How to Make Carbon Fiber

Carbon fiber is a popular composite of carbon and plastic resins that is used in aerospace and auto mechanics. Making your own carbon fiber at home can be achieved for a fraction of the price of buying the pre-made parts, and it's not that difficult to do.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• 1 Hollow mold in desired shape
• 1 can of spray fiberglass resin
• 2 sheets of fiber cloth (8"x11" - found in auto parts stores)
• 1 Autoclave device
• protective goggles
• Protective gloves
• Breathing mask
• small can of clear epoxy
• medium sized paintbrush (thick bristles)

1. Heavily spray the fiberglass resin into the inner part of the mold that you purchased from an automotive store. Make sure that it is completely saturated on the inside with the resin spray.

2. Press the fiber cloth sheets firmly into the inner part of the mold. Make sure that every part of the mold is covered by the sheets. You may need to rip one of the sheets into pieces, to accommodate gaps and spaces in the mold.

3. Spray the inside of the mold with the fiberglass resin spray once again, making sure to fully saturate the fiber cloth on the inside of the mold. Hold the mold away from your face while you are doing this.

4. Seal the mold, as according to its design, and place into the autoclave device. The mold should sit in the autoclave for about 15 or 20 minutes, and must be left to cool for three hours once removed from the device.

5. Open the mold, and remove the hardened carbon fiber from it. Finish by spreading the clear epoxy over the carbon fiber, with the paintbrush.

Tips & Warnings

• Always wear gloves, a face mask, and goggles when working with spray resins and epoxy.
• Fiberglass resin can be harmful if inhaled.

[hamfam]

on 1/12/2010 No mold release agent? Really!!