Dubbar Bus

We were contracted by a company that produces campers and food trucks to design and fabricate for them a set of composite molds that they can use to produce a uni-body for a particular style of bus. The first stage was in design and CAD. The bus itself stretches out 17.5", is 8' in height and 8' in width. Because of the size of the bus and budget to work with, we decided to approach machining the plug in an unconventional way. Instead of machining the entire bus as one plug and creating flanges to make the mold sections, we instead modeled the flanges in CAD software and prepared each mold section in a CAD model to be machined as individual mold sections . We then casted the individual mold sections with fiberglass and bolted the sections together to make and entire working mold.