Most complicated CARBON FIBER part in the DarkAero 1!

An instructionnal explanation about how to make a mould for complex carbon fibre part

Dark Aero just finished building a carbon fiber part called the trunnion frame. This structural component transfers loads from the landing gear into the rest of the airframe. It was made on a male mold using a manufacturing process called infusion. The mold for this part was a bit different than our standard molds. Normally we CNC cut a mold pattern from tooling board and then use the mold pattern to create a final mold. The trunnion frame mold was instead directly CNC cut from an assembly of MDF stock.

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