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Mads uses a Shapeoko 5 Pro CNC machine to fabricate fiberglass clamshell drain covers for a 44-foot catamaran.0:12 The project serves as a test for mold-making techniques, transitioning from simple 2D parts designed in Carbide Create to complex 3D geometries modeled in Fusion 360.1:48 To create the molds, he uses polyisocyanurate (ISO) foam, which he bonds with epoxy to achieve the necessary thickness.10:37 He coats the foam molds with Duratec surfacing primer, which he notes is easy to sand, followed by wax and a PVA release agent.16:12 After laying up fiberglass, he encounters "bridging" in the corners of the part, which he attributes to difficult geometry and insufficient consolidation of the glass into the mold's tight radii.19:56 He concludes that future attempts will require better glass placement or a switch to gelcoat and chop-strand mat to better conform to the mold's shape.21:17

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