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.
We made a 3D model of the original hull-line draft.
2.Mold CNC processing
We applied Sprayputty to a loft, and milled the mold.
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
Then we did the same to the mold for the hull.
Next, we layered gel coat and fiberglass to the completed molds and removed the pieces after they had cured.
6.Finishing and Rigging
We did the finishing on the deck and hull and installed the rigging.
We connected the deck to the hull.
After coupling, we did the final polish and installed the fittings.
It took only 7 weeks from modeling to final product.