From this
moment forward we are getting started on making the prototype. The plan was
already made and approved. Now it is time to make the mold, which will be used
for thermoforming the HIMACS plates. First we drew, with a stencil, the shape
onto the MDF 9mm sheets. By hand all shapes were cut with an electric hand saw.
After cutting all shapes, the shapes were getting marked with 5 dots. These
dots were marking to drill holes in. We used an 8.5mm drill to make the holes. Through
these holes five rods were placed to keep all shapes together to get a sturdy
and stiff mold. At both sides, the shape holds itself together with a ring and
a bolt.
The pictures
below show the previous mentioned steps. By doing it in an assembly line setup,
making the mold was quite efficient.
