It is best practice to pour from the first container into a second and mix again to ensure there is no unmixed resin.īefore laying the carbon, the mold should be coated in a film of resin. Be sure to accurately and thoroughly mix the resin with its hardener. XCR Coating & NW1 Polishing Compound (optional): Use these to post-process your carbon fiber part, providing a better cosmetic finish on your end product.įor this project, we are using the EL2 laminating resin.The back of the part is then finished with our Economy Peel-Ply which provides a neat inner surface. EL2 Laminating Epoxy: Which is specifically designed for wet layup processing and offers excellent strength and wet-out performance.XC110 210g 2×2 Prepreg Carbon Fiber: We are using three plies in this project but any dry composite reinforcement can be used.3D Printed Part – For this tutorial, we use the Ultimaker S5 which is an affordable, end-to-end 3D printer with hundreds of ready-to-print materials.Molds made with this process are not suitable for elevated temperature cures, as used in prepreg production, even when the HDT of the PETG is not theoretically exceeded, we have found the stress of the vacuum bag will lead to excessive warping and distortion. It would also be possible to process using resin infusion but due to 3D prints generally not being 100% airtight, an envelope bagging method may have to be used. Generally molds made in this way are best suited to hand layup processing (with or without a vacuum bag). The resulting mold from this process will work with most conventional resin systems, such as epoxy polyester and vinylester. The most reliable release agent for this process is PVA release agent, as it helps to smooth out layer-lines while providing a reliable release from the epoxy resin. ABS should be avoided as a direct mold material as you may find if difficult to get a good release from epoxy resin.Īfter 3D printing, the mold should be prepared with a release agent. PET-G filament is highly recommended due to its good release properties with the epoxy resin. To bring the finish up to a perfect standard the part can be coated in XCR coating resin and flatted and polished to a high-quality finish. Non-cosmetic parts can be used directly from the mold, however, the surface will be slightly compromised by the resolution of the 3D print and limitations of a hand layup process. We will be taking a FFF print with the barriers already modeled and release-coating it before manufacturing the carbon fiber part using a simple hand layup process. This tutorial is a bare-bones carbon fiber process meant for those without the specialized equipment needed for more technical processes and high-temperature epoxies. In this tutorial, we skip the process of using a pattern to create a mold and directly create a mold using 3D printing. UltiMaker 2+ Connect Air Manager Bundle.Commercial Grade Carbon Fiber Fabric 2×2 Twill 3k 6oz/203gsm $3.93 – $60.Kevlar Plain Weave 195d 38″/96.52cm 1.7oz/58gsm $36.25 Out of Stock Add to Compare.Fiberglass Woven Roving Plain Weave 18oz/610gsm 50in/127cm $9.95 Add to cart Add to Compare.Carbon Fiber Fabric Unidirectional Intermediate Modulus 12k 8.85oz/300gsm Hexcel IM2 $2.78 – $34.79 Select options Add to Compare.A suggested ratio is about 1-1.5lbs of resin per lb of fabric purchased. However, you will have waste no matter what method is used. Due to the variables in processing, it is hard to give an accurate amount of resin needed to purchase for making your part. You should have 55 grams of fiber left when your process is working correctly. For example, you have a part weighing 100 grams, and you would burn off the resin, which would leave the fiber behind. To calculate actual resin % in your part, a burn test is used. The average rule of thumb is around 45% (+/- a couple of percent). Too much resin will cause a weaker part, not stronger. Vacuum bagging a wet layup will improve the resin content. Wet-layup by hand will also have a higher resin consumption in the final part and depends on the user’s techniques. This does not account for the resin used in the flow lines and consumables such as flow media or breather cloth. Resin consumption is provided for the approximate amount of resin by weight in the final part after processing by vacuum infusion.
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