CARBON FIBER FABRICATION
Constructing the Tooling
To build a model of my design out of carbon fiber, I first 3D modeled a negative mold which was then CNC'd out of foam. Shellac, primer, and wax were then used to prep the tool for laying up the carbon fiber.
Several plies of carbon fiber were carefully cut out in varying orientations to assemble a “kit”.
Each ply of carbon fiber was laid into my tooling one by one while applying resin in between.
To squeeze out air and excess resin, I used a process called "vacuum bagging". Release film and white breather cloth were layered over my tooling, all of which was covered with nylon bagging film.
Air hoses connected to an external vacuum pump suck out the air compressing the bag around the tooling. A vacuum gauge was used to ensure the bag was holding pressure and that there were no leaks.
A wedge was used to extract the now cured carbon fiber part from my tooling. Excess carbon fiber was trimmed off using an air cut-off tool before final assembly.