Surface level documentation on carbon fiber manufacturing. Please reach out to the appropriate mechanical lead or expert to instruct you with more detail before attempting.
All composites work should take place in the composites room and using appropriate PPE
Flat Layups
5 layers of mould release chalk (wipe between each layer application, and let sit after application for ~5 minutes).
Layer epoxy → CF → epoxy → CF … etc. → epoxy → fabric.
General rule is weight of carbon fiber == weight of epoxy resin solution.
aeropoxy epoxy resin solution = 100 parts epoxy, 27 parts hardener.
Other notes:
Bends and complex curves have a higher chance of introducing air bubbles which will stop the epoxy from flowing into that particular area. This leads to small dents/holes/dry spots once the epoxy is cured. Air bubbles are almost unavoidable because small air particles will enter the resin as you are mixing it with the hardener.
To avoid air bubbles you can:
de-gas your resin using a vacuum chamber
let the epoxy mixture sit for longer (but you will need a longer pot life)