Brandon Robinson |
12-29-2011 09:49 PM |
Youtube carbon fiber fusion molding. The process isn't terribly difficult. You need tools and mats. The woven graphite, epoxy, a vacuum pump, a mixing pot, plumbing and fittings, bagging, seal tape and releasing film and a bubble fabric( i can remember the name). The setup will be so expensive you will have to make more and sell them to recover the cost. Basically you make a mold out of an existing part, apply the releasing film then lay up layers of woven graphite until you reach your desired thickness. Remember to account for compression. Then add a layer of the bubble fabric (this layer allows the vacuum to pull across the whole part) Bag the whole package up. Add fitting to the bag on opposing corners and mix your epoxy in the pot. Attach a ball valve to one fitting on the bag with a hose running into the epoxy pot and the vacuum pump to the opposite fitting on the bag. Use the vacuum pump to suck the epoxy resin through the woven graphite and bag. The vacuum will compress the part and pull all the bubbles out of the part. Watch the epoxy pass through the part until it reaches the vacuum fitting and use the ball valve to stop epoxy flow. Leave the vacuum pump on until the epoxy you chose has set up. This keeps pressure on the part and draws any off-gas and bubbles out of your part. Use a Dremel or body-saw to trim off access, drill holes, buff to a shine and install.
Once you have mastered this you can build an entire carbonfibre car. Take the body parts off and use them as molds, bag it all up and FUSION.
Hope this help explain how simple it can be. The cost are not cheap but once you have the setup you can make anything you wish.
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