Continuo con el proceso de fabricación. Aunque no tiene que ver con el mecanizado CNC, aun así lo veo interesante, de cara a ver el proceso de fabricación de una pieza en fibra de carbono, desde la concepción en el ordenador hasta la ultima capa de laca y acabado definitivo. Y en ello estoy:
Tal y como quedo la ultima entrada, el «Máster» o modelo 1:1 de la superficie final ya esta listo para trabajar con el. Así que se empieza por masillar los desperfectos del enganchón, y ya de paso redondear las esquinas del modelo, de esta forma, cuando vaya a aplicar la fibra, sera mucho mas sencillo que coja la forma y no se venza por si misma.
Ahora viene lo importante. Hay que dejar que el gel coat catalice un poco. y empiece a ponerse duro. De esta forma, en cuanto apliquemos la resina, no arrastraremos el gel coat, porque ya estará casi duro, pero no hay que dejar que endurezca del todo, con una media hora es suficiente. Así que ya se puede empezar, resina, y fibra de vidrio MAT, la de los pelos, hasta que digamos basta. Yo calculo que cada dos capas hace un milímetro, y para que el molde tenga rigidez, por lo menos 3 o 4 mm harán falta. También he aprovechado para aplicar mas fibra en las zonas donde mas se puede necesitar, en las esquinas, o los bordes
I continue with the fabrication process. Even though this has no relation with CNC machining, I see this interesting, in order to see how a carbon fiber part is done, from the idea to the last laminate layer and finish. And I’m on it:
Once the model is finished as you can see in the last post, the Master, or 1:1 model of the final shape, it’s ready to work with. So I will start by putty the defects, and round the corners of the model, in this way, when you go to apply the fiber will be much easier to take the form
Not much to explain here, is perhaps one of the most tedious tasks, sanding and sanding and putty defect. The better the putty is applied, there is less sanding. First give the shape, removing material with a 40 grit or 60, removing excess, and giving a general way.
Then apply finer sandpaper, followed with a 180, for example, until you remove scratches from the previous grit, and so what you’re left with the smoother surface possible.
The next step, one of the most important, is the application of the release. I’ve used that can see in the picture, so generous. The instructions advise least 3 layers, allowing to dry between them. I applied at least 7. I do not want to risk.
After applying the release agent, you can start rolling the mold. I advise having absolutely ALL the material at hand, and ready to apply. It is important to forecast all the tools that are to be used, and mentally review the process steps to avoid haste and poorly made.
You had it all ready, so we continue with the process: First, apply Gel Coat. It is an epoxy based paint is ideal for copying the surface, and with very good grip to the resin and fiber. So generate a surface where later apply the carbon fiber will be tough and durable, and copied to the last detail. With a brush and carefully apply a generous layer
Now comes the important thing. You have to let the gel coat catalyzes a little. And starts to get hard. Thus, as we apply the resin and not drag the gel coat, because almost be hard, but do not let it harden completely, with a half hour is enough. So now you can start, resin, and fiberglass MAT, the hairs, until we say enough. I estimate that every two layers makes a millimeter, and the die has stiffness, at least 3 or 4 mm will be needed. I’ve also taken to implement more fiber in areas where you may need more in the corners or edges
This is the final result, we now have to wait for the resin to cure.
Once cured, must demolding, which always makes me a little nervous … I will have well-defined surfaces out? will have applied the release agent right? the response has been positive, as it has unmolding the first and almost in one fell swoop:
As seen in the images, the result is magnificent. This mold is perfect, and has gone very stiff. You will not have deformation or by time or by weakness. Obviously, the images already clean, but you have to take the radial and review all sides, and sand the surface to not hurt, as the stiff fibers are like knives.
In the next post, the piece of carbon fiber …