Resin Infusion of carbon fiber with balsa core - any experience?


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John Hansen
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Does anyone have hands on experience doing resin infusion of carbon fiber with a balsa end grain core. In my research on the methods, I find statements of vendors that indicate balsa end grain can be fabricated as a core between carbon fiber this way but at this time, actual evidence or instructions by someone experienced doing this still eludes me. Does anyone know anyone what has done it (successfully), or is it mere hyperbole by the vendors of the balsa core material? FYI, I have written to one notable vendor with no response. I have also done a patent search and with one notable exception there are no patents that shed light on the process of sealing the end grain. The referenced patent simply says
"seal the end grain". 
But how to seal it and with what to seal it? And how much weight is added to the balsa when it is sealed? Is this all a secret?
Looking for replies with experience.... no theories or conjecture, please.


A Lifelong Learner

Edited 5 Years Ago by John Hansen
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Matthieu Libeert
Matthieu Libeert
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Lester Populaire - 3/5/2019 12:28:46 PM
John Hansen - 3/5/2019 4:05:59 AM
Does anyone have hands on experience doing resin infusion of carbon fiber with a balsa end grain core. In my research on the methods, I find statements of vendors that indicate balsa end grain can be fabricated as a core between carbon fiber this way but at this time, actual evidence or instructions by someone experienced doing this still eludes me. Does anyone know anyone what has done it (successfully), or is it mere hyperbole by the vendors of the balsa core material? FYI, I have written to one notable vendor with no response. I have also done a patent search and with one notable exception there are no patents that shed light on the process of sealing the end grain. The referenced patent simply says
"seal the end grain". 
But how to seal it and with what to seal it? And how much weight is added to the balsa when it is sealed? Is this all a secret?
Looking for replies with experience.... no theories or conjecture, please.

Done it plenty times on kiteboards, furniture and other projects. works very well, but even after sealing it will soak up a lot of resin. The mechanical properties are extremely high tho. this is why balsa cores are used in wind mill blades in the areas of the highest stresses and on composite bridges.

For resin uptake you have to do your own tests really. the density of balsa has a huge range and the coating can or cannot make a big difference. i would recommend to use a viscous coating resin or a gel-coat with a short pot life, mixed with microballoons.

cheers

Easy composites has a video of it using wood strips in their longboard video with flax if I'm correct Wink If you want to be sure, make a small 25cm x 25cm test plate and you'll be able to calculate how strong your laminate is as well as how much the Balsa is soaking the resin


Matthieu Libeert
Founder MAT2 Composites X Sports
website:
www.mat2composites.com




John Hansen
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Matthieu Libeert - 3/6/2019 1:21:20 PM
Lester Populaire - 3/5/2019 12:28:46 PM
John Hansen - 3/5/2019 4:05:59 AM
Does anyone have hands on experience doing resin infusion of carbon fiber with a balsa end grain core. In my research on the methods, I find statements of vendors that indicate balsa end grain can be fabricated as a core between carbon fiber this way but at this time, actual evidence or instructions by someone experienced doing this still eludes me. Does anyone know anyone what has done it (successfully), or is it mere hyperbole by the vendors of the balsa core material? FYI, I have written to one notable vendor with no response. I have also done a patent search and with one notable exception there are no patents that shed light on the process of sealing the end grain. The referenced patent simply says
"seal the end grain". 
But how to seal it and with what to seal it? And how much weight is added to the balsa when it is sealed? Is this all a secret?
Looking for replies with experience.... no theories or conjecture, please.

Done it plenty times on kiteboards, furniture and other projects. works very well, but even after sealing it will soak up a lot of resin. The mechanical properties are extremely high tho. this is why balsa cores are used in wind mill blades in the areas of the highest stresses and on composite bridges.

For resin uptake you have to do your own tests really. the density of balsa has a huge range and the coating can or cannot make a big difference. i would recommend to use a viscous coating resin or a gel-coat with a short pot life, mixed with microballoons.

cheers

Easy composites has a video of it using wood strips in their longboard video with flax if I'm correct Wink If you want to be sure, make a small 25cm x 25cm test plate and you'll be able to calculate how strong your laminate is as well as how much the Balsa is soaking the resin


Matthieu, Thank you for your input. I have viewed the video tutorial that you mention and it really is an interesting process. My search is for videos that use end grain balsa between carbon fiber with the single objective of lowest possible weight for my UAV frame and monocoque. Many tutorials including the Easy Composite video do not discus how to optimize for lowest weight while achieving the strength needed for the design parameters of the UAV.
I am planning the  testing you describe and will be creating videos along the way as a way to document for myself my research. I did not set out thinking I would be a pioneer as I do the research in this type of resin infusion. I won't mind receiving the glory and fame of such an endeavor, but I simply did not expect it. :-)


A Lifelong Learner

Edited 5 Years Ago by John Hansen
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