In 2017, we were required to make our own nosecone. To maintain consistency with the rest of the rocketBecause its high strength to weight ratio, we decided to use a fiberglass/epoxy composite. To manufacture this, we needed a mold to hold the shape of the part while it cured; we decided on a female mold because it would make it easier to remove the part after curing.
...
The first attempt at a nosecone mold was to layup fiberglass on top of an existing nose cone. However, the mold tended to flex during the layup and cure because it was so thin.
For small (~3") nose cones, the fiberglass nose cone mold is sufficient. A tutorial can be found here.
 |  |  |  |
|---|---|---|---|
| The block of MDF being glued together before machining. | The mold being machined on a CNC router. | The mold after being coated with gelcoat, and sanding. | Closeup of an alignment pin and pry slot. |
...