Mould making - Dimensions?


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ThePharaoh415
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Hi, I have a few questions about making a mould. If I were to make a mould for a part that's supposed to be a cover for something else, for example, a motorcycle swingarm, I assume the dimensions in the mould would have to be bigger than the actual part, and if so, how much bigger?  How does one determine how many layers of carbon fiber should be used in the product?

Hanaldo
Hanaldo
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Have a look on YouTube for EC's latest tutorial about making an offset mould. 

For cosmetic parts, generally ~0.65-0.75mm is thick enough. If you are consolidating the layup with vacuum, that thickness is typically achieved with a single layer of a 200g woven carbon, and a single layer of a 450 or 650g woven carbon. Or you could do 3 layers of the 200g, etc. Basically the fibre weight corresponds pretty closely to the thickness is will add to the laminate, ie. a 200g fabric will add around 0.2mm, a 450g fabric will add around 0.4mm, a 650 around 0.6mm etc. 
MarkMK
MarkMK
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Just to add to Hanaldo's points...I regularly make one or two covers and the moulds were created using 1mm sheet wax over the original part

I tend to use two layers of 240g twill for the parts themselves, which gives sufficient structural integrity without feeling too flimsy, whilst not causing any fitment issues around some of the corners and edges. If the part to be covered has quite sharp angles and returns, you just need to be confident that you can achieve good consolidation of the chosen fabric into the mould corners so as not to hamper the fit of the cover.

If you prefer to use heavier backing fabrics, then you might need to take extra care to ensure that everything's tightly pressed into the corners to avoid unwanted bridging


Warren (Staff)
Warren (Staff)
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Yes sheet wax is great for this.  As mentioned above, we have recently released a tutorial showing just that technique.  You can find it here: Using Sheet Wax to Create Offset Moulds

In this video tutorial we explain why offset moulds are needed when making cover components and how to use sheet wax to create an offset mould. We then use our Epoxy Mould Making Starter Kit to make an offset fibreglass mould which in a follow-up tutorial we use to produce a carbon fibre frame protector/cover component.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
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