Brake duct fabric layout?


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AlpineCoupe
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Hi all - I'm new to the composite world. I have made a couple of small parts but am still learning a lot. The question I have is how to lay out the fabric on a brake duct I am going to be making. 

I am struggling to determine if I should lay out the carbon fiber as shown in the picture below - essentially 5 separate pieces, as indicated by the different colored outlines. Or attempt to find a way to wrap the shape in fewer separate pieces. 

The piece will just be directing airflow so it will not see large loads so strength is not the utmost concern, I just want to make a solid part.

Thanks in advance for the help!
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AlpineCoupe
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Fasta - 11/13/2019 3:37:01 AM
AlpineCoupe - 11/12/2019 8:13:48 PM
Fasta - 11/12/2019 5:59:37 AM
I would consider just two pieces for this shape.

One piece large enough to lay over the longer tapered end, down the sides onto the flange and also including up the tube on that side only.

The second piece can lay up the vertical side inc up the tube end and wrap to overlap first layer on the sides, plus the flange at the bottom.

Assuming you are using 200g 3k materials then it would be best cut to be +- 45 degrees to help it contour the shapes. If you have a nice material like 90g or 120g carbon then that would be even nicer/easier if the part is very small. It's hard to tell the scale from the picture?

Then a second layer of the same carbon or fibreglass which is often easier as it is usually lighter weight/softer and easier to apply, in turn makes a cleaner finish part on the back side.

You could also wrap the surface with peel ply very carefully with a smaller pieces.

Thanks, Im using some
~
200g 3k 2x2 twill, Ill cut some tonight and see if I can make the 2 piece wrap work. Im still learning so it's hard for me to visualize how it can all wrap and work. Thanks for the help!

The 3k material is not so flexible as other materials but it all depends on the shapes and corners you have to deal with, cutting pieces to fit where the edges are on the corners will just make things worse for getting it stay down in place. Also since twill material is a loose weave if you cut it into small pieces then it also falls apart much more too so the bigger the piece the better for twill weave.

Looks like a nice shape part for vacuum infusion, if the mould has some good size flanges there?

I was actually going to start trying vacuum infusion using this piece. The flanges seem to be plenty big for it to work. Im glad you think it will work to infuse it!
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