Machining the carbon fiber plates, as I have already told in a previous post, you can have many different applications, especially because the tremendous advantage of this material stiffness, and low weight. Not its cost, which unfortunately is quite high. But thanks to my wife, I came up with a way to lower the cost of producing carbon fiber plates:
For some time, I have stored an amount of a little peculiar stuff I have not been able to use so far. It is a reinforcement for floor construction, some sheets of unidirectional carbon fiber and laminate layers and curing and protection Peel Ply. In the picture you can see that they come in a form of sheets of carbon rolled 50m long, with a section of 50×1, 5mm
Specifications are in this Link
Visually are rigid plates, which can be broken by hand if we force perpendicular to the fibers, but if we try to break in the fiber direction, is virtually impossible. Are used to paste on the ceilings, and entire buildings reinforce …
As we came up to take advantage of these sheets to put them next to each other and form a surface. To be unidirectional, you should use two layers, but orienting perpendicularly, we have a high stiffness in two directions, which is basically what we have with the braided carbon fiber fabric, + -45 °. After adding a layer of normal carbon cloth above and below the package, we will have a theoretically rigid plate and finished with a very nice aesthetic fiber carbon.
At least this is the theory. Let’s see what happens in reality:
First of all this is that I rolled mbrace I commented:
I’ve got two boards of wood, mold I will use, which will apply the resin, and will copy us so flat and smooth our carbon plate surface. Of course you have to apply good industrial mold release layer. While dry, I proceed to cut the sheets into strips Mbrace so as to cover the carbon surface I want to do:
First a layer, then the other. In this image still has the Peel Ply layer of protection, which of course must be removed before applying the resin. Short blades so as to cover the surface you want to do, at an angle of 45 °. Do this just another layer oriented at -45 °
also cut the two cloths, top and bottom, the corresponding meassure:
Unfortunately, I was not much resin at home, just 75 gr, I do not know if it will be enough, so I’ll have to ration it properly, running the risk that it is not quite right. First layer of resin soaked fiber:
Then put the sheets that I cut the Peel Ply taking away, of course, and extending well the resin:
Then another layer after forming -45 º, and finally the carbon cloth. Then put the melamine board top, I press hard:
The more torque, more pressure, and more resin retire, more compacted and better all remain the plate, so I put up all the weight I can.
The next day, with the cured resin, time demolding: obviously it has been very easy and this is the result.
I must say that it was a first test, and was just a little short of resin, so unfortunately I have left some areas without soaking well. Aesthetically it’s not valid, but structurally, it has been made a real brick:
I do not know if the detail is well appreciated, but I comment my impressions:
Once clean, trimmed the excess, a rectangle of 3.7 +-0.1mm thick, is extremely rigid. I tried to flex in all directions, even twist, and I assure you that by hand, making all the strength I could, I can not bend practically nothing. Structurally behaves like a solid carbon plate should behave. Knowing the direction of the threads I’ve put, knowing this place it would be interesting to take advantage of maximum strength directions.
Aesthetically, except that it had little resin, due to the surface pressure has been very good. Matte finish, but pretty polished. Overall the piece does not need further sanding for mounting on a chassis, just put it in the cutter and cut the geometry we want.
After this experience, I just happen like 5 or 6 areas for improvement that can manufacture these plates much more efficient. But as first experience, I’ll sooo happy.
But … Why is it useful? In another post I have been discussing what to do with the cutting of carbon fiber, and as plates can be obtained very interesting pieces in carbon fiber, both structural function (car chassis Rc, aircraft carriers for motorcycle etc …) as aesthetic function (pendants, ornaments, keychains, etc. ..). The main advantage of this method is to take advantage of the item you thought you could not take anything, and having it there in the end does something. As a rough estimate:
To make a 1m2 carbon plate, 4mm thick, you need the following:
- Overall, three layers of carbon of a weight of 300 (most common) make a thickness of 1mm, so we would need 12 layers of carbon 1m2
- To paste all these layers about 125gr Epoxy resin needed
With this process, the 10 layers and replaced it with material that I have, so I get cheaper and less laborious, of course.
As you will upload here more forward progress.