Challenge:

Electric motor prototype required an aesthetically pleasing cowling with relatively low overhead cost for one-off fabrication.

Methods:

• Conceptual sketch design for stakeholders for unified vision.

• Part and female molds modeled in Fusion 360.

• Epoxy foam board CNC milled and surface coated for low-cost tooling.

• Wet layup of carbon fiber part with veil for longevity in harsh marine environment.

Results:

Successful delivery of cowling on-time and within budget for final prototype assembly.