Filling voids advice - like Bugatti


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ant...
ant...
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So I've been working on producing a carbon fibre coffee cup for many years, I want it to be perfect and its almost there.  For the past 2 years I've had the project on the back burner having spent many thousands on equipment and tests.  But last week watching the How Its Made featuring the Bugatti Veyron, I saw how their carbon nose cone always comes out with voids in tights places and that these areas were repaired to produce a flawless finish.  That made me think my process might be good enough and I can finish my cup with a few repairs.

These images show how my cup is one solid piece but the outside is always susceptible to tiny bubbles or sometimes voids, the inside is almost always perfect.  

My Process - The alloy mould is secured in a vacuum chamber while infusion resin is pumped from the mixing container into the mould from its base, this enables the cup to be one piece with all smooth sides and the vacuum chamber limits bubbles & voids.  My next test will include curling the mould in a high pressure oven maybe 100psi (pressure cooker LOL).  But I've tried loads of ways to get a 100% perfect result and id become disappointed until I saw the Bugatti repair process.
With a little help I mights just get a finished mug...

Question - Can these voids be filled?  any suggestions?  

Im guessing sand the holes back to remove any release agent, maybe with some acetone and fill with a syringe of general epoxy.  then rub it back to a perfect round finish.


http://www.talkcomposites.com/Uploads/Images/1325fe1e-b6ed-43f5-a978-b7bc.JPG http://www.talkcomposites.com/Uploads/Images/b19d8eb0-a52c-4d6e-8bfd-e10a.JPG http://www.talkcomposites.com/Uploads/Images/8b8a7c94-3f7d-46e3-a3e3-c511.JPGBTW this big hole is drilled to practice fitting the carbon handle.
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Matthieu Libeert
Matthieu Libeert
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I follow ChrisR on this one... pouring hot beverages in an epoxy cup isn't always a good thing...if not postcured, put your cup in the oven at 80°C, remove it and you'll see you'll be able to bend it. It will also feel sticky and have some smell...proper postcure is the least you can do, use a high thermal resin is even better. 
Seems like a good project though! but I would never buy something like that for safety reasons... the solution with an insert would solve everything.

Best of luck! 

OT: you could try to use the GC50 gelcoat maybe with a needle?! 

Matthieu Libeert
Founder MAT2 Composites X Sports
website:
www.mat2composites.com




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