How to Mold Carbon Fiber
This article will discuss how to mold carbon fiber. Lightweight composites are used in aerospace, automotive, and military applications. By learning how to mold carbon fiber correctly, these lightweight composite products can be extremely strong and useful.
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Things You'll Need
- Carbon fiber
- Epoxy resin
- Mixing bucket
- Paint brush
- Plastic squeegee
- Mold release
- Safety equipment
Instructions
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First, one must understand what type of product they are constructing and why they are going to mold carbon fiber. If the carbon fiber is for aesthetics, such as the pattern that is popular on automotive hoods, then "low-modulus" carbon fiber can be used that is inexpensive. However, if one needs a carbon fiber component for say, a racing bike, and this part needs to be as lightweight and as strong as possible, then higher-grade carbon fiber should be used. As well, for a better quality product, one needs to decide how to mold the carbon fiber; either through autoclave curing, vacuum infusion, or simple hand lay-up. Since this is an introduction on how to mold carbon fiber, we will discuss the hand lay-up process.
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After you have found your source for the carbon fiber and resin, (Many on-line retailers these days) the mold needs to be constructed. The mold will be the shape the carbon fiber will take. The mold could be as simple as a pre-existing component that you want to replicate, or the mold could be custom manufactured or machined. Materials to make carbon fiber molds can be purchased from the same locations that sell carbon fabric and epoxy resin.
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Now that you have your mold, take the mold release and apply it to the mold. The mold release agent is important if you want to remove the finished carbon fiber laminate from the mold. Essentially, it prevents the carbon fiber from bonding to the mold.
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Next, cut and lay the dry carbon fiber fabric in the mold, be sure no wrinkles occur on curved areas. If you need more layers of carbon fiber, cut those now too.
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It is now time to mix the epoxy resin. Follow the instructions as close as possible, and try to estimate how much resin you will need. Mixing too much resin is a waste, and too little is a problem. Use a clean paintbrush to cover the carbon fiber fabric with a thin layer of resin. Then, use the squeegee to remove excess resin and air bubbles. This is key in making the end product light weight.
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Now add the other layers of carbon fiber, and repeat the process. It is best to do this at the same time so the resin cures at the same time creating a solid and strong bond.
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Finally, wait for the carbon fiber composite to cure, pop-it out from the mold, trim the edges, and sand out any imperfections. You are finished!
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Tips & Warnings
Work in a cool room, too hot and the resin will cure faster then desired.
Practice on a small scrap sample to get the hang things, and timing of the resin.
Pay attention to the carbon fiber in corners and acute angles. It can bunch up easily.
Always use safety equipment and work in well ventilated areas.
