One of our favorite builds in recent memory was the rear cover for the Yeti Snow MX—an innovative system that converts a standard dirt bike into a snowmobile. Here’s how we took this component from a CAD file to a production-ready part, built to withstand backcountry snow terrain with the strength and weight advantages of carbon fiber.
1. CAD Design: Translating Vision into Engineering
The process starts with a CAD model. We worked closely with the Yeti Snow MX team to understand their requirements—fit, durability, aesthetic, and performance—and used SolidWorks to engineer the mold-ready shape of the rear cover.
2. Glue-Up Design: Preparing for Precision CNC Machining
Before we begin cutting, we design a glue-up block to serve as the blank from which the mold will be machined. The block is made from multiple pieces of tooling board, aligned and bonded in preparation for multi-axis cutting.
Using our DMS 5-axis CNC machine, we precisely cut the mold from the glue-up block. This step defines all the surfaces and contours needed to create the part, and the precision of the CNC ensures that the carbon layup fits perfectly every time.
4. Layup: Carbon Fiber Layering & Vacuum Bagging
Once the mold is complete, we begin the carbon fiber layup process. Multiple layers of pre-preg carbon fiber are placed into the mold by hand, ensuring tight conformity and material integrity. The part is then sealed in a vacuum bag to remove air and compress layers together evenly.
5. Autoclave Curing: High Pressure, High Performance
The vacuum-sealed mold goes into our autoclave, where it’s cured under high heat and pressure. This process compacts the fibers, eliminates voids, and results in a lightweight, ultra-strong part with a flawless surface finish.
6. Final Machining & Finishing Touches
After curing, we trim and machine the part to final spec, polish any surfaces as needed, and ensure all mounting holes and edges are precise. The result is a production-quality component that is strong, durable, and ready for harsh winter conditions.
Bringing the Snow to Life
This part not only looks incredible—it performs under pressure. Thanks to its high strength-to-weight ratio and precision tolerances, the carbon fiber rear cover improves handling while surviving the demands of rugged snowmobiling.
