How to make carbon fiber octogonal pipe


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macbar
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Hi
I need to make 50 cm long carbon fiber octagonal pipe 50mm flat-flat with wall thickness of 2mm, outside surface quality is important. Im looking for ideas how to make it. Currently the best solution i came with is to do vertical vacuum infusion with heat formed pvc pipe as outside mold. If you have any ideas, guidance please share.
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Chris Rogers
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It all depends on what you mean by 'outside surface finish is important' - MDF can get you shiny provided you want to do a little painting after.  MDF will not have nearly the dimensional perfection of aluminum either - but it will totally work if you seal it well with epoxy and use a good release system over primer - or a surface film (like PTFE film) for release.

If you're trying to do this cheap and tolerance and strength aren't super critical, you could probably do fine with a bagged wet-layup in MDF molds - things would be tight doing the layup though!  You could even make the molds by hand with a table-saw and some body filler.  It all depends on how good you need it. 

Infusion would be an option but 500mm is a bit far to infuse and it's more trouble.  Infusing across the tube would be fine if you design-in a thicker split-line for the two outermost plies of carbon to turn out and act as resin flow media and vacuum outlet.  This would be easier and less risky than end-to-end but there is a small cosmetic penalty.  Everybody is suggesting pre-preg because for something this small it is much easier to control and keep tidy.

 What type of laminate are you after?  Would a 60% uni in the 0-direction and the rest +/-45 and one woven surface ply work? 

Like: (from the outside)
200g at 0/90
300g uni at 0
300g uni at 0
200g at +/-45
300g uni at 0
200g at +/-45
300g uni at 0
200g at +/-45

This would be easy enough to wet-lay with the +/- 45's lapped - or laid out in one long staggered stack the full circumference of the tube and rolled around the internal bag.  It might be messy with wet-layup but you could also use braided sleeve for the +/- plies.  

Two pieces is tough - too bad you can't buy it somewhere.  Hexagonal would be an off the shelf thing but I've never seen octagonal!

The problem is that once you go down the short-cut road you'll never get anything as nice as pre-preg in Steve's aluminum mold - but it'll take more time and probably cost almost the same money in the end.  Wood CNCs can cut aluminum if you do it right - and machine shops could whip this out pretty fast.  And low temp pre-preg can be cured in aluminum molds with one of those silicone heater strips like used for 3D printer beds stuck to one mold half.





Edited 5 Years Ago by Chris Rogers
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