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/wax (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. Do not forget to tare (or subtract) the weight of the cup that holds the resin.
Aeropoxy epoxy resin solution = 100 parts epoxy, 27 parts hardener (the ratio might differ depending on the hardener and resin used so make sure to read the container label).
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 after the epoxy cures. Air bubbles are almost unavoidable because air particles will enter the resin when you are mixing it with the hardener.
To minimize air bubbles you can:
de-gas your resin using a vacuum chamber
let the epoxy mixture sit for longer after mixing (but you will need a longer epoxy pot life)