CF Aeroshell
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Using resin infusion, my team & I made a 9' carbon fiber aeroshell in-house.
For only $601.
and it weighs <3kg, perfect for a hyperloop pod
We used resin infusion & a 0.25" foam core
How'd we do it?
EPS Foam
CNC a negative into a huge EPS foam block (very cheap)
Prep
2. Cover foam in bondo & primer, sand to 2000 grid, then add release wax
Layup
3. Add carbon fiber ply's & a foam core in the center. Use spray tack to keep in contours
Infusion
4. Infusion layers:
peel ply
mesh
vacuum bag
resin tubes
Description:
What did I work on:
Biggest challenges:
What would I do different next time:
EPS Foam
Applying Bondo, Primer, & Wax
Layup
4 plys of 2x2 twill weave (same orientation)
foam core to add rigidity to the flat surfaces
Peel ply for release, mesh layer to let resin distribute
The mold was porous, so we had to bag the entire block
Bag sealed to mold
Around entire mold
Infusion
Resin was mixed & offgassed
Inlet at one end, vaccum pump at the other
Raw Composite
Yes, it was pain in the ass easy to get the part out of the mold
Trimming & Adding mounts
Completion!
Misc
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