Intake plenum

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bytesandbolts	b bytesandbolts posted 7 Years Ago HOT Topic Details
b Group: Forum Members Posts: 2, Visits: 18	I'm looking for some general advice on making an intake plenum to suit a low boost turbo engine (7 PSI) out of carbon fiber using vacuum infusion, utilising my 3D printer to create the mould. This would be the first carbon fibre part that I've made, based on a design drawn up in Autodesk Fusion 360 shown below. So far I've spent a few days doing research online, reading other posts in this forum relating to intake manifolds and 3D printing moulds and watched numerous videos on producing carbon fibre parts. However I still have a few open points I'd like to get peoples opinion on. Based on the plenum shape I'm assuming I would create a positive mould. Should I use tooling gel or something like 3M Super 77 sparingly to ensure the CF attaches to the shape. Does this sound right to create a 3D printed mould; use PLA filament, smooth down the edges, spray a few coats of plastic filler primer and seal with S120 mould sealer. For the 4 bolt end flange I'm guessing this can't really be formed using CF. Instead could I go about inserting an aluminium flange that could form part of the mould and be covered in CF. Would this hold up under boost? Layer up wall thickness to be around 2mm, from what I've read this would be strong enough. I'm happy to post pics as I go a long, I'm currently doing prototype prints of the mould.
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bytesandbolts	b bytesandbolts posted 7 Years Ago HOT Post Details
b Group: Forum Members Posts: 2, Visits: 18	+x oekmont - 5/28/2018 11:10:50 AM -Are you sure, that you are able to get a positive mould out of the part? If so, a positive mould would be a good option. But resin infusion might be tricky either way. Possible, but no beginner part. -tooling gel definitely not, spray tack might be very helpful -i don't know if the mould sealer works on top of primer. You should use 2 component primer, as the one component stuff causes many problems while demoulding. -why that. I see no reason this can't be made out of crp. ideally in one piece with the rest, by attaching a removable plate at the end of your positive mould. This might make infusion even harder. -for low positive pressure, this should be enough. - Just to confirm my understanding, positive mould being layering on top versus into the mould correct. This prototype print is what a mould could look like, and I would be layering on the CF on top if I've understood the process correctly. - Please could you suggest a suitable spray tack if that's different to 3M Super 77. - I'll have to do a bit more research on the priming/sealing stage by the sounds of things. - I'm not sure I understood by what you meant using a removable piece. Would doing a wet layup with vacuum bagging perhaps be a preferable process for a newbie?
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