Fabrication - carbon fiber

[Spooph]

I know it is possible to buy already prepared carbon fiber sheets to make parts for vehicles, but how does one actually make the carbon fiber sheets. I was wondering if anybody knows about how to do this, resources that involve this process, and anything else, pertanent to the subject... thx

Crash

[The_In_Kid]

its like fibreglass...

you take the carbon fibre cloth then apply some special epoxy then sometimes bake and/or let it dry...

[Redfox]

You gotta go and purchase a few things to do it right.

You obviously need the carbon fiber material, and it comes in rolls just like any other fabric would. Then you buy a 2-pack epoxy resin for CF... you also need some M.E.K. (Methyl Ethyl Ketone?? i can't remember) solvent for clean up. This epoxy resin is sticky stuff, so you must use gloves when playing with it! It also wouldn't hurt to buy a chemical mask to prevent u from breathing the fumes. The M.E.K. fumes will start to kill your brain cells when u start breathing it. Which means you must work in a very very well ventilated area. If in doubt, work outside.

You will also need a metal roller to roll the CF when you are making it. The place that sells the CF to you should have them. They look like screw threaded rods between a coat hanger sorta thing that allows you to roll the rod over the CF. This is important because it helps you get the epoxy resin into the CF material and get the air bubbles out.

You will also need a sort of mold release agent. It is usually white or pink stuff that comes in a can and you paint it onto whatever surface you are going to make the CF on.

The process can be tricky because the epoxy is very sticky. U mix the epoxy in the right ratio, and then lay down the first layer of CF sheeting and pour the epoxy over it and then roll it into the fabric. It doesn't hurt to do a few layers at a time, depending on how thick you want it. Remember to cross lay the sheeting at different angles to get the best strength from the finished product.

Then you gotta wait for the epoxy to set... once this is done, you can sand it down with an orbital sander for a smooth finish, and then add more layers for more strength or thickness. When you are sanding, you MUST wear a mask and do it outside. The epoxy/CF dust is very bad to inhale. Also for added strength, it is recommended that you chuck it in an oven to "bake" it... this increases the bond strength i believe. If you don't have an oven hot enough, you could just make a wooden hot box and put a bar heater in it. Doesn't have to be very hot, but you can get the temps from the CF ppl...

Basically you are only finished when you are happy with it. Feel free to add as many layers as you want. Then it's just a matter of cutting it out with a jigsaw or hacksaw or bandsaw...

Long process eh?! I suggest u just stick to buying the CF pre-fab sheets to save you the trouble. Unless you need to make a formed shape, ie. one with curves and twists etc...

Hope this helps... :)

[vtl1180ny]

Who's a decent priced supplier of CF sheets? I'm also looking for Delrin and Nylon also...

[baih]

do a search here in this forum. there are a couple of shops that sell sheets of carbon fiber.

[vtl1180ny]

And... Hobby shops are going to charge you more than a supplier would...

[royat4]

peguin hobby has it but i costs a lot

[Spooph]

Thanks a ton guys, this helps so much, atleast i know where to start. The reason for me asking is because I need to make parts that have curves in them..... If it was all straight forward the pre-fabed sheets will be the obvious choice, and thanks again for all the help..