Carbon Fiber Construction: methods and contractors 1

[EngineerJoe]

Hi,
Hi,

I am looking at constructing a carbon fiber part that is essentially a 9"x12" sheet bent into a U shap. It need to have a strength comparable to a part made form 16 gauge sheet steel. I would most appreciate if some one could kindly point me to

- a description of process and technique for constructing carbon fiber composites, and
- a shop / contractor who can make small quanties of such things.

Thanks in advance.

 

[patprimmer]

Um
Um
Where are you?

I guess you want someone within 10,000 miles of your normal location

Regards
pat

 

[EngineerJoe]

Pat,

I am in San Diego, CA...

 

[patprimmer]

Some fabricators that supply FRP and carbon fibre composites to the aerospace industry, top end of the yachting, motor cycle aftermarket or autoracing industry should be equipted to make your product from sheet moulding compound.

I am based in Sydney Australia, so I have no first hand knowledge of fabricators on the USA west coast, however, there should be an abundance of these people on the USA west coast, especially in the LA region.

Any of the sheet moulding compound suppliers should be able to steer you in the right direction. I expect that suppliers of these compounds in your region might be CIBA, maybe DuPont, or Shell Chemical (or whatever they call themselves in your part of the world this week)

Google search's on sheet moulding compounds, carbon fibre composites, epoxy resin suppliers and polyester resin suppliers should at least identify someone who can at least give you some advice from first hand experience on a competent local fabricator.



Regards
pat

 

[EngineerJoe]

Pat, thanks for the advice. In addition, do you know of any step by step guide for constructing a simple carbon fiber part (say a flat sheet)?

 

[patprimmer]

It's probably over 15 years since I was involved in the high tech fibre industry, but I think that nowadays, you can buy carbon fibre composite sheet as a finishede sheet or as a sheet moulding compound, where it is already layed up with the resin (called a prepreg). you then form it and cure it in an oven.

You can form it in a number of ways
1) By laying it over a mould made from whatever is convenient, durable enough for yor purposes and will withstand the cure temperatures, including the exotherm
2) Similar to above, but with a properly made mould (read much more expensive) which has a solid border where you can lay the prepreg, then lay a cover over it, seal the edges to the mould, then you evacuate the air and the outside air pressure holds the cover to the mould.
3) Similar to above, but place the mould and prepreg into a bag, and evacuate the bag.

You need to cure the resin and you need to be sure that cover, bag and mould materials will withstand the temperaturs involved.

I am sure the resin and fibre and prepreg manufacturers will have current documentation, which will be more accurate and relevant than my long term memory.

I should have remembered this before. Try a google search under Prepreg


Regards
pat

 

[EngineerJoe]

Pat, Thanks for the info.