How do I fabricate this part with carbon fiber

Talk to these guys

You need to know the stress factors involved, fit and finish required, and other specific info, to manufacture a suitable replacement....

http://www.instructables.com/id/Simple-methods-for-molding-fiberglass-and-carbon-f/

https://www.youtube.com/watch?v=IAdVO8Rkv6c

http://www.wikihow.com/Make-Carbon-Fiber

1. What are your qualifications in designing this part?
2. Are you an Engineer?
3. Is this part involved with any type of vehicle?
4. Is this part anywhere near a human life safety device?

You post as Anonymous so I bet you're not an engineer. A professional engineer would already know how to do this and where to get it done!

It can't be done.

By you.

What qualifications do you posses that make you think you can do this.processes

Your question indicates that you are unaware of the materials and processes required to perform this simple fabrication.

You will need professional help.

Lyn-Door Ent. Has recently started distribution of 3D printers that use short length carbon fiber material. The initial offerings are reasonable, but the cost of the special fabricating material may be a drawback. Good luck.

I cant say I agree with others who say you need to be an engineer to do this. I have built things and they have turned out all right, even though I'm not an engineer. You do need a good understanding of trigonometry at least. First thing to do would be to get the equipment required to do the job, at the minimum you will need a vacuum pump and an autoclave, you can make a mockup out of wood or automotive clay to see if it is even possible to wrap the object in a single carbon sheet, start out cheap using fiberglass for example before buying any equipment. Good luck, remember, ingenuity is the mother of invention.

I agree that one does not need to be an engineer to fabricate the part.

However, carbon fiber laminates get a good part of their strength by virtue of the fact that it is usually unidirectional fiber laid in alternating orientation/directions. Usually 0, 90, 0 or 90, 45, 90, or some variation. So using a single piece of cloth would negate the strength advantage of carbon fiber.

So, changing materials involves a lot more than changing fabrication methods.

Who knows if carbon fiber is even needed in this application?

That would require engineering/analytical skills obviously not possessed by the AP.

Been there, done that.

It's not that we're saying one should be an engineer, I have found that an expert has failed more times than a layman with an opinion has ever tried.

Doing a carbon graphite layup, will require a number of tries to get a satisfactory result. Problem one may have is delaminating. That's only my speculation, because I would say myself, like a number of responses, never tried it.

Some of the response, are to be considered, such as stresses, there are a number of posts about carbon fiber construction on this site. And example, Carbon fiber construction stress failures applied to bicycles comes to mind. The OP should search that here on CR4, you may come up with some ideas.

The point I was driving, is talk to an expert, that has actual experience with carbon fiber construction one would be surprised at what one will learn, and be able to save and reduce a few fails.

Maybe you could get a spool of continuous strand carbon fiber and lay it on to a rotating form while applying a bonding agent? Or maybe not.....

As mentioned earlier, carbon fiber strength is from being layered in multiple directions.

Well.......................................................

It's called filament winding and it IS used to fabricate carbon fiber tubing. It requires a filament machine that cost$ a LOT of money.

It lays down the filament while traveling back and forth along a carrier to orient the fibers in a specific cross pattern, just as unidirectional cloth is oreinted.

Like bias ply?

Your best bet is to contact a local company that makes carbon fibre parts and see if it is possible. We don't know where you are, what this is for, what size the part is or how many need to be made which greatly limits our advice.

What is the part actually for and how big is it, etc. Is this for a 8 foot wide pipe or a circuit board pin? More information and application please!

You know what they say about assumptions don't you?

I think I will wait for more information from the original poster. I have a feeling that some new piece of supplied information will greatly effect our assumptions (which usually happens).

There's a full moon somewhere tonight. The inmates have escaped the asylum.

I shall try, "to sleep, perchance to dream".

Farewell, for now.

Thank you for your help, but most of you got off topic. I am an engineer but I share the idea that you don't need to be one to do this. The thing is I am not a composite expert, my expertise are in the machining topic.

Sorry because more information was needed;

I am machining a mold out of Al6061, this part will have 6 layers [90,90,45]s . But I want to turn a laminate into a circular tubular part without having to do two separate parts and doing a second process to join them. Its going to be used for a prosthesis idea. Its going to be a vacuum infusion process.

And that's where you should address this to composite experts.

I agree with Phoenix911. Consult the experts in the field of carbon fiber layup. I disagree with your method of molding the part with layers. Like Lyn posted earlier, a part like yours should be wound in crossing layers from spools of thread. I believe your layering mold will impart a fracture point where the layers connect.

I started my mold making career in 1980 and I don't think a mold will work for your application. A carbon fiber part is designed and engineered from the very inception of the idea. As you stated this part is for a prosthetic so it deals with a living being and lawyers love medical malpractice lawsuits especially from untried practices. Be very careful on how you proceed.