Making Carbon Fibre Parts by Resin Infusion - Complete Startup Guide

Introduction

This tutorial provides a complete guide for making carbon fibre parts using the resin infusion process. Whether you are a beginner or looking to refine your skills, this guide covers the necessary materials, techniques, and steps to successfully create lightweight carbon fibre components.

Step 1: Understand the Resin Infusion Process

• Overview: Resin infusion involves placing dry carbon fibre reinforcement in a mould and then infusing it with resin under vacuum to create a strong composite part.
• Key Benefits:
  • Produces lightweight yet strong components.
  • Allows for complex shapes due to the flexibility of the process.

Step 2: Gather Materials and Equipment

• Essential Materials:
  • Carbon fibre fabric
  • Epoxy resin
  • Hardener
• Equipment Needed:
  • Mould (can be made from various materials)
  • Vacuum pump
  • Vacuum bagging film
  • Infusion consumables (e.g., tubing, connectors)
  • Scissors and a roller for resin application

Step 3: Prepare the Mould

• Cleaning: Ensure the mould is clean and free from debris.
• Release Agent: Apply a suitable release agent to prevent the part from sticking to the mould after curing.

Step 4: Lay the Reinforcement

• Cutting: Cut the carbon fibre fabric to the required size, ensuring it fits well within the mould.
• Positioning: Lay the carbon fibre in the mould, ensuring proper alignment and coverage.

Step 5: Set Up Infusion Consumables

• Infusion Lines: Attach infusion lines to the mould to allow resin to flow.
• Vacuum Ports: Set up vacuum ports in the mould for air removal.

Step 6: Seal and Pull Down the Vacuum Bag

• Vacuum Bagging: Place the vacuum bag over the mould and seal it securely.
• Vacuum: Use a vacuum pump to remove air from the bag, ensuring the carbon fibre is compacted against the mould.

Step 7: Calculate Resin Quantity

• Volume Calculation: Measure the volume of the mould to determine how much resin is needed.
• Mixing: Prepare the resin and hardener according to the manufacturer's guidelines.

Step 8: Run the Infusion

• Infusion Process: Open the resin feed line to allow the resin to flow into the mould under vacuum.
• Monitoring: Keep an eye on the infusion process to ensure the resin is spreading evenly and there are no air pockets.

Step 9: Demould the Part

• Curing: Let the part cure as per the resin specifications.
• Removal: Once cured, carefully remove the vacuum bag and take the part out of the mould.

Conclusion

You've now completed the process of making carbon fibre parts through resin infusion. Key takeaways include the importance of preparation, the correct setup of materials, and careful monitoring during infusion. For further learning, consider exploring more advanced techniques or experimenting with different types of carbon fibre and resin combinations. Happy crafting!