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A Guide to Direct Molding

Direct molding guide

Direct Molding Process

Yamaha's original direct molding process begin directly with the mold, solving the frequent pull problem that plagues the traditional mold-prototype-plug-mold system.

To show off our direct molding technique, we built a one-off reproduction of a CAT-21 motorboat. This model was first built and sold in the 1960s.

1.Modeling

1.Modeling

We made a 3D model of the original hull-line draft.

2.Mold CNC processing

2.Mold CNC processing

We applied Sprayputty to a loft, and milled the mold.

3.Direct molding the deck

3.Direct molding the deck

We set a "surfacer" to the mold milled by the CNC processor, and did a final check of the mold.

4.Direct molding the hull

4.Direct molding the hull

Then we did the same to the mold for the hull.

5.FRP molding

5.FRP molding

Next, we layered gel coat and fiberglass to the completed molds and removed the pieces after they had cured.

6.Finishing and Rigging

6.Finishing and Rigging

We did the finishing on the deck and hull and installed the rigging.

7.Coupling

7.Coupling

We connected the deck to the hull.

8.Final work

8.Final work

After coupling, we did the final polish and installed the fittings.

9.Finished

9.Finished

It took only 7 weeks from modeling to final product.

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Gamagori office , Marine Business Operations ,
Yamaha Motor Co., Ltd.

Feel free to ask about the details of our CNC mold manufacturing, estimates, or anything else.

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