Page History

...

Above: Hermes 1 nose cone mold (4 layers of 1" thick MDF, sanded and finished with gel coat), manufactured by Raul Largaespada. 

Overview of Nose Cone Design

Hypersonic optimum

5.5:1 fineness ratio

...

Fiberglass Nose Cone Manufacturing Procedure

Required Materials

...

...

Overview of Nose Cone Design

...

Talk about mold materials used (MDF, gel coat), why fiberglass used

Manufacture Mold

Required Materials:

• 1" MDF OR Blue foam (HOW MUCH?)
• Epoxy (WHAT KIND)
• Pins (??)
• Ruler
• Router
• Table saw or Bandsaw
• PPE: safety goggles, gloves

1. Create design of mold in Solidworks (using "Solidworks mold tools" --> helpful tutorial: https://youtu.be/yqROZFStz6c)
2. Calculate how much MDF needs to be used (based on thickness, dimensions of nose cone). Make sure to account for extra area for pry slits and alignment pins. 
3. We want the mold to be very regular (90 degree angles) so that alignment when routing will be easier. Cut MDF using a table saw or a bandsaw (where can we find table saw?)
4. Glue layers together (using what?)
5. Alignment pins and pry slits? (what are pry slits? what order should this be done in? how many pins?)

...

2. Download Mastercam: http://ist.mit.edu/mastercam
3. Plot a path to cut the mold using Mastercam
4. Go to Hobby Shop to get help from peeps
5. Take notes of helpful tips and add to this Wiki article
6. When routing:
   1. Make sure the router is routing the correct shape- pause if necessary.
   2. Lots of sawdust will be generated, so follow the router tip with a vacuum to get most of it.

Mold Preparation

Required Materials:

• Sandpaper (400 - 2000 grit)
• Gel coat (WHAT KIND)
• PPE: Respirator, gloves

1. Sand the mold, starting with 400 grit and working up to 1000 and 2000. This will take a long time!
2. Apply 5 layers of gel coat (respirator required)

Nose Cone Layup

Required Materials:

• Fiberglass (WHAT KIND)
• Epoxy (WHAT KIND)
• Partall Paste #2 (#1016 Parting Wax)
• PVA (polyvinyl alcohol) Film
• Spray gun
• Squeegees
• Acetone
• Epoxy boats
• Popsicle sticks
• Scissors
• PPE: gloves

1. Cut fiberglass layers (HOW BIG)
2. Mold release/lubricant (more than you think you need!)

Nose Cone Tip

Required Materials:

• Steel
• Bolt
• Washer
• Lathe