Making a complicated carbon bicycle part.. help

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Making a complicated carbon bicycle part.. help

Making a complicated carbon bicycle part.. help

Author	Message
Mathiasg	M Mathiasg posted 5 Years Ago HOT Topic Details
M Group: Forum Members Posts: 1, Visits: 11	Hey guys! I am new to this forum! I’ve started working around with carbon 2 years ago but now I’m trying to make some more advanced parts. I would need some help or ideas on how to make the piece (linked bellow) in carbon. It needs to be really strong between the two red pods because the pods are the handle of the bike. I don’t really have a lot of experience in split moulding ect. But my idea was to 3D print the top and bottom half molds and bonding the two pieces afterward. Any ideas and tips would be gladly welcomed! https://imgur.com/gallery/XOuMkDd Mathiasg
	Reply Like 6
Lester Populaire	L Lester Populaire posted 5 Years Ago HOT Post Details
L Group: Forum Members Posts: 311, Visits: 13K	+x Mathiasg - 10/19/2020 6:03:38 PM Hey guys! I am new to this forum! I’ve started working around with carbon 2 years ago but now I’m trying to make some more advanced parts. I would need some help or ideas on how to make the piece (linked bellow) in carbon. It needs to be really strong between the two red pods because the pods are the handle of the bike. I don’t really have a lot of experience in split moulding ect. But my idea was to 3D print the top and bottom half molds and bonding the two pieces afterward. Any ideas and tips would be gladly welcomed! https://imgur.com/gallery/XOuMkDd Mathiasg So I just wanna make sure that you are aware of the risks involved here. If your bar snaps the first thing that hits the ground will be your face. and when you put the power down on an oval you will put some considerable stresses through that thing. furthermore the clamping area of the stem is super important and hard to get any meaningful results with just some calculations. A tapered aluminum sleeve in this area would be an elegant solution, but then you might run into some bonding issues. Anyway - here are some pictures of how i made a handlebar: FDM printed mandrels and first dummy mould halve to get the split line perfect assembled and sanded fillered prepping to laminate the mould Gel-coat Mould halves made in vacuum infusion. suuper chunky mould so it doesn't deform under pressure of the bladder inflation moulding handle bar made in bladder inflation moulding.
	Reply Like 6
Chris Rogers	C Chris Rogers posted 5 Years Ago HOT Post Details
C Group: Forum Members Posts: 120, Visits: 933	Lester that's a beautiful process and part! Is the whole part flax or is there some carbon hiding in there?
	Reply Like 5
Hanaldo	Hanaldo posted 5 Years Ago HOT Post Details
Group: Forum Members Posts: 2.5K, Visits: 28K	A lot more skill in that than the pictures can really show, love your work Lester.
	Reply Like 4
Lester Populaire	L Lester Populaire posted 5 Years Ago HOT Post Details
L Group: Forum Members Posts: 311, Visits: 13K	+x Chris Rogers - 10/23/2020 12:46:22 AM Lester that's a beautiful process and part! Is the whole part flax or is there some carbon hiding in there? This one is 100% flax but this perticular one was just to figure out the process and mostly to see if i can make a bladder inflation mould out of composites as i haven't seen that anywhere back when i made it. i was afraid of creep over time as the mould was pressurized for a long time during the curing of the prepregs. I am still planning on making a ride-able one which will most likely be a hybrid part, but i will make for the bike i am currently making so i need the frame first. was thinking about making a couple youtube videos as well to give some pointers to other guys. And thanks Hanaldo. Love your work too! Composites a really cool in the sense that it is really accessible and pretty much everyone can make cool stuff with minimal equipment if you are willing to put in the hours.
	Reply Like 4
Warren (Staff)	Warren (Staff) posted 5 Years Ago HOT Post Details
Group: Administrators Posts: 2.5K, Visits: 8.5K	I agree that it is really accessible and you don't need much experience either. Most people can experiment with some small parts and in choosing a process that works for them, very quickly start making some very good quality parts. Warren Penalver Easy Composites / Carbon Mods - Technical Support Assistant
	Reply Like 5
Fastskiguy	F Fastskiguy posted 5 Years Ago HOT Post Details
F Group: Forum Members Posts: 11, Visits: 18	+x Lester Populaire - 10/23/2020 6:29:05 AM +x Chris Rogers - 10/23/2020 12:46:22 AM Lester that's a beautiful process and part! Is the whole part flax or is there some carbon hiding in there? This one is 100% flax but this perticular one was just to figure out the process and mostly to see if i can make a bladder inflation mould out of composites as i haven't seen that anywhere back when i made it. i was afraid of creep over time as the mould was pressurized for a long time during the curing of the prepregs. I am still planning on making a ride-able one which will most likely be a hybrid part, but i will make for the bike i am currently making so i need the frame first. was thinking about making a couple youtube videos as well to give some pointers to other guys. And thanks Hanaldo. Love your work too! Composites a really cool in the sense that it is really accessible and pretty much everyone can make cool stuff with minimal equipment if you are willing to put in the hours. If you ever make those videos I'd love to see them, that is some really fine work there!
	Reply Like 5