I want to make a flat sheet (or rather block) of carbon fiber that is 3cm thick? It's not a big block, roughly 7x7cm. I can only imagine infusion would be pretty useless for this as vacuum will have hard time pushing down that thick of a sheet so I'm thinking wet lay up and put something really really have on top to compress. What say you? Also, most importantly, how many layers do you think i'm gonna need to build that kind of thickness?

I like the forged carbon idea, easy to make a part in the end but the tooling and set up could be expensive relative to other ways. But the forged thing would great.




You could also lay up a 30 000g stack of pre preg carbon and sandwich it in between two metal plates. Simply clamp or press and cook. You might make a block that did 3 or 4 parts so with allowing for some trimming it could be 100mm x 300mm.

At 1000g per mm

30 000g of 200g pre preg cloth is about 150 layers of material. $80 per sqm

30 000g of 300g unidirectional is about 100 layers. $40 per sqm

I assume you might be CNC shaping the block?




To do 100 or 150 layers of wet laid carbon would be a super sloppy mess and a PITA to do.

With the pre preg you may also need to clamp it and heat it a bit (60 deg for 10min) along the way with so many layers. Maybe do this de-bulk every 5000g?