Working with composites is all about using the correct the process. Without the proper tools, techniques and materials, outcomes can be disastrous. With MSXI, the process required about 90% of the car to be created in a single layup. This process let to a poor outcome in which composites separated and the structural integrity of the vehicle was compromised.
A note about panels
Similar to the body of most production cars, MSXII's aerobody will be modular and be made up of a number of different panels. There are several benefits to this:
- If a pannel is damaged, we can easily manufacture a replacement.
- Strategically positioned panels will be removable, allowing easy access to critical mechanisms such as steering and suspension inside the car
- There is very little financial risk in each layup: if one goes poorly, it will not set back the project significantly
- Easier panels can be created first, leaving the more difficult panels for later once the aerobody team has had more practice with composite work
The Process
Sketching
Sketching is fundamentally important the the look and feel of the overall car. All automotive manufacturers begin the design of the bodywork with sketching and artists interpretations. The following video offers a glimpse of part of BMW's design process: "The first contact that the designer has with the project is the piece of paper and a pencil”.
Another benefit of sketching is it allows you to iterate much faster. Digital surface modelling is a very time intensive process when done properly whereas multiple sketches can be created in a faction of the time.
Surface Modeling
We will be using Solidworks to model the surface of the aerobody. Solidworks has a number of powerful surface modelling features but they are sometimes difficult to use, especially for those just starting out. The following video offers a good introduction to modelling surfaces in solidworks:
Foam Model
Fibreglass Mould
Final Layup
There is an excellent video series on youtube that shows the entire process of making a fibreglass mould, followed by layups inside that mould: