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Anonymous Poster #1

How do I fabricate this part with carbon fiber

04/17/2015 3:23 PM

I am working on changing some parts from metals to carbon fiber and other composites but I need help regarding this part, its a circle profile that i want to merge to a rectangle profile (basic laminate) where the part will hold.
I want to do this with one using single carbon fiber cloth (not to parts joined together).
Appreciate your help

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#1

Re: How do I fabricate this part with carbon fiber

04/17/2015 3:30 PM

Talk to these guys

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#2

Re: How do I fabricate this part with carbon fiber

04/17/2015 3:34 PM

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

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#3

Re: How do I fabricate this part with carbon fiber

04/17/2015 3:55 PM
  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!

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#4

Re: How do I fabricate this part with carbon fiber

04/17/2015 4:19 PM

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.

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#5

Re: How do I fabricate this part with carbon fiber

04/17/2015 7:44 PM

ecig tip?

ne how bu how,

but your English is better than i would expect from fasttech

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#6

Re: How do I fabricate this part with carbon fiber

04/18/2015 3:19 AM

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.

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#7

Re: How do I fabricate this part with carbon fiber

04/18/2015 11:12 AM

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.

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#8
In reply to #7

Re: How do I fabricate this part with carbon fiber

04/18/2015 11:23 PM

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.

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#9
In reply to #7

Re: How do I fabricate this part with carbon fiber

04/19/2015 5:27 AM

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.

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#10

Re: How do I fabricate this part with carbon fiber

04/19/2015 2:38 PM

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.....

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#11
In reply to #10

Re: How do I fabricate this part with carbon fiber

04/19/2015 3:10 PM

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

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#12
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Re: How do I fabricate this part with carbon fiber

04/19/2015 3:40 PM

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.

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#13
In reply to #11

Re: How do I fabricate this part with carbon fiber

04/19/2015 4:56 PM

Like bias ply?

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#14

Re: How do I fabricate this part with carbon fiber

04/19/2015 7:10 PM

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!

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#15
In reply to #14

Re: How do I fabricate this part with carbon fiber

04/20/2015 12:34 AM

I do not know the size and application of the object. However since the question is more of processing nature I would like to put my views. Assumption the part is of medium size around 1 Meter or so. Also the inner profile is more important than the outer one. Choose a good binding material that's dissolves in acids or base. Mould the same to the desired shape and size. This can be done in multiple sections. The sections need to be joined before fabric layout. Place the joined part in vertical position. Use of proper carbon fabric layout and resin infusion plan should be correct. Choose correct injection points and vacuum points. Use Vacuum bagging as per normal VARTM process. Give vacuum. Maintain a vacuum pressure of .75 bar-.80 bar. Inject resin from lower. Allow the resin to infuse wholly into the layout. Start appropriate heating cycle. After curing remove the initially used binding material by pouring acid or base. Finally some cutting and finishing work and the job is ready.

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#16
In reply to #15

Re: How do I fabricate this part with carbon fiber

04/20/2015 12:43 AM

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).

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#17
In reply to #16

Re: How do I fabricate this part with carbon fiber

04/20/2015 12:52 AM

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

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

Farewell, for now.

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#18

Re: How do I fabricate this part with carbon fiber

04/21/2015 4:07 PM

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.

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#19
In reply to #18

Re: How do I fabricate this part with carbon fiber

04/21/2015 4:12 PM

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

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#20

Re: How do I fabricate this part with carbon fiber

04/21/2015 5:33 PM

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.

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#21

Re: How do I fabricate this part with carbon fiber

04/21/2015 6:20 PM

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.

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