DS Composite Project Gallery

Removing paint and scarfing for bonding

Removing the rotten wood core

Replacing rotten core with syntactic foam (epoxy and glass microspheres)

Paddle after lamination and curing under vacuum

Two sided CNC machined compression mold for carbon bike saddle

Compression molding CNC machined tools for carbon fiber saddle

Cured carbon bike saddle after top tool removed

Compression molded part before trimming to shape

Acceptable surface finish from prototype wooden tooling

CNC cutting of channels for resin casting in kiteboard core

Resin casting for perimeter, binding and fin mounts in assymetrical kiteboard core

Planing kiteboard core to thickness and exposing resin casting on both sides

Translucent resin casting in CNC machined kiteboard core

Cutting a white oak table top to shape on CNC router table

8’x3’ white oak table on CNC router table

CNC machined structural aluminum pieces for testing jig

CNC cutting of aluminum clamping pieces for rail testing jig

CNC cutting aluminum clamps

Completed CNC machined aluminum clamping parts

Aluminum clamps and baseplate after CNC machining

Assembled CNC machined jig for testing strength of bicycle saddle rails

Assembled CNC machined rail clamping mechanism

CNC machined rail clamping mechanism with top portion removed

Assembled CNC machined rail clamping mechanism with top half removed