Sail Lifevideo
⛵️ Analog vs digital window molds - It's time to go old school again. Ep 678
10 May 2026 · 24 min · 62K views
What this video covers
Mads, the owner of a 44-foot Antares Yachts 44 catamaran, pivots from digital 3D-scanned mold fabrication back to traditional analog methods to create thermoformed 10mm acrylic windows.5:36 After encountering persistent CNC errors and alignment discrepancies between 3D-printed MDF molds and the boat’s actual cabin top, he opts for manual fairing and hand-built molds.12:05 He constructs a two-part male and female mold system using fiberglass, polyester resin, and filleting wax, following techniques shared by a professional window fabricator.20:22 During the gel-coating process, he experiences "alligatoring," which he attributes to an insufficiently thick application of gel coat.19:39 To form the final windows, he plans to heat the acrylic in an oven and press it between the two molds outside the heat source.21:38 The project also includes minor 3D-printed upgrades, such as a battery charger mount and a custom water tank deck fill adapter.2:26
More from Sail Life
From Sail Life — see the channel’s boat, crew, and every analysed video.
The Sailing Directory Newsletter
One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.