After finalizing our canoe’s dimensions, our next step is to design the mould for the concrete to cast in place on Casting Day to form the canoe. The team often decides on the type of mould, female or male mould (the one in the picture above is a female mould) and then the mould is designed using a 3D software. Afterwards, the mould is divided into different sections where it is further divided into layers for easier construction.
For next step, A small part of our team would be trained to use a CNC milling machine. Using the parts from the software, the CNC milling machine and large pieces of Styrofoam, the separate moulds are curved into shape. After all the 30+ pieces mould are created they are then assembled, with the help of pipes to ensure that the alignment is perfect. Finally, the surface of the mould is sanded and covered by a layer of tape or plastic wrap, this will allow for easier removal of the canoe after it has cured. Now, we are all ready for Casting Day!