Filling voids advice - like Bugatti


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ant...
ant...
Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)
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So I've been working on producing a carbon fibre coffee cup for many years, I want it to be perfect and its almost there.  For the past 2 years I've had the project on the back burner having spent many thousands on equipment and tests.  But last week watching the How Its Made featuring the Bugatti Veyron, I saw how their carbon nose cone always comes out with voids in tights places and that these areas were repaired to produce a flawless finish.  That made me think my process might be good enough and I can finish my cup with a few repairs.

These images show how my cup is one solid piece but the outside is always susceptible to tiny bubbles or sometimes voids, the inside is almost always perfect.  

My Process - The alloy mould is secured in a vacuum chamber while infusion resin is pumped from the mixing container into the mould from its base, this enables the cup to be one piece with all smooth sides and the vacuum chamber limits bubbles & voids.  My next test will include curling the mould in a high pressure oven maybe 100psi (pressure cooker LOL).  But I've tried loads of ways to get a 100% perfect result and id become disappointed until I saw the Bugatti repair process.
With a little help I mights just get a finished mug...

Question - Can these voids be filled?  any suggestions?  

Im guessing sand the holes back to remove any release agent, maybe with some acetone and fill with a syringe of general epoxy.  then rub it back to a perfect round finish.


http://www.talkcomposites.com/Uploads/Images/1325fe1e-b6ed-43f5-a978-b7bc.JPG http://www.talkcomposites.com/Uploads/Images/b19d8eb0-a52c-4d6e-8bfd-e10a.JPG http://www.talkcomposites.com/Uploads/Images/8b8a7c94-3f7d-46e3-a3e3-c511.JPGBTW this big hole is drilled to practice fitting the carbon handle.
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ant...
ant...
Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)Supreme Being (133 reputation)
Group: Forum Members
Posts: 17, Visits: 92
Ive taken pics off the TV to show you what was shown on the How Its Made - Bugatti program.


http://www.talkcomposites.com/Uploads/Images/4446c97d-9899-4927-9e75-0815.JPG
The sanding process has shown the voids on the rear of the Veyron, these are actually very similar in size to my cup, perhaps these can be filled with just the 2 pack lacquer.









http://www.talkcomposites.com/Uploads/Images/0ea81e68-5e0a-4239-9739-66dc.JPG
Here you can see a lady marking up a void on the bumper of the Veyron and actually its a bit of a mess if it were to be left, so its apparent to me that they are able to repair some severe voids, good enough for the bonnet of the most expensive car in the world.  So I should be able to repair the tiny voids on my mug.

The CF steering wheel is full of voids and thats a piece which we would expect would need to be perfect.

What the CF cladded supercars do have that my mug doesn't is large vast areas of absolutely perfectly laid material, beautiful curves, patterned surfaces, all of which move your eye away from a tiny repair.  This has given me hope for the possibility of repairing my mug to a perfect finish.
GO

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