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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.12:22 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.16:16 During the gel-coating process, he experiences "alligatoring," which he attributes to an insufficiently thick application of gel coat.18:22 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

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