How do I build a thing out of carbon fiber?

September 24, 2011 9:57 PM

I've got a very simple plastic widget that I wish to duplicate in carbon fiber. I'm looking, naturally, for that deep piano finish that CF can provide and I need the replacement to be 3-dimensionally identical. The trick is that this widget has a bit of thickness to it, even though only one side is exposed. Are there any good online tutorials or technique write ups on how to make a solid thing out of composite material?

I'm familiar with layup over foam, wood, etc, and even dissolving foam to make cavities. I don't think that layup over a plug would work as the layup would increase the size of the final product, thus my confusion.

posted by TheNewWazoo to Sports, Hobbies, & Recreation (1 answer total)

There are a number of ways that you could potentially do this depending on the nature of your particular widget, your budget, and how much strength/stiffness you need from your product. Without knowing the details I would suggest (with the method that will produce the best results first) matched molds, a female mold or a male mold (the latter two could potentially be with or without vacuum bagging). As you said you could also do it over a plug but the size of the plug will have to take into account the thickness of the the carbon fiber you are going to add to achieve the correct final size. This is potentiality more work than making a mold but again will depend on the part. With either a male mold or a plug you will end up spending a ton of time trying to get the nice carbon fiber finish (which appears to be the main thing you're looking for) and my not ever get something really nice. With a female mold (or matched molds) the visible surface will be in contact with the mold it will have a nice finish, assuming of course that the part you make the mold from has a nice finish.

TAP Plastics has a number of tutorials about mold making (silicone is what you want so you don't have to worry about mold releases). There are some composite wet lay-up tutorials on youtube. This one looked good to me, but probably your best bet is to watch a few and try to get a general feeling for it. There are also a number of books about this topic; I have this one, which is pretty good, but there are lots more.

If you post a little more information or memail me I'll try to help you out more.
posted by Medw at 2:10 AM on September 25, 2011 [1 favorite]