Making your own composite parts: looking for tips

[tcj103]

Originally Posted by Gdeaver

...If those mid temp prepegs came from there then they are probably of a grade and quality that are not available to all teams in small quantities...

...Another thing about aerospace prepegs that you should be aware of is that there may be additives in the prepeg that are very toxic in the uncured state....

Without going into detail, the material is somewhat custom, but not the chemical makeup of the epoxy or the fiber size/density/layup. I believe the only thing "custom" about this stuff is the type of roll it comes on, for the machine it goes into. MSDS data has also been checked, this is your basic epoxy; avoid skin contact when uncured; vapors are not a big concern (use ventilation) and wash hands with soap and water if you do get it on your skin.

So the equivalent material is available on the open market, just in a different width form, which for the finished product, is moot. For the cost accounting, we'll cross that bridge when we get to it.

Even if it ends up not being allowed, the students are learning how advanced materials are made, and that's worth the effort!

BTW: While I'm not an expert in composites manufacturing, I did do the 2 week course at Abaris training, in Reno, NV, for aircraft composite manufacturing and repair, so I guess I know enough to be dangerous! We covered wet lay-up, prepreg, vacuum bagging, and repair of honeycomb and foam core structures.

My original question was looking for cheap core material; I think I found it in Polyisocyanurate Foam, which is used for aicraft core material, but luckily is also a nice building insulation material sold at Lowes, in 8'X4' sheets, at about $13 per sheet in 5/8" thickness. It seemed to handle the toaster oven test at 300 deg F. Dow brand Super Tuff-R. Just peel off the foil insulation first.

[RyanN]

Team Fusion has used composite material in 2005 and 2007 for the electrical board, the ramps last year, and armor in 2005 (we had a bulletproof robot). We get our composite material from a local company that one of our student's dad work for. We have had good experience with carbon fiber and fiberglass with a balsa wood core. As to make it, I'm not really sure. I know you need resin, heat, and a vacuum bag to suck the air out.