Once the design is finalized and a buck created, a mold is created for one of two types of materials: fiberglass or urethane.
Again, it’s not just Nissans they create parts for! Rangers, Expeditions, F150s; Stillen has hundreds of molds for urethane and fiberglass body parts.
The guys are constantly creating bumpers, side skirts, and many more parts every day. Demand is very high.
There is a process to not only getting the urethane injected into the mold, but also to getting it back out after it has cured without breaking the mold. Occasionally a mold does get broken as the urethane can be very tough to separate and that's why bucks are kept handy for mold replacement.
On the other side of the urethane room was a welding room where the supporting metal structure of the molds are created.
This is the machining room where parts like differential covers, brackets, and more are CNC machined. Stillen has 4 units including a couple of new HAAS CNC machines.
It’s still an amazing site to watch one of these machines slowly create a part from a solid chunk of steel or billet aluminum.