Resin infusion of a double sided chair

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Resin infusion of a double sided chair - issues with one side

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deagrateful	deagrateful posted 11 Years Ago HOT Topic Details
Group: Forum Members Posts: 11, Visits: 96	Hi guys, I'm a furniture designer and after doing a few infusions (and then doing a great 3 day course @ easy composites) I'm absolutely hooked on composites. The possibilities in my field are endless and are barely being touched upon. I'm currently working on a chair design which is a continuous curve and is usable in two different seating positions (reclined and social). The pattern (plug?) is made and all polished up ready for an infusion and I have an exact 1:6 scale replica for which I've been using to create the test models. I'm having issues with achieving a decent surface quality on the outside face. I should mention that the final finish I am after on the outside face is the textured matt surface that peel ply leaves. This means that sanding isn't an option. The inside face is glossy. All layers are securely tacked into place with epoxy spray adhesive. The first test had the following layers (working from the inside out): pattern surface > 3 layers of 200gsm 2/2 twill carbon > peel ply > easy flow mesh > vac bag This resulted in a thickness of 0.7mm. The inside face was perfect and the outside was a little bumpy. The second test was closer to the final desired thickness of 5mm and had the following players (from inside out again) pattern surface > 1 x 200gsm 2/2 carbon > 1 x 650 gsm 2/2 carbon > 1 x 2mm lantor soric > 2 x 200gsm 2/2 carbon > peel ply (for finish effect) > vac bag This resulted in a thickness of 3.5mm. The inside face was again perfect but the outside had a very undulated finish with light bunching. The infusion spiral and connectors left deep marks but on the actual pattern this won't be a problem as I have included wide flanges and they will be placed to the sides. This finish isn't even good enough for sanding and then skinning over with a light weave... I can replace the Lantor Soric with a few layers of 650gms carbon which should give me a slightly better finish I guess... But this would reintroduce infusion mesh and would leave different marks. So my question is how can I get a nice level and flat peel ply finish on the outside face? I'm pretty much up for trying anything at this point! If this isn't at all possible, what other options do I have? (an outside gloss face wouldn't be durable enough for a chair). Any help would be extremely appreciated as I'm tearing my hair out at the moment! Pics below: chair test pics Tags infusion two smooth faces
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deagrateful	deagrateful posted 11 Years Ago HOT Post Details
Group: Forum Members Posts: 11, Visits: 96	Thanks for taking the time out to help me with this guys, your advice is absolutely invaluable. The sanding back and then re laying up with peel ply is something that hadn't crossed my mind and could work really well (it certainly takes away a little bit of the pressure of having to achieve a 100% layup in one shot). @ FLD: Both layups were infused the same way and the test without the Soric didn't collapse (the pipes didn't indent the piece) so you may well be on to something here. I think I may forgo the Soric in favour of a few thicker layers of carbon f. Nice idea about the textured seating area! Could you recommend a decent non scratch lacquer? @ Wozza: Forgive me for being a dunce , but how would I go about ensuring that the infusion is not so resin rich. I think my fears of pin holes may have meant that I clamped off the resin line to long after the vacuum line. Is it easier to accidentally over infuse when using a core such as Soric? I'm glad the design seems to have gone down well, I can keep the forum updated with progress shots if anyone is interested? Edited 11 Years Ago by deagrateful
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Resin infusion of a double sided chair - issues with one side

deagrateful - 11 Years Ago

Firstly - awesome design, I love it! The problem you are having is creases / uneveness in the peel...

FLD - 11 Years Ago

Missed this, nice design ;) as FLD mentioned, some are creased from the peelply, others to me look...

ChrisR - 11 Years Ago

Have to agree, looks like it's way too resin rich. So much so that the bag has gone very slack. That...

wozza - 11 Years Ago

Thanks for taking the time out to help me with this guys, your advice is absolutely invaluable....

deagrateful - 11 Years Ago

No apologies needed its all part of the learning curve :) not an easy part for your first go. Soric...

wozza - 11 Years Ago

Hi Warren, that all makes sense, I hadn't realised that it was possible to over infuse by that much...

deagrateful - 11 Years Ago

My favourite thing about infusion is its possible to very accurately calculate your resin...

Hanaldo - 11 Years Ago

Did quite a bit of head scratching over this last night so please excuse the long reply :) I would...

wozza - 11 Years Ago

Warren, luckily I have already made the full size pattern oversized on the width (by about 70mm) so...

deagrateful - 11 Years Ago

[quote][b]deagrateful (17/10/2014)[/b][hr]Warren, luckily I have already made the full size pattern...

wozza - 11 Years Ago

Sorry not the best of pictures but hopefully gives an idea of soda blasting. Warren

wozza - 11 Years Ago

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Resin infusion of a double sided chair - issues with one side

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