I'm having a bit of a hard time conceptualizing how I would go about creating a mould for making a one-piece carbon fiber louver panel such as the one I have pictured.  

The flange around the perimeter is easy enough, but I can't quite reason how I would work out the open transition between the vane edges without making a solid transition then cutting out the opening.

Does anyone have a better idea for handling the louver vanes in a way that wouldn't require cutting out large pieces of the part during postprocess?

...has anyone made composite louvers before? What was your mold process?

Thanks everybody.

     

I made something similar for e46 m3 gtr vents. Making CF part is simple but the finishing is a bit frustrating......a lot of precision cutting and triming (one wrong move and you can bin the part).