How do I ensure aluminium honeycomb is bonded to fabric for composite sandwich ?

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How do I ensure aluminium honeycomb is bonded to fabric for composite sandwich ?

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downforce	downforce posted 13 Years Ago HOT Topic Details
Group: Awaiting Activation Posts: 6, Visits: 23	Hi If I want to create a decent thickness solid composite sandwich panel to use as a caravan side panel (sort of) and I need to construct the components like the sides, top, floor, front and back I am considering using aluminium or solid core with a combination of CF/Glass and Kevlar for strength and impact combination - possibly with ply on the inside to bolt things to internally. I have a couple of specific questions; 1) I cant find anywhere that explains how to create an Aluminium core composite and how to bond the core to the fabric and if it can be infusion formed. 2) If I am going to construct a big 3D construction, how do I choose the right sandwich components for a good combination of rigidity and flexibility and ease of production - I am thinking about silver glass (or 2x2 CF) on the outside with 2x kevlar layers around aluminium or foam core ? 3) If I find the right combination of sandwich materials and create a side panel and a roof panel how do I join the two - I understand the different techniques but just want to choose the right combination of epoxy, bolts, extrusion etc. - I don't want to just bond the two together and find the roof peels off on the motorway! What particularly concerns me 4) It occurred to me that I could build a box-ally frame and then I would have a solid base, for example to bolt a spare wheel to. Then I thought should I try and build a frame into the composite shell or just both the sell to the frame or is having a frame overkill. Thanks DF Tags Aluminium Honeycomb Bonding Chassis Rigidity
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