Foam Buggy Mold

CMU has an annual tradition called buggy where teams of students design a gravity and human pushed airfoil shaped vehicle that a driver lays in. The buggy is then raced across a 0.84 mi loop around Flagstaff Hill next to campus.

This is foam buggy mold that was made from 2" thick pink insulation foam that was CNC'ed. The 3D model of the buggy was sliced in 8 sections with the largest piece slightly under 8' and the smallest piece about 4'. The 4'x8' sheet of insulation foam was secured to the CNC bed using screws and scrap pieces of 1/4" plywood. A rough and finish pass were done with 0.5" extended flat and ball nose end mills respectively.