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Carbon
Fiber Laminates
The Basics of Using Carbon
Fiber Laminates
by Todd Johnson
If
using carbon-fiber composites was easy, they would be everywhere. Using carbon
fiber takes as much science and mechanical skill as it does art and finesse.
The Basics
Whether you are working on a
hobby project or trying to trick out your car, first think carefully about
why you want to use carbon
fiber.
Although the composite is versatile, it can be expensive to work
with and may not be the right material for the job.
Carbon fiber has a lot of
benefits. This material is extremely lightweight, incredibly strong, and it has
excellent mechanical properties.
However, carbon fiber is also
trendy, which means people may use it for the sake of using it.
For example, if all you really want is the surface finish of a
carbon-fiber weave, then save yourself the trouble and simply apply a
carbon-fiber vinyl adhesive film.
Carbon fiber is quite expensive compared to similar composites.
Carbon Fiber Vinyl Film
Carbon fiber vinyl film is
available in rolls or sheets. It has the look and texture of actual carbon
fiber.
However, this adhesive-backed film
is as easy to apply as a sticker. Simply cut it to size, peel, and stick.
Many distributors sell
this film, which is dramatically inexpensive compared to actual carbon fiber.
The carbon fiber film has
great UV resistance and does provide some impact-resistance. It's used in
everything from cell phones to sports cars.
How to Use Carbon Fiber
It's not difficult to learn
how to laminate carbon fiber. First, again ask yourself what the purpose the
carbon fiber is going to serve.
If it is purely for aesthetics, then a single layer of
inexpensive carbon fiber will probably do the trick. This layer can cover a
thicker laminate of fiberglass.
However, if you're planning a structural component or something
else that needs to be strong, more robust use of carbon fiber may be warranted.
If you are building a snowboard in your garage or designing
an aircraft part using carbon fiber, do some planning before you begin.
This can help you avoid manufacturing a part that will fail, and
also prevent you from wasting expensive material.
Use a composite
material software program, many of which are free, to design the specific
carbon fiber item you need.
The program knows the properties of the carbon fiber and applies
this data to the laminate being designed.
Consult with a professional engineer when you're designing a
critical part or piece, the failure of which could cause harm to yourself or
others.
Laminating carbon fiber is no
different than fiberglass or other reinforcements. Practice learning how to
laminate carbon fiber with fiberglass, which is a fraction of the cost.
Pick your resin carefully. If
it is a part intended for its appearance and free of gel coat, use a
high-quality polyester or epoxy
resin.
Most epoxies and polyester resins will have
a yellowish or brownish tint. A clear resin will be your best choice. Any resin
used in surfboard manufacturing is usually as clear as water.
You're now prepared to
laminate your carbon fiber composite.
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