How to make carbon plate with both faces finished


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quinn
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Infusion seems to be the way to go, but you only get one finished face with peel ply texture on the other. What's the best way to get 2 finished faces? I tried a small 150mm square by just clamping 2 peices of aluminum tooling plate together and it worked perfect with really good fiber to resin ratio, but I need some larger 500x500 plates (2mm thick). I could use 2 plates of glass backed up by something else like mdf maybe, but I imagine just clamping around the outsides is not going to squeeze the middle well enough unless I get tricky with the clamping. Maybe some thick peices that span across with clamps on outside to hopefully put enough pressure in the middle. 
Any other good way to do this other than clamping? If clamping is the best option, what's the best choice of clamping plate material and method for doing it? 
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quinn
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oekmont - 8/27/2018 4:27:36 AM
Because of (simplified) leverage a sandwich structure has basically the same strength as a solid one. If you use a core like airex, rohacell or soric lrc, you can get 1,5mm core material, wich ends up to almost exactly 2mm with 240g+100g skins. 100g could be a biax cloth, wich isn't nearly that expensive as a 100g weave.

Are this very heavy stressed joints? You can bolt through the structural cores quite good, especially if you are using (cf) washers. M3 and m4 are quite "elegant" screw sizes, and since weight is critical you are likely using titan or even aluminium and therefore are not brute forcing the screws and use loctite. For heavy bolting you might consider cutting a hole in the core locally and filling it with around 1000g/m^2/mm-core carbon cloth before infusing.

Yep, using ti bolts. I would say the joints aren't normally under heavy stress, but during crashes definately, and crashes happen. Probably 75% of the time the frames will survive crashes so definitely wouldn't want to add weak points. Probably worth adding the carbon cores in bolt locations. I'll definitely look into it. If grams can be lost without losing strength, I'm all for it.

So one of these cores would also act as flow media? 

Edited 7 Years Ago by quinn
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                                 Gosh, yes, forgot about that :-)
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