THE ATELIER
Where the mould is the design
A fiberglass piece is made twice: once as a plug and mould, once as the object. The first is the real design work.
Forms are modelled digitally, milled or hand-shaped as a plug, then faired until the reflection runs clean. Laminates are laid by hand for wall thickness where load asks for it. Everything after that is patience — filling, fairing, priming, blocking, painting, polishing. Nine people, one surface.
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FROM THE ATELIER FLOOR
01 Form Digital modelling, silhouette tests, 1:5 study prints.
02 Plug Milled or hand-shaped master, faired until reflections run straight.
03 Mould Split tooling with flanges planned around the parting line.
04 Lay-up Hand-laid laminate, thickness mapped to load paths.
05 Demould Release, trim, bond internal ribs and fixing bosses.
06 Fairing Fill, block-sand, prime, repeat. The longest stage.
07 Finish Pigmented coat to house colour or RAL, then polish.
08 Crate Foam-cradled, edge-protected, plywood crate, photographed.
4.5 m MAX SINGLE-PULL LENGTH
12 wk NEW MOULD TO FIRST PIECE
RAL FULL COLOUR MATCHING
40+ COUNTRIES SHIPPED