DSDavid Stout

CAM · Moldmaking · Composites

Composite Wing Tooling & Manufacturing

SolidWorks mold design, Fusion CAM, CNC machining, and repeatable carbon-shell manufacturing for the 2026 wings.

2026 competition season · May 2025 — May 20262026 wing shells manufactured

Overview

I led the design, Fusion CAM, CNC machining, and composite process for reusable MDF tooling for the 2026 Formula SAE wings. Sharing airfoil sections and chord lengths allowed seven hollow-shell airfoils, plus backups, to be produced from three female molds, trading aerodynamic flexibility for manageable tooling time. Improved CAM, cleaning methods, and trained operator coverage reduced machining time from roughly 12 to 8 hours for mirrored diffuser-mold sections. The airfoil tools produced smooth shell surfaces; the proposed diffuser was never validated or installed on the car. Seam placement and process documentation remain opportunities for improvement.

My Contribution

I designed the molds in SolidWorks, prepared and modeled laminated MDF stock, developed Fusion CAM, obtained faculty program review, set up and ran the Haas mills, and trained section members. Brandon Warner mentored my CAM and CNC development. I also led surface preparation and carbon manufacturing, with the section sharing layup work.

Engineering Approach

Epoxy replaced wood glue between MDF layers after weak bonding was found. The main-element top and bottom used separate female tools; secondary top/bottom cavities shared a tool that was machined in three sections on the VF1 and joined with dowels. Layups used three bidirectional-carbon layers plus an outer twill layer placed first against the female surface. During shell layup, the team pulled as close to full vacuum as practical while the molds supported the laminate. After cure, top and bottom shells were bonded around the internal structure under lower vacuum, using only enough to hold the assembly during adhesive cure without pulling the shells concave. The numerical gauge reading and units remain unconfirmed. The two tertiary elements were wrapped around printed forms rather than molded. CAM refinements, finishing tolerance, hand sanding, machine protection, and frequent dust removal balanced time and surface quality.

Results & Current Status

The reusable airfoil tools produced shell pieces for seven airfoils, plus backups, with smooth finished surfaces. Approximately ten layup runs were completed. For two mirrored diffuser-mold sections, improved CAM, cleaning methods, and trained operator coverage reduced machining time from roughly 12 to 8 hours. This comparison applies to diffuser tooling. The proposed undertray system—including the diffuser, barge boards, and wheel-wake mitigation devices—was never validated or installed on the competition car.

Team Credits

Mold design, stock preparation, CAM, CNC setup/run, and manufacturing lead: David Stout. CAM/CNC mentorship: Brandon Warner. Program review and operator approval: laboratory faculty/operations engineers. Layups and fabrication support: the aerodynamics section.

Next Steps

  1. Improve seam placement so it is less likely to disturb flow at the leading edge.
  2. Evaluate shell thickness and composite structure to reduce dependence on printed internal supports.
  3. Preserve process parameters, inspection records, and tool revision history.

Airfoil Molds & Shell Manufacturing

From machined MDF tools to a finished carbon shell: selected views of the tooling, hands-on preparation, and manufacturing result.

Two MDF main-element female molds after machining
The main-element top and bottom tools after machining, before the complete surface-preparation process.
David cutting carbon fabric for Formula SAE wing layups
Preparing carbon fabric for the wing shells. I led the tooling and composite process; section members shared fabrication and layup work.
Carbon shell produced with the secondary-element mold
A secondary-element carbon layup result, connecting the machined cavity to the manufactured shell.

Watch the Process

Short, silent clips. Choose Play to load a video.

Main-Element Mold Machining
Actual machining of the main-element MDF tooling, viewed across the workpiece.

Diffuser CAM & Machining

The diffuser work demonstrates CAM development and mold machining. The proposed undertray system was never validated or installed on the competition car; these are tooling records, not evidence of vehicle aerodynamic performance.

MDF diffuser mold section after machining
The diffuser tooling after machining. The approximately 12-to-8-hour comparison described above applies to mirrored diffuser-mold sections.
Fusion CAM toolpath view for a front diffuser-tooling section
A selected front-section diffuser CAM toolpath view.

Watch the Process

Short, silent clips. Choose Play to load a video.

Diffuser CAM Simulation
A Fusion machining simulation of the rear-section tooling. This is CAM playback, distinct from the actual machining recordings above.

Supporting Files & Models

Choose a mold to explore in 3D, then download an individual STEP or the complete bundle.

Inspect all five molds in the viewer, including the three separate secondary-mold sections. These are surface visualizations derived from the STEP exports, with an illustrative MDF color. Download a GLB from the viewer, or use the STEP files below for precise CAD inspection.

STEP geometry for inspection, measurements, and section views. The secondary mold contains three separate sections; the bundle includes all five tools and process notes. CAD feature history and executable CAM are not included.

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