[s1900ahon]

Originally Posted by Bryce Paputa

On the most recent iteration we had a flat core (either 1/8th or 1/4th, don't know where we got it from) that we did one big lay up on. Not completely sure on the foam type, but it looks pretty similar to http://www.aircraftspruce.com/catalo.../lastafoam.php.

Thanks.

We've had good success using HDPE for a mold material and directly CNCing the mold shape (we have a router-based gantry-style CNC). Then doing a layup of carbon x3, peel ply, perforation film, breather/bleeder, and vacuum bag. After curing, the next night we did a second layup of core (1/4 nomex honeycomb), 3x carbon, etc. A carbon part in 3 days was the most efficient recipe we've developed or executed.

This recipe could be adapted to cut foam opposite to the mold, adjusting to the thickness of the first layup.

Scott