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Mikerw
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Group: Forum Members
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Hey guys, We have just designed and 3d printed a prototype of a brake duct we want to use but need to make it out of carbon. Now, i have no composite experience what so ever! So whats my first step? Or any one local to me (SG80NZ) fancy a challenge?   
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Lester Populaire
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Group: Forum Members
Posts: 311,
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+xHey guys, We have just designed and 3d printed a prototype of a brake duct we want to use but need to make it out of carbon. Now, i have no composite experience what so ever! So whats my first step? Or any one local to me (SG80NZ) fancy a challenge? Not too complex of a part. Prepreg would certainly be beneficial to get an even finish on the part, and will have a higher glass transition temp (generally speaking). What kind of temperatures will that thing see? If you persue it, i would print half the negative mould so you have a well defined split line, make the first half on the mould like this, rip off the printed half and laminate the second half of the mould. Check the easy composites youtube channel for details on mould making.
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Hojo
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If these are one-offs you could sand the A surface smooth, use a release agent on the printed part and laminate directly to make a carbon part. Really depends on what your expectation and volume are. Pretty simple part to do this way or make a mould
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Mikerw
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Group: Forum Members
Posts: 6,
Visits: 14
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+x+xHey guys, We have just designed and 3d printed a prototype of a brake duct we want to use but need to make it out of carbon. Now, i have no composite experience what so ever! So whats my first step? Or any one local to me (SG80NZ) fancy a challenge? Not too complex of a part. Prepreg would certainly be beneficial to get an even finish on the part, and will have a higher glass transition temp (generally speaking). What kind of temperatures will that thing see? If you persue it, i would print half the negative mould so you have a well defined split line, make the first half on the mould like this, rip off the printed half and laminate the second half of the mould. Check the easy composites youtube channel for details on mould making. We see temps of around 500' on the disc and 260' at the caliper. This runs pretty close to the disc but will have air flow through it for the most part, and hopefully our disc temps will be reduced significantly with nice ducting installed. Will check out the youtube channel! This is a skill that we could do with in the race shop!
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Mikerw
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Group: Forum Members
Posts: 6,
Visits: 14
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+xIf these are one-offs you could sand the A surface smooth, use a release agent on the printed part and laminate directly to make a carbon part. Really depends on what your expectation and volume are. Pretty simple part to do this way or make a mould Volumes are very low, currently need 2 units, although having spares might be a good idea! Is there any youtube vids showing what you mean?
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Lester Populaire
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Group: Forum Members
Posts: 311,
Visits: 13K
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+x+x+xHey guys, We have just designed and 3d printed a prototype of a brake duct we want to use but need to make it out of carbon. Now, i have no composite experience what so ever! So whats my first step? Or any one local to me (SG80NZ) fancy a challenge? Not too complex of a part. Prepreg would certainly be beneficial to get an even finish on the part, and will have a higher glass transition temp (generally speaking). What kind of temperatures will that thing see? If you persue it, i would print half the negative mould so you have a well defined split line, make the first half on the mould like this, rip off the printed half and laminate the second half of the mould. Check the easy composites youtube channel for details on mould making. We see temps of around 500' on the disc and 260' at the caliper. This runs pretty close to the disc but will have air flow through it for the most part, and hopefully our disc temps will be reduced significantly with nice ducting installed. Will check out the youtube channel! This is a skill that we could do with in the race shop! During use with loads of airflow is probably really not critical. However, bring the car to a stop after some laps and having the brake system heat soaking everything around it will certainly warp a resin with a tg of 60°C. The laminating on the 3d printed part will work well for this part, wasn't thinking of that. Even tho i just built a whole bike like this... Just make sure to use an appropriate high temp resin.
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f1rob
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Group: Forum Members
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If you only want a couple as others have said prob your 3D part down on the outside, seal an release an use that as your mould.
Mark your split line an laminate one half to the line
Cover a 25/ 30mm section of the carbon on the split line with ptfe tape.
Laminate the 2nd half of the component going 20mm onto the 1st laminate.
Would be easier if you printed a solid part as the one shown has to be through bagged
Use ltm110 an you will be able to give it a low enough cure to not affect the 3D
Strip parts from 3D an post cure then join with 9394 an you have a brake duct with a lovely smooth internal surface
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Mikerw
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Group: Forum Members
Posts: 6,
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+xIf you only want a couple as others have said prob your 3D part down on the outside, seal an release an use that as your mould. Mark your split line an laminate one half to the line Cover a 25/ 30mm section of the carbon on the split line with ptfe tape. Laminate the 2nd half of the component going 20mm onto the 1st laminate. Would be easier if you printed a solid part as the one shown has to be through bagged Use ltm110 an you will be able to give it a low enough cure to not affect the 3D Strip parts from 3D an post cure then join with 9394 an you have a brake duct with a lovely smooth internal surface All makes sense. The more i thing about it the more it makes sense to print the inner void shape and mould around that, then maybe do the flat flange as a separate piece and bond them together..?
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Lester Populaire
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Group: Forum Members
Posts: 311,
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+x+xIf you only want a couple as others have said prob your 3D part down on the outside, seal an release an use that as your mould. Mark your split line an laminate one half to the line Cover a 25/ 30mm section of the carbon on the split line with ptfe tape. Laminate the 2nd half of the component going 20mm onto the 1st laminate. Would be easier if you printed a solid part as the one shown has to be through bagged Use ltm110 an you will be able to give it a low enough cure to not affect the 3D Strip parts from 3D an post cure then join with 9394 an you have a brake duct with a lovely smooth internal surface All makes sense. The more i thing about it the more it makes sense to print the inner void shape and mould around that, then maybe do the flat flange as a separate piece and bond them together..? Nah print the void with a flat base, or stick it onto a flat board and laminate everything in one go!
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AlpineCoupe
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Group: Forum Members
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+x+xIf you only want a couple as others have said prob your 3D part down on the outside, seal an release an use that as your mould. Mark your split line an laminate one half to the line Cover a 25/ 30mm section of the carbon on the split line with ptfe tape. Laminate the 2nd half of the component going 20mm onto the 1st laminate. Would be easier if you printed a solid part as the one shown has to be through bagged Use ltm110 an you will be able to give it a low enough cure to not affect the 3D Strip parts from 3D an post cure then join with 9394 an you have a brake duct with a lovely smooth internal surface All makes sense. The more i thing about it the more it makes sense to print the inner void shape and mould around that, then maybe do the flat flange as a separate piece and bond them together..? I'm not sure how feasible it is for you to do this but I used expanding foam to fill the inside of a 3d printed part so I could use the foam as a mold. Your shape may not allow for that though in terms of getting a good release of the foam from the inside of your part. Just thought I would put the idea out there in case you can make it work.
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