By AlpineCoupe - 11/8/2019 3:07:30 PM
Hi all - I'm new to the composite world. I have made a couple of small parts but am still learning a lot. The question I have is how to lay out the fabric on a brake duct I am going to be making.
I am struggling to determine if I should lay out the carbon fiber as shown in the picture below - essentially 5 separate pieces, as indicated by the different colored outlines. Or attempt to find a way to wrap the shape in fewer separate pieces. 
The piece will just be directing airflow so it will not see large loads so strength is not the utmost concern, I just want to make a solid part.
Thanks in advance for the help!
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By Warren (Staff) - 1/29/2021 9:24:55 AM
If you use a loose fabric you may be able to use one piece. Many a year ago when I first started here, one of my initial tasks was to make a similar shaped NACA duct in pre-preg. Our expert laminators would do it in a single piece of pre-preg with the join on the back edge. Took a bit of practice to achieve a good result. Obviously you have the tack of pre-preg to help hold it, but a raw fabric has a lot more flex than a pre-preg. If you struggled you could use the lightest of dusting of a spray tack but the more you use the more the surface will need finishing.
Certainly in more than one piece you should be fine.
As Hanaldo says, top down would be easiest. From your picture you have a big flange so plenty of room to make a decent resin break.
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