore information about this process please post or send it to me.
Thanks
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Old Apr 04, 2012, 12:39 PM
low tech high tech
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Southern Vermont
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Here's a tool that might help.

Incredible Resource
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Old Apr 04, 2012, 05:32 PM
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In Teh Garage (Rossville, GA. USA)
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Nevermind
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Old Apr 04, 2012, 05:38 PM
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In Teh Garage (Rossville, GA. USA)
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Quote:
Originally Posted by videorov View Post
I wonder if they are using CNC machines to make the molds or maybe even
stamp the molds out.

If you find anymore information about this process please post or send it to me.
Thanks
UM, how do you stamp out a mold without machining the stamp first?

heres your sign
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Old Apr 04, 2012, 07:18 PM
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Quote:
Originally Posted by RogueTitan View Post
UM, how do you stamp out a mold without machining the stamp first?

heres your sign
Yea your right. Im sure they must CNC the mold but that mold might be
for the styrofoam beads to go into and if they wanted more molds then
they would have make a mold that could be used in a stamping machine.
Which Im guessing they would just make another mold the CNC way.
They are made with more precision then stamping them out.
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