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To manufacture replacement windows for an Antares Yachts 44, the project involves thermoforming 10mm acrylic sheets over custom-made plaster molds. The process begins by using an EinScan Vega 3D scanner to capture the curvature of existing boat windows.1:02 To ensure accurate data capture on the smooth, reflective acrylic, the surface is coated with 3D scanning spray and marked with 12mm tracking dots.15:56 The resulting point cloud is converted into a 3D mesh for CAD modeling.16:37

For the molds, a CNC machine cuts a plug from MDF, which is then sealed with TotalBoat High Performance Epoxy and coated with wax.3:55 Plaster of Paris is poured into the plug to create the final mold, with some tests incorporating 3% chopped fiberglass strands for added strength.5:33 To optimize heat distribution during the thermoforming process, a four-channel data logger monitors temperatures inside and above the plaster molds while they dry in a 6000-watt DIY electric oven.14:47 The project also includes installing an Airlock 1 air purification system to manage cabin odors.9:10

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