After finalizing our canoe’s dimensions, our next step is to design the mold for the concrete to cast in place on Casting Day to form the canoe. The team often decides on the type of mold, female or male mold (the one in the picture above is a female mold) and then the mold is designed using a 3D software. Afterwards, the mold 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 molds are curved into shape. After all the 30+ pieces mold are created they are then assembled, with the help of pipes to ensure that the alignment is perfect. Finally, the surface of the mold 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!