LogoFoam Cores

Our planes have curved wing and stabilizer planforms. The foam cores for those can be made by simply cutting a foam sheet along the wing outlines, then sanding the leading edge so it fits the mold (vacuum does the rest). In fact that's how we did it for some early planes (Ariane RAK1, CS, etc.). The following method is a little less work of course:

The CNC mill is carving a set of Ariane V7 wing cores (left/right, top/bottom) from a polystyrene foam sheet. The channels for the (curved) spar are milled, too.
The cores are cut off the sheet with a hot wire cutter.
The cores, ready to use (see Building an Ariane V7). A single foam sheet can produce- layer for layer - several core sets.

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