Abstract: A flexible molding component used with a base mold improves on existing methods of forming fiber reinforced composite parts. The molding component is formed of a flexible body structure having an interfacing surface and a perimeter region including a perimeter seal configured for sealing engagement with the base mold. Resin and vacuum distribution channels are formed in the interfacing surface to deliver resin to a fiber lay up disposed on the base mold and draw the resin across and through the lay up, respectively, to properly mix the resin/fiber combination which forms the desired part. Application of the vacuum causes the perimeter seal of the flexible body structure to sealingly engage with the base mold to enclose materials between the body structure and the mold, as well as causing the interfacing surface to draw against the resin/fiber combination, and the mold to shape the combination into the desired part.

Abstract: A machined part is provided. The machined part is formed from a porous substrate material that is machined to shape. After machining to shape, a resin is infused into the machined part precursor to a layer thickness depending on the end use of the finished part. The resin is then allowed to harden to complete the part. The finished part may be used as a prototype tool, a tool for forming other tools such as mold parts and finished tooling.

Abstract: A boat hull is provided that has a substantially seamless construction wherein the boat hull is an integral monolithic structure. In the formation of the boat, the boat interior components for example deck precursors are positioned in the mold prior to formation of the hull so that the boat hull can be made in a one shot molding process.

Abstract: An insert for use in the fabrication of a watercraft hull to form an inboard/outboard propulsion system passageway. The design of the insert incorporates a semi-rigid body having an inboard surface, an outboard surface, and sidewalls interconnecting the surfaces. The semi-rigid nature of the body facilitates the insert fitting tightly with the build up of laminate layers forming a watercraft hull while maintain dimensional stability during the manufacture of the hull. The insert is further configured to be easily removed from the completed watercraft hull to reveal the finished inboard/outboard propulsion system passageway.

Abstract: A flexible molding component used with a base mold improves on existing methods of forming fiber reinforced composite parts. The molding component is formed of a flexible body structure having an interfacing surface and a perimeter region including a perimeter seal configured for sealing engagement with the base mold. Resin and vacuum distribution channels are formed in the interfacing surface to deliver resin to a fiber lay up disposed on the base mold and draw the resin across and through the lay up, respectively, to properly mix the resin/fiber combination which forms the desired part. Application of the vacuum causes the perimeter seal of the flexible body structure to sealingly engage with the base mold to enclose materials between the body structure and the mold, as well as causing the interfacing surface to draw against the resin/fiber combination and the mold to shape the combination into the desired part.