Practical CAD Techniques for Composite Pattern/Mould Design

Composites video tutorial from Easy Composites covering the design principles and practical CAD techniques required when preparing 3D models for CNC machining into composite patterns. In the tutorial, we’re using Autodesk Fusion 360, although the tools and processes are generic and would apply equally to any other engineering CAD package such as Catia, Solidworks or Onshape.

The tutorial begins by looking at the more basic steps of checking draft angles, adding trim allowance, closing apertures, creating flanges and setting up the stock material. The second half of the tutorial looks at a more complex ‘split-mould’ and covers the process of using draft analysis to create the optimum parting line, as well as design-in features such split-mould clamping bushes.

00:00 - Introduction
02:00 - CAD Packages and Features
03:39 - Draft Analysis
05:42 - Creating Trim Allowance
06:56 - Creating Mould Flanges
10:42 - Cutting into Stock
18:26 - Split Mould Parting Line and Faces
25:06 - Stock Material Cutting
28:10 - Mould Alignment with Clamping Bushes
28:32 - Drawing the Bush Locating Pads
33:55 - Creating the Pattern

For a full list of products used in the tutorial or to discuss any questions you may have about taking your composites project from the screen to the real world, visit the tutorial project page on the Easy Composites website:

EU Customers:

UK & Rest of World Customers:

[Hellsatanx]

I've learned so much from this dude over the past 10+ years its actually crazy, and its free! unbelievable great work

[christophercuk]

The quality of the production and content of these videos never ceases to amaze me. Thank you for making these!

[designbydave]

@31:57 - That absolute fire insert shot of slamming that num pad!! 🔥

[landonf]

I am honestly more excited for new Easy Composites videos than Hollywood movies these days. Thanks for delivering outstanding content and making the world a smarter and more capable place.

[scottkramer]

If you are planning to use CNC machining to make the pattern, I don't see why you can't just machine the mold and skip the whole process of making the pattern. You will still need to do some hand working to remove the machining marks and prepare a suitably smooth mold surface. You may even want to apply a hard surface coat. I'm just saying I think that making a pattern is obsolete now that we can use CAD and CAM.

[maxnits]

Cool! This is next level! Your tutorials are growing exponentially in quality and usefulness. Thank you for your work!

[renzovelezthe]

Been following since i was in college and couldnt afford anything. now i just started to create molds and was able to produce carbon fiber parts for my motorcycle. I owe it to this man and his company. greetings from Philippines. i guess learning CAD is our next goal haha

[lilcouple]

you guys are single handly describing every step of a very complex manufacturing technique in such a comprehensible and great way one video at the time. Without you guys, formula student teams around the world wouldn't be able to make the carbon fiber parts of their cars 🤣👏

[DennisDaroczy]

I would like to see the video of the internal layup of the aircraft fuselage.
Thanks again, your videos are very helpful.

[williamfreret]

Impressive the time that can be saved as well as the accuracy obtained but far too complicated for a 61-year-old man...😟 I note that manual work is still necessary and that robots are not yet doing everything, at least for now! 😊

[insmnc]

So glad you put this out! I've been pulling my hair out this week trying to design a mold for my first pre preg part. Perfect timing for me

[chrisshaw]

You know, as a truck driver, that had nothing to do with anything you guys do, and consequently will never be a customer, I just want to thank you for the high quality videos you put out on the process. I'm obsessed with them. It's incredibly interesting how it all works, and I appreciate you guys being so thorough. I literally watch every video you guys come out with. The dude in the video is a great presenter.

Just wanted to let you guys know that your video's reach even those who aren't potential customers, and provide a great deal of entertainment.

[pierrex]

Impressive. I feel like you could probably teach entire courses for people/ companies who want to go into composites. A lot of the trial and error could be avoided by attending classes with hands on experience. A lot of insanely overpriced niche parts could get so much cheaper if more people had the skills to design and produce these parts. Especially if using fiberglass instead of carbon fiber, for example.

[SONOBT]

What a time to be alive! A world of decentralized manufacturing is upon us.

[ScottMoyse]

This is a super handy video! Nice work... however, I thought you might be interested in the content of this video, where Jake explains a bit about how to sketch splines and why to do it the way he shows. Jake worked on the Autodesk Shape Manager team in Cambridge for a number of years, so really knows his stuff.

[kamokrooked]

I've become a composites expert over the past decade thanks to your incredible video. Thanks for your passion and dedication to teaching. I haven't made a single part from composite, but I know I could thanks to you.

[karlh]

Awesome tutorial, you have helped me so much with production methods.

[IngeBall]

Friday and now this!
It deserves a pint or "two" 😆

[ngrader]

16:19 Oh my... If Futurama has taught me anything? Put flames on it, it'll go faster.

[iggyigner]

Best educational content in this field on YouTube. Giddy each time one of these comes out.