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url | https://www.youtube.com/watch?v=fA2-i34UVUo&feature=youtu.be |
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Foam Model
Fibreglass Mould
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Full Sized Model
Once, we have designed the aerrbody in CAD, we will then obtain full sized models of the car body. These will likely either be made of foam or MDF. More complex curves will be made using a CNC machine while less complex geometry can be made by hand. The surface finish of the model is very important because any imperfections on the model will end up on the final body panels.
Fibreglass Mould
The next step is to create a fibreglass mould or tool of the body panel. This is done by first applying a coat of mould release to the model. Then tooling gelcoat is applied followed by several layers of fibreglass and resin. The result is a fibreglass mould into which you can do a carbon fibre layup.
Final Layup
The final carbon fibre layup is complex and there are numerous ways to do it (infusion layup, wet layup, etc.). This step will always require the use of vacuum bagging. A process where a plastic bag is wrapped around a the mould and all the air is sucked out; thus applying pressure to the carbon fibre and transferring all the detail of the mould to the final part.
There is an excellent video series on youtube that shows the entire process of making a fibreglass mould, followed by layups inside that mould:
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width | 400300 |
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url | https://www.youtube.com/watch?v=UgKvDw1E60E |
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height | 250180 |
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Widget Connector |
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width | 400300 |
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url | https://www.youtube.com/watch?v=YWbGx_BJVvM |
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height | 250180 |
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Widget Connector |
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width | 400300 |
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url | https://www.youtube.com/watch?v=YWbGx_BJVvM |
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height | 250180 |
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