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Designing replacement eyebrows for a 44-foot Antares Yachts 44 catamaran requires high-precision CAD modeling and mold verification to ensure the new fiberglass parts match the cabin top's complex curvature. The project involves using an Einstar Vega 3D scanner to capture existing geometry, though the scanner struggles with accuracy over large, flat surfaces, often introducing unintended distortions.2:18 To validate the CAD model before committing to expensive fiberglass layup, the process involves CNC-machining an inverse female mold from 2-inch thick XPS foam.4:28 This foam mold is then test-fitted against the boat to identify gaps or alignment errors.4:29 Challenges include managing the steep learning curve of Fusion 360, addressing surface waviness identified by zebra striping analysis, and compensating for non-flat, warped foam stock.7:32 The project highlights the necessity of verifying large-scale 3D scans with physical templates or test molds to prevent material waste.

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