So, the final design stage began, comprising development of the fibreglass molds however, the mold plugs were large and could not be fabricated by any conventional manufacturing process.  The shape was complex and the mold-makers, regardless of their skills, were unable to replicate the shape accurately.

Methods procured the necesary materials and machine time from various vendors and machine work-centres, and supervised the shaping process of each of the mold plugs into their respective intricate primary shapes using a multi-axis CNC milling process.