This suggest that it was made in single process

Yes, of course
To get an idea of how many layers I need for building a wing I start to cut many layers and laying them in the mould. The different shape is choose in order to fit at the wing's profile, more material in the centre, less in the leading and trailing edge. When the mold was full i try to close. I added layers until the two shells needed  some pressure to close. (as I said it is an empirical method)

You mean full like this

Yes, the size is too small to make it hollow, you need the maximum rigidity available.





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I am a little bit confused - here you are opening mould with wing and right before you were presenting stack of prepared layers of different size. This suggest that it was made in single process. i guess that it requires specific amount of material to be put inside.
Making it from two separate parts (infusion?) would require such precise dosing of material. (wing form two halves might be hollow inside?)


You mean full like this

or more like this

but fully hollow?

HI All,

Can you tell something more about molds you are making? From which material do you make those green molds?

Hi, the molds were made with       https://www.easycomposites.co.uk/epoxy-tooling-gel-coat
I think it's easy and smart material for the mould surface. The thickness and the strenght of the mold is given by several layer of glass fiber (chopped and some woven scrap) and epoxy resin. Fot the TBar's moluld I add also some wood.

When you are molding elements (wings) from solid carbon, how are you calculating amount of carbon to be put inside

It's a little bit empirical, in other experiences, I noted how many layers (and their weight/m2) I used and the thickness reached for planar objects.

Did you think about making wing from two separates parts 

It's what I do

and then glueing them together?

In my opinion isn't enough, You have to join also with a fabrics.

Does your mast have wooden core, or it is also solid carbon?

It's full carbon, various pattern and some Hight moulus.






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Can you tell something more about molds you are making? From which material do you make those green molds?
When you are molding elements (wings) from solid carbon, how are you calculating amount of carbon to be put inside (if you put too much it will loose shape? if to few, it will loose strength?)? Did you think about making wing from two separates parts (infusion) and then glueing them together?
Does your mast have wooden core, or it is also solid carbon?

Your video shows you pouring what looks like a resin over the board, and then cuts to you peeling off a film. If this is as easy as it looks, I want in!                                                     

Thanks,

It isn't so easy but it take only some triks and a lot of patience.

You finish the surface with peel ply in order to hawe a rough but flat surface. After that you put some resin (the same you are using for the project) and cover with a film. You can use a HDPE film (High Density Polyethylene ) for curved surfaces, or a 0,20 mm thickness PET sheet (Plyethylene terephthalate). I used HDPE for te top of the board and PET for the bottom. The PET as a surface more shiny than HDPE but need a small amount of wax.
You put everithing in a vacuum bag, be carefully that the bag didn't generate some fold. Now starts an orrible work..... you start from the center of your piece and push trought the bag the excess of resin and EVERY bubble..  You can use a small plastic plate.
It's seems stupid but, , if it is well done (you need some experience), the results are ok (I think that in the video you can appreciate the surfaces). This method didn't work if you have complex surfaces.







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Magnificent as ever. You've got a knack for making videos let alone carbon parts! 

A two new video, the first for those who like the construction process



and the second just  to have an idea of how it works. Hawe a good fun








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awesome as always.
 

The new wing is finished. Now everything is ready for the test ... just missing the wind








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