FIFTH the modeling paste. The milled rough model is then coated with resin and the long and grueling process of aplying the modeling paste. The paste is a chemical miracle, two components after being mixed by a machine and aplied by hand via a laying nozzle.
the machine:
http://www.dekumed.de/indexeng.html
A deck model being laid. At the beggining of the shift and after 12 hours
the model paste applied
SIXTH again to the CNC. The modeling paste is then milled just like the EPS before. Only with a lot more love and accuracy.
The hull being milled
SEVENTH putty and sand paper. The most boring aspect of design begins. One needs to locate holes, dents or imperfections of the model and fill them with putty and then sand it down to perfection. A milimeter big dent takes 10 takes to make a perfect surface. Some final adjustments can be made at this stage.
EIGHTH making of the glass. After the model is perfect, it is sprayed with a special kind of surface putty. That putty is then sanded with increasingly fine sandpaper until it is as smooth as glass. Any imperfections here and it will show in the final product. A mistake here will mean a disaster.
This is it for the modeling phase of design. Next the mold is made with fiberglass reinforced palstic and that mold is used to create final components. I have made hull models of 50m long yachts to just half a meter models of hatches. It's a diverse job