By Nerd Lab - 8/3/2018 4:46:23 AM
We are casting a complex part with a lot of sharp and opposing angles, which has proven to be extremely difficult to accomplish with a single sheet layup. While we did close in on the goal, the method proved to be unsound. Changing methods, the best results have come from approaching the layup with multiple carbon fiber pieces. This required a lot of precise cuts and matching of weave, as you might imagine. The problem now is that we get stray, quite noticeable, carbon fiber 'fragments' in our parts. My question is to know if there is a way to apply some type of temporary backing to a section of non-prepreg roll which would keep the weave intact to allow me to cut and lay out the shapes I need and reduce stray fragments, then being able to peel off the backing upon layup.
There is one YouTube video of an Aussie showing how to apply a mix of PVA/H2O and thin 'paper' which dried as a backing which you can then peel off in layup. That didn't work for us. Is prepreg the only answer? I would also think that since we're spraying clear gel coat in the mold before layup, any PVA would ruin the bond between the resin and gel coat. Is there a resin soluble product that we could bond the carbon fiber and paper with? We also use spray adhesive to keep a couple of key parts in place which claims to dissolve in resin but that seems to risky.
The templates in the picture attached are a few of the shapes that we need perfect.
Thanks for any help,
Sr. Nerd Lab  Technician
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By Nerd Lab - 8/4/2018 5:36:48 PM
Thank you for the ideas and feedback. I'm going to put in an order for a few test yards of the web lock and the ProFinish, assuming that they have that in 11X11 to match up with the weave used by Tesla.
The spray adhesive method worked out rather well when it came to using a scalpel for some of the shapes but the real test will be when I lay up some parts next week.
Thanks again all.
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