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Pulaski Carbon Composites Fabrication Process

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.

 
 Rhino Model of Tooling

Rhino Model of Tooling

 CNC'd Foam Tooling

CNC'd Foam Tooling

 Tooling Prepped for Lay Up

Tooling Prepped for Lay Up

 
 

Kitting

Several plies of carbon fiber were carefully cut out in varying orientations to assemble a “kit”.

 
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Lay Up

Each ply of carbon fiber was laid into my tooling one by one while applying resin in between.

 
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Vacuum Bagging

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.

 
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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.

 
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Trimming

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.

 
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