Hand Laminate & Vacuum Bag a Simple Carbon Fibre Part (inc. Vacuum Cleaner method!)

Summary

In this tutorial, Paul from Easy Composites demonstrates how to produce a carbon fibre frame protector using a wet layup and vacuum bagging process. He walks through the preparation of materials, the mould release process, and the application of carbon fibre layers. Paul explains how to use both professional-grade and household equipment for vacuum bagging, offering insights into achieving excellent results with minimal resources. The video highlights various reinforcement options and emphasizes the versatility of wet layup for creating high-quality composite parts, making it an accessible process for beginners and enthusiasts alike.

Takeaways

• 😀 Wet layup and vacuum bagging processes are accessible and effective methods for producing high-quality composite parts.
• 😀 Mould preparation is essential for a successful wet layup; proper use of Mould Release Wax ensures smooth de-moulding.
• 😀 The Laminating Starter Kit includes all necessary materials for wet layup, such as carbon fibre, resin, and tools for mixing.
• 😀 A vacuum bag is prepared larger than the part itself, using sealant tape and ensuring no creases for proper sealing.
• 😀 Resin mixing must be done thoroughly to avoid air bubbles and ensure accurate ratio and curing.
• 😀 The first layer of reinforcement should be applied carefully to avoid cosmetic imperfections, and the resin should be worked through the fabric using stippling techniques.
• 😀 Repeat the resin application and layering process for each subsequent ply, ensuring proper tack down and consolidation of the fabric.
• 😀 Vacuum bagging enhances the wet layup process by applying even pressure and removing excess resin, resulting in a cleaner finish.
• 😀 Using a peel ply and breather layer during vacuum bagging ensures a clean, smooth surface and helps with bonding.
• 😀 Even with household tools like a vacuum cleaner, excellent results can be achieved using the vacuum bagging method, making it accessible for beginners.
• 😀 The final surface finish may have minor imperfections, but the result is still highly satisfactory, and a clear coat can be applied for perfection.

Q & A

What is the main focus of this tutorial video?

The video focuses on demonstrating how to use the wet layup and vacuum bagging process to create a carbon fibre frame protector.

What materials and equipment are required for the wet layup process?

The materials include carbon fibre, resin, mixing tools, gloves, brushes, peel ply, breather, and vacuum bagging film. The equipment includes a vacuum pump and regulator, digital scales for weighing the resin, composite shears for cutting materials, and a vacuum cleaner for smaller projects.

What is the purpose of applying Mould Release Wax in this process?

Mould Release Wax is applied to the mould to create a thin, protective film that helps in easily removing the cured part from the mould after the layup process.

How does the resin mix ratio impact the final result?

The resin mix ratio must be followed accurately to ensure proper curing. An incorrect ratio could lead to poor bonding or insufficient curing, affecting the overall strength and appearance of the composite part.

What is the significance of the first layer of reinforcement in the wet layup process?

The first layer of reinforcement is crucial as it is the cosmetic layer that will be visible in the final product. It's essential to apply it carefully to avoid trapping loose fibres, which could lead to cosmetic imperfections.

Why is stippling used instead of traditional brush strokes during the laminating process?

Stippling is used to gently press and consolidate the resin into the fabric, avoiding the disturbance of the weave. Brush strokes could shift the fabric, while stippling ensures a smooth and controlled application.

How does vacuum bagging enhance the wet layup process?

Vacuum bagging improves the wet layup process by removing excess air and resin, ensuring an even distribution of resin and reducing voids or imperfections in the final laminate. It also helps apply uniform pressure during the curing process.

What are the differences between using professional vacuum equipment and a household vacuum cleaner for vacuum bagging?

Professional vacuum equipment provides a more precise and controlled vacuum level, usually around 20%. Household vacuum cleaners can also achieve a similar 20% vacuum, making them a viable, cost-effective option for small projects without the need for professional equipment.

What are some of the potential challenges when using vacuum bagging with a domestic vacuum cleaner?

One challenge when using a domestic vacuum cleaner is ensuring that the vacuum bag is properly sealed and that the vacuum level is consistent. Additionally, it may be harder to maintain a low vacuum level without the use of a regulator.

What alternative materials can be used in the wet layup process, besides the standard carbon fibre?

Alternative materials like carbon/Kevlar hybrids, blue carbon hybrids, and carbon fibre spread tow can be used in the wet layup process. These materials offer different aesthetic and performance properties.