This resource from Boxford describes the design and manufacture of a vacuum-forming mould that can be used to make a toy yacht. The resource includes a copy of an exemplar stereolithography file that can be used to manufacture the mould on a rapid prototyping machine. Several images of the CAD models, the use of a rapid prototyping machine and faults in vacuum formed products are included. The required characteristics of a vacuum-forming mould are explained in detail. The use of CAD software to design and test a virtual model of the mould is described. The manufacture of the mould is carried out using a rapid prototyping machine. The mould can then be tested in practice, and the design refined. Curriculum links include the use of CAD/CAM in the design process and iterative designing.

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