Motorsport Composite Fundamentals: Preparation

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Preparation

07.10

00:00	We've covered a lot of ground up to this point in the course, with plenty of considerations around different materials and construction techniques, as well as a lot of information about a range of other tools and consumables.
00:13	It's been a lot to take in, so in any case all of this seems a little overwhelming and unclear, we've put together a simple three step process that you can follow for any hand lamination job.
00:24	This section of the course isn't about teaching you anything new.
00:28	This is about understanding how to implement everything that you've already learnt into real world composite construction.
00:34	Of course, every project is going to call for a different approach, so think of this more as reiterating the important concepts in one place for clarity, and in the typical order that they'll be carried out to ensure that you don't overlook anything important.
00:49	If anything we cover over these three steps doesn't ring a bell or make total sense to you, be sure to check back to the relevant module in the course for a refresher.
00:58	Before we begin, there's one quick note.
01:00	Due to the wide nature of pattern or plug making, which often doesn't include any hand lamination, we're not going to include this in our three step process.
01:09	The important thing to remember is that the purpose of the pattern is to create an accurate and sturdy representation of the final parts that we can use to construct a mould.
01:19	Also remember that the surface finish will be carried from the pattern to the mould and then to the part.
01:25	Composite moulds on the other hand are often construction using wet lay up techniques like we'll discuss in the following steps, so while the focus will be on the construction of the parts, everything also applies to mould making.
01:38	Let's start with the first step in the process, preparation.
01:41	Every successful project starts with a solid plan.
01:44	You might be familiar with the five P's, prior planning prevents poor performance or something to that effect.
01:51	While the actual preparation stage may be short in practice, the number of things to consider is more than any other stage, so bear with me for this module and things will shorten up in the following stages.
02:02	Let's begin.
02:03	First, where are we going to do the work? Our workspace needs to be considered as this has an impact on the quality of the work done and therefore the final product.
02:12	This usually consists of two spaces, a relatively clean area where we can do our lamination, usually with a drop sheet to catch any resins, and a dirty area that we can get messy when cutting and shaping parts, often outside the workshop.
02:26	Having the correct PPE on hand and easily accessible will reduce the temptation to go without.
02:32	It's imperative that we always have the right PPE for the job.
02:36	Without it, best case we might suffer mild skin irritation, worst case could mean serious irreversible damage to our eyes, hearing and respiratory system.
02:45	Gloves, eye protection, a respirator and hearing protection are all must-haves, and we'd also recommend having some form of coveralls to save your clothes and expose skin.
02:55	If you're ever in doubt, review the safety data sheet for whatever materials that you're working with.
03:00	We'll assume that the correct PPE is worn at all times throughout the following steps of the process.
03:06	If you're familiar with working on cars, you'll know that having the correct tool for the job can not only make the work significantly easier, but also the product better.
03:16	The tools we have will of course be largely limited by our budget, but it's always better to have the tool we'll use for a certain job on hand, so when it comes time, we're not scrambling to find it.
03:27	It's not only going to waste time, but if we're working with curing resin, it could waste the material.
03:32	The same idea extends to consumables.
03:35	Not just the core materials we'll use in the construction, like the reinforcement, gel coats, resins or any other additives, but the ancillaries like mixing cups and sticks, brushes, filleting wax and flash tape, just to name a few.
03:48	It's important to think through what's involved at each step, make a list of what's required and ensure we have it on hand.
03:55	Release agents are another important one and at this point we're getting into the preparation of our mould for use.
04:00	This could also be the preparation of our pattern surface for use in mould making.
04:05	Release agents, whether that's a chemical semi -perm, a wax or a PVA parting film, should always be applied as per the supplier's instructions.
04:14	This includes cleaning the surface and in some case the use of a sealer that needs to be applied first.
04:20	We usually build up a number of layers and sometimes use a combination of different products.
04:25	From this point on, it's important to consider the compatibility of the chemicals, materials and products that we use.
04:31	The next practical job will be applying the gel coat, if we're going to use one of course.
04:36	In the case of mould making, this could be applying a tooling gel coat to the pattern surface.
04:41	This could arguably be part of the preparation stage or the lamination stage, but before we apply any resin to the mould surface, it's best to have a plan for the lamination stage.
04:52	There are typically two routes for the construction of composites via hand lamination.
04:57	Our choice will depend on a lot of factors, like application and budget, but essentially we'll choose the reinforcement and this will mostly guide our choice of resin.
05:06	In either case, we need to have a plan for the layers of reinforcement that will form the laminate based on the thickness of the part, as well as the structure or stiffness and strength that we're trying to achieve.
05:17	How we intend to lay up the part will determine if we use a waxed or unwaxed resin.
05:22	If we laminate in stages, then unwaxed is the pick, where waxed will be the best if we're laminating in a single stage.
05:29	With the reinforcement and resin choices locked in, we need to make sure we have enough of each on hand.
05:34	We also need to ensure our resins are still in usable condition as shelf life is always something worth keeping in mind.
05:42	We'll often use a small amount of resin filler or bog when hand laminating complex moulds to help reduce the chance of voids.
05:49	This will essentially just be our laminating resin, thickened with fumed silica aka cabosil.
05:55	Once we understand the materials we'll use in the laminate, we'll be able to choose a gel coat that's suitable and compatible.
06:01	At this stage our gel coat can be catalyzed and either brushed or sprayed onto the mould surface.
06:06	The key considerations here around achieving a complete coverage and even thickness, usually around half a millimeter, and also allowing enough time for the coat to cure to a slightly tacky surface.
06:19	This concludes the preparation stage, so let's summarize the considerations for our first step.
06:25	The first things to tackle are the workspace we'll use, having the correct PPE, as well as the tools and consumables that will be used at each step.
06:33	We can then prepare the mould with release agents, following the supplier's instructions closely, and building up enough coats to ensure a trouble-free release.
06:42	We can then prepare our foundational materials such as the reinforcements and resin.
06:47	It's important that we have a good idea of the approach we'll take in the next lamination step.
06:51	These materials will determine the gel coat we use, if we're going to use one, and then it can be applied at this point as somewhat of a preparation of the mould.
07:00	Whether the gel coat is sprayed or brushed on, the thickness, coverage and cure time are all critical things to keep in mind.